description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
|---|---|---|
FIELD OF THE INVENTION
This invention relates to a device for maintaining a locked and closed state of a space-separating device in a releasable manner, in particular the protective device of a machine.
BACKGROUND OF THE INVENTION
In production engineering, for example, among other things, for safety reasons, machines and systems are set up within a space separated from the exterior and in which a person is not permitted to remain during operation of the machine. For example, to have access to the machine for maintenance work, the space-separating device generally has a closable opening. Generally speaking, operation of the machine should only be possible when the opening is closed, and the closed state is locked. Access to the machine is only possible when the locking of the closed state is neutralized.
DE 203 15 959 U1 discloses a device for monitoring the state of a space-separating device, in which it is ensured that a person located within the separated space is not able to close the space-separating device and lock it from the inside. Otherwise, there would be the risk that the machine could start inadvertently or intentionally while a person is located within the space-separating device.
DE 196 32 962 A1 discloses a door actuation device. From the interior of the space-separating device, a latch locking the closed state can be transferred into its unlocking position. The space-separating device can then be opened. Conversely, the latch cannot be transferred into its locking position, this movement possible only from the outside. In this way a type of “escape unlocking” is implemented.
DE 10 2005 057 108 A1, published at a later date, discloses a safety switch for producing a release signal depending on the position of a movable protective door. The part to be attached to the protective door has an actuator movable between a first position and a second position. The part to be attached to the frame has a recess engagable by the actuator in the second position. A blocking element can block the actuator in the second position.
DE 298 24 200 U1 discloses a device enabling an individual inadvertently locked within the protective enclosure to leave this protective enclosure. At the same time, the machines located within the protective enclosure can only be operated when the door on which the device is located is not only closed, but locked.
SUMMARY OF THE INVENTION
An object of this invention is to provide a device for maintaining a locked and closed state of a space-separating device in a releasable manner which overcomes the disadvantages of the prior art.
In one embodiment, the device is intended to enable not only locking of the closed state of the space-separating device, but to maintain the locked and closed state, for example, as long as the machine located within the space-separating device is in an operating state hazardous to people, for example, when the machine is running down after it has been turned off.
In one embodiment, in spite of maintaining the locked and closed state, the locking of the latch can be neutralized from within the space-separating device. The device is intended to ensure permanently reliable and safe operation.
This object is basically achieved by a device where the space-separating device can be protective hoods, protective doors, or an arrangement of partitions or separating gratings by which the inner region around a machine, such as a machine tool or an industrial robot, is separated from an outer region in which individuals can remain even during operation of the machine. The first part of the space-separating device can be designed, for example, as a frame part. A second part such as, for example, a door or window is movable. In the case of a door, conventionally the second part is pivotally coupled to the first part or is movably guided thereon.
The device has a latch for locking the closed state of the space-separating device. In one embodiment the latch is movably supported in the device and can be transferred from the retracted position into the locking position by an actuation element, such as a knob, to engage a latch receiver by blocking it and to lock the closed state. By the holding element, the latch can be blocked in its locking position. The locked and closed state of the protective device can then be blocked and maintained closed.
One or more sensors can detect the closed state of the protective device, locking of the closed state and/or maintaining the locked and closed state and can signal that status to a device controlling the machine. By this control, the machine can be started only when the space-separating device is closed, the closed state is locked and/or the locked and closed state is blocked. The blocking and/or the neutralization of the blocking can take place likewise in a signal-controlled manner. For example, the control can provide for the blocking of the latch to be neutralized only when the machine is in the safe state, for example, when a machine tool or an industrial robot is stopped, so that it cannot pose a danger to people. The blocking and/or release can be driven in a controlled manner for this purpose.
In one embodiment the holding element is spring-loaded and can, for example, engage the latch and block it as soon as the latch and holding element have sufficiently approached one another. The blocking can also be neutralized by a controllable drive, for example, by an electromagnet or a piezoelectric drive. Alternatively, the holding element can also be kept spring-loaded in a non-blocking position and can be transferred by a drive into the state blocking the latch in its locking position. In another alternative embodiment, the holding element can also have two stable states and can be switched back and forth between those two states by a drive.
The device moreover has a release element permitting neutralizing of the blocking of the latch. This release element can also be actuated from the inside of the space-separating device, optionally even against the action of a driving or spring force acting on the holding element. This arrangement ensures that a person located within the space-separating device is easily able, in particular without actuating an EMERGENCY OFF button, to neutralize the maintaining of the locked and closed state. Optionally, by neutralizing the blocking of the latch the device can produce a signal which signals to be machine control that the machine is to be transferred into the safe operating state, for example, is to be turned off.
The blocking of the latch can be neutralized by the rotary motion of the release element relative to the latch. In one embodiment the release element is located and pivotally supported on the latch for this purpose. Reliable neutralization of the blocking of the latch thus can be enabled with simple mechanical elements.
In one embodiment, following the rotary motion, the release element together with the latch can be moved. The locked and closed state of the space-separating device can then also be neutralized, whereupon the space-separating device can be opened. In one embodiment the actuating element located within the space-separating device dictates dynamic coupling in only one direction, specifically in the direction of neutralizing the locking position of the latch. Conversely in the other direction a trip-free mechanism prevents the position located within the space-separating device from being able to transfer the latch into its locking position.
In one embodiment the release element is a dual-arm lever which can be turned around an axis of rotation. The configuration as a dual-arm lever can implement different force and path ratios, for example, a relatively high torque for neutralizing the blocking of the latch can be made available with comparatively small actuating forces. Conversely, a correspondingly large lever arm can make available a comparatively large path, for example, for lifting the holding element out of a catch depression and thus for neutralizing the blocking of the latch. Moreover, the interval between delivering the force for neutralizing the blocking of the latch on the one hand and the position of the lever in contact with the holding element on the other hand can be chosen to be large. In this way the mechanical elements necessary for actuation can be located within the device such that the design is small. Alternatively or in addition, the actuating elements located on the inside and outside for neutralizing the blocking of the latch and the actuating elements provided for transferring the latch into its locking position can be located at a distance to one another. This spacing is especially advantageous for some applications.
In one embodiment the release element can be actuated by a knob. The initial rotary motion of the knob at the outset results in rotary motion of the release element with which the locking of the latch can be neutralized. As turning continues the latch moves linearly out of the locked position.
The release element can be turned, for example, by an element movably supported in the device and connected to the first knob by a coupling device. The coupling device in this case converts the rotary motion of the first knob by 90° into linear motion of the displacement element. For this purpose the coupling device can have first and second levers hinged to one another at an articulation point as a hinged joint. The first lever is nonrotatably connected to the first knob. The second lever is connected directly or indirectly to the displacement element by other elements. When the first lever is turned, the displacement element is moved. As a result first the blocking of the latch can be neutralized, and then the latch can be guided out of its locking position. In the reverse direction there is no motion coupling between the displacement element and the latch, in particular not with respect to linear motion.
In one embodiment the device has a second knob actuatable from the outside of the space-separating device, specifically located on the outside of the device. By the second knob, the latch can be moved into its position locking the closed state. In one embodiment the axes of rotation of the first and second knobs have an offset to one another. This offsetting has the advantage that each part of the space-separating device to which the device is attached need not be provided with a through hole for the common axis of rotation of the two knobs, as is necessary in the prior art. This metal-cutting at the installation site is disadvantageous for many reasons. On the other hand, the offset of the two axes of rotation ensures that in the closed state of the space-separating device there are no light gaps which are disadvantageous especially when within the space-separating device a laser machining device is present, and the emergence of laser light from the space-separating device must be reliably prevented.
In one embodiment the latch and/or the holding element are made such that they positively engage one another in the position blocking the latch. For example, the latch can have a recess with a catch flank in which the holding element catches in the position blocking the latch. The positive locking ensures that the resulting self-locking can implement a high holding force without correspondingly high drive forces having to be made available by a motor. This arrangement is especially advantageous because the release element optionally must overcome those forces activating the holding element.
In one embodiment, the device has a first sensor by which the position of the latch locking the closed state of the space-separating device can be signaled. The first sensor can be a safety switch as is conventionally used in safety engineering. In addition to contact safety switches in which a mechanically encoded actuator is introduced into the switch head and triggers a switching process there, non-contact or electronic safety switches can also be used which wirelessly transmit signals between an actuator and a read head. In one embodiment an actuator is in the form of a transponder on the latch. In the position locking the closed state of the space-separating device, the actuator moves into the response region of a read head so that only in the position of the latch locking the closed state of the space-separating device is signal transmission between the read head and the transponder possible. In one embodiment the transponder is located near the jacket surface of the latch, and the read head is located near or on the wall of the latch receiver. Alternatively, the actuator can also be located on or near the face-side end of the latch.
In one embodiment the device has a second sensor for signaling the position of the holding element blocking the latch. This second sensor can also be made generally as a non-contact safety switch. The holding element could be made specifically as a coupling element, for example, for signal coupling between the transponder located on the latch and the read head. Fundamentally, the first sensor and the second sensor can be made separately. Alternatively, the holding element can couple the transponder of the first sensor to a second read head of the second sensor so that there would be only one transponder on the latch. In this case it would also be possible to separately detect whether the latch is in its blocking position and whether the locked position is blocked by the holding element. In another alternative, signal coupling between the transponder and read head of the first sensor could only be possible when the holding element is in its position blocking the latch.
In one embodiment, the second sensor is an optical or magnetic sensor, such as a photoelectric barrier or a Hall sensor. Those sensors can be easily configured in a small design and optionally also directly on a circuit board. The holding element can be made as a pivotable lever, with a catch projection located at a distance from the axis of rotation for interaction with the lock.
Other objects, advantages and salient features of the present invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses a preferred embodiment of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings which form a part of this disclosure:
FIG. 1 is a schematic top plan view of a device according to an exemplary embodiment of the invention in the locked and blocked condition;
FIG. 2 is an enlarged top plan view in section of the device of FIG. 1 in the locked and blocked condition;
FIG. 3 is an enlarged top plan view in section of the device of FIG. 1 in the locked and unblocked condition;
FIG. 4 is an enlarged top plan view in section of the device of FIG. 1 in the unlocked condition; and
FIG. 5 is a side elevational view in section of the device of FIG. 1 in the locked condition.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a schematic top view of one exemplary embodiment of the device 1 according to the invention for maintaining the locked and closed state of the space-separating device 2 , in particular the protective device of a machine 4 , in a releasable manner. A first stationary part 6 has an opening closable by a second part 8 . The first and second parts 6 , 8 can be moved relative to one another allowing the opening to be at least partially closed. In the illustrated embodiment the second part 8 is a door pivotable around the first axis 10 according to the first arrow 12 . The open state of the door is shown by the broken lines. A person can enter the interior of the space-separating device 2 through the opening and can, for example, equip, maintain, or repair the machine 4 . During operation of the machine 4 , a person is not permitted or is not to remain within the space-separating device 2 .
For this purpose the device 1 has a first component 14 located on the first part 6 and a second component 16 located on the second part 8 . The first component 14 has a receiver for a latch 18 movably supported in the second component 16 . The closed state of the space-separating device 2 shown in solid lines can be locked by latch 18 so that the space-separating device 2 cannot be opened in this state.
The locked state can be signaled by a safety switch by way of a first connecting line 22 on a control device 20 which controls the machine 4 according to the filed control program by way of a second connecting line 24 . Conversely, the machine 4 , by way of the second connecting line 24 , delivers feedback about the operating state to the control device 20 . The control device 20 can control the device 1 , for example, with respect to maintaining the locked state. The safety switch in the embodiment has a read head 26 located on the first component 14 and an actuator 28 located on the latch 18 . Signal exchange between the read head 26 and actuator 28 is possible only in the illustrated locked state.
The device 1 moreover has a holding element 30 located in the first component 14 in the embodiment. Holding element 30 can be pivoted around a second axis 32 according to the arrow 34 . The latch 18 can be blocked in the illustrated locking position by the holding element 30 . The holding element 30 and the latch 18 are positively engaged. In the embodiment, the holding element 30 for this purpose engages a recess in the latch 18 . The recess has a catch flank providing self-locking relative to the reset motion of the latch 18 .
By a release element 36 ( FIG. 2 ), the blocking of the latch 18 can be neutralized. Specifically, the holding element 30 can be lifted out of its position shown in FIG. 1 . The blocking is neutralized by a first actuating element actuatable from the interior of the space-separating device 2 and formed by a first knob 42 rotatable around a third axis 38 according to the third arrow 40 ( FIG. 1 ). Following the neutralization of the blocking of the latch 18 , as the first knob continues to turn, the latch is retracted into the second component 16 so that the locking of the closed state is also neutralized and the second part 8 can be opened.
In one embodiment, the holding element 30 can be manually disengaged from the latch 18 only in this way. Specifically, the holding element 30 cannot be disengaged by the second actuating element accessible from the outside of the space-separating device 2 formed by a second knob 48 around the fourth axis 44 according to the fourth arrow 46 ( FIG. 1 ). With the second knob 48 the second part 8 can be closed, and by turning the second knob 48 the latch 18 can be extended into the illustrated locking position.
The space-separating device 2 in the embodiment is a protective cab or a protective grating having flat elements attached to profiled rails 50 , 52 extending perpendicular to the plane of the drawing of FIG. 1 . The components 14 , 16 of the device 1 can also be attached to these rails. As is apparent from the schematic of FIG. 1 , the third axis 38 of the first knob 42 and the fourth axis 44 of the second knob 48 extend parallel to one another and are laterally offset relative to one another so that it is not necessary to drill through the profile rails 52 into the interior of the space-separating device 2 for passage of the fourth axis 44 .
FIG. 2 shows a cutaway view of the embodiment of the device 1 which has been enlarged compared to FIG. 1 . The first component 14 is connected to the first profile rails 50 and thus to the first part 6 ( FIG. 1 ) by connecting means (not shown). Within the first component 14 the holding element 30 is mounted to be able to pivot around the second axis 32 extending perpendicular to the plane of FIG. 1 and in the illustrated maintained locked state. A projection 54 on the end side of holding element 30 engages a recess 56 of the latch 18 .
The essentially cylindrical latch 18 in cross section can be shaped to be circular or essentially rectangular is formed of a plastic base part, with a metal insert part 58 . Specifically, the insert part 58 is a metal sheet bent into a U-shape in cross section. The insert part 58 forms the recess 56 and is used in particular to accommodate the blocking forces. In a part inserted into the latch receiver 60 in the illustrated locked and blocked state, near the jacket surface on the latch 18 an actuator 28 is made as a transponder and can be read out from the read head 26 only in the illustrated position so that the locked and closed state of the space-separating device 2 can be signaled.
The projection 54 of the holding element 30 and the recess 56 in the insert part 58 each form a surface essentially parallel to one another and enclose a right angle with the direction of motion of the latch 18 for unlocking. In an attempt to retract the latch 18 by turning the second knob 48 around the fourth axis 44 , this action results in positive locking between the latch 18 and the holding element 30 by which very high holding forces can be applied. The control device 20 or, for example, a manual EMERGENCY OFF can route the holding element 30 out of its holding position, for example, by an electromagnet 62 located in the first component 14 being energized. The magnet armature 64 then comes into contact with the arm of holding element 30 opposite the projection 54 relative to the second axis 32 , with the holding element 30 turning counterclockwise in FIG. 2 .
Regardless of such controlled neutralization of holding or blocking, turning the first knob 42 around the third axis 38 moves a displacement element 66 within the second component 16 . A release element 36 is then turned clockwise around a fifth axis 68 extending perpendicular to the plane of FIG. 2 . In this way, a release element section assigned to the holding element 30 comes into contact with the holding element 30 and lifts it in the course of rotary motion out of the recess 56 to neutralize holding or blocking. Conversion of the rotary motion of the first knob 42 into linear motion of the displacement element 66 takes place by a coupling device having first and second levers 82 , 86 and shown in a side view in FIG. 5 . Coupling of the motion between the second knob 48 and the latch 18 can take place in a similar manner.
When the first knob 42 is turning, the displacement element 66 and a pin 70 located thereon are moved to the right in FIG. 2 . The pin 70 then comes into contact with the oblique surface 72 and the linear motion of the pin 70 is converted into rotary motion of the release element 36 by interaction of the pin 70 with the oblique surface 72 of release element 36 . The release element 36 is made as a lever having two arms relative to the fifth axis 68 . The action surface of the displacement element 66 lies on the side opposite the contact surface for the holding element projection 54 relative to the fifth axis 68 . The axis pin for supporting the release element 36 is formed by the latch 18 or is fixed on it.
FIG. 3 shows a cross-sectional view of the embodiment of device 1 corresponding to FIG. 2 , but in the state in which the first knob 42 is turned around the third axis 38 so far that the pin 70 is moved completely along the oblique surface 72 and is held in a sector-shaped receiver 74 of the release element 36 . In this state the release element 36 is turned maximally around the fifth axis 68 . The holding element 30 is lifted completely out of the recess 56 so that holding or blocking is neutralized. As the first knob 42 continues to turn, as the displacement element 66 continues to move, the pin 70 entrains the release element 36 . By way of the release element's support on the fifth axis 68 and the latch 18 , and the pin 70 moves latch 18 in FIG. 3 to the right so that the latch 18 emerges completely from the latch receiver 60 . Accordingly, the locking is also neutralized.
If the holding element 30 , for example, is monitored in its position by a photoelectric barrier or a Hall sensor, the state shown in FIG. 3 can be signaled such that there is no longer any holding or blocking. At the same time it can also be signaled by the actuator 28 and the read head 26 that the space-separating device 2 is still in a closed and locked state.
FIG. 4 shows an enlargement comparable to FIGS. 2 and 3 , but in the state of the device 1 in which the latch 18 is retracted almost completely into the second component 16 by complete turning of the first knob 42 . The displacement element 66 is located like the latch 18 on its rear stop. Continued turning of the first knob 42 in the direction of rotation leading to neutralization of blocking is no longer possible.
Based on the existing motion coupling, on the outside of the space-separating device 2 the second knob 48 is now in its end position which is opposite relative to FIG. 2 and has been turned back in particular by turning the first knob 42 . In the illustrated state the second part 8 ( FIG. 1 ) can be opened relative to the first part 6 . The actuator 28 is no longer located in the read region of the read head 26 so that the unlocked state can be signaled. If it is necessary or advantageous that the closed state of the second part 8 still is to be signaled, an additional safety switch can be located, for example, on the facing end sides of the first and second part 6 , 8 and, independently of the locking position of the latch 18 , signals the closed position of the second part 8 .
For relocking from the position shown in FIG. 4 the latch 18 must again be introduced into the latch receiver 60 . This is not possible by turning the first knob 42 because the displacement element 66 in FIG. 4 is indeed moved to the left, but there is no respective motion coupling with the latch 18 . This arrangement reliably prevents a person located on the inside of the space-separating device 2 from moving the latch 18 into its position locking the closed state. Rather, for this purpose the second knob 48 must be turned to move the latch 18 out of the second component 16 .
On or near its face-side end, the latch has a bevel 76 . With the bevel 76 , the latch 18 can lift the holding element 30 out of its position shown in FIG. 4 , in which the holding element 30 with its projection 54 projects over the recess 56 into the latch receiver 60 . When the latch 18 has been fully inserted into the latch receiver 60 , the projection 54 in turn engages the recess 56 and blocks the latch 18 in its locking position. In this motion of the latch 18 , based on the motion coupling between the release element 36 and the displacement element 66 , especially due to the contact of the sector-shaped receiver 74 with the pin 70 , the first knob 42 undergoes a reset motion until it again assumes the initial position shown in FIG. 2 .
Preferably, the holding element 30 integrally forms an action surface 90 which is accessible from the outside of the device 1 . In any case after removing a cover, holding or blocking can be manually neutralized, preferably with a suitable tool.
FIG. 5 shows a side view of the device 1 offset by 90° relative to FIGS. 2 to 4 , in particular of the component 16 from the direction of the position of the first knob 42 . A coupling device is shown for converting the rotary motion of the first knob 42 into linear motion of the displacement element 66 . FIG. 5 corresponds to the position of the latch 18 in FIG. 2 . A square 78 turnable by a first knob 42 is nonrotatably connected by its shape to a driver shaft 80 . Shaft 80 in turn is nonrotatably connected to the first lever 82 . At the articulation point 84 formed, for example, by a pin, the first lever 82 is connected to the second lever 86 , which is in turn connected to the displacement element 66 at a position spaced apart from the articulation point 84 . Second lever 86 is articulated in particular at another articulation point 88 on the displacement element 66 . In this way, as the first knob 42 turns around the third axis 38 which runs perpendicular to the plane of the drawing of FIG. 5 , the displacement element 66 is moved back and forth, there being motion coupling with the release element 36 only in one direction.
While one embodiment has been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims. | A device ( 1 ) maintains a locked and closed state of a space separating device ( 2 ) in a releasable manner, in particular a protective device of a machine ( 4 ). The device has a first part ( 6 ) with an opening and a second part ( 8 ). The parts are movable relative to one another. The opening is at least partially closable. The device ( 1 ) includes a latch ( 18 ) for locking the closed state of the space-separating device ( 2 ), a holding element ( 30 ) for keeping the latch ( 18 ) in the latched position, and a release element ( 36 ) for releasing the catch of the latch ( 18 ). The catch of the latch ( 18 ) may be lifted by a rotational movement of the release element ( 36 ) relative to the latch ( 18 ). | 4 |
RELATED PATENT APPLICATION
This application is a National Phase Application of PCT/IL03/00036 International Filing Date 14 Jan. 2003, which claims priority from U.S. Provisional Patent Application No. 60/348,380 filed 16 Jan. 2002.
FIELD OF THE INVENTION
The present invention relates to a pricing optmization apparatus and method.
BACKGROUND OF THE INVENTION
The setting of prices of consumer products or services is one of the most important decisions a business enterprise is faced with. The price of a product or service is one of the main factors that determines the willingness of a consumer to purchase it, thus having a significant influence on the business performance of an enterprise. Nevertheless, a methodological approach for setting prices is seldom encountered in enterprises.
A standard practice in enterprises is to add a fixed gross margin to the cost of a product or service, without segmenting customers according to their willingness to pay. It is also possible to charge an optimal price according to the demand function of each customer. In this way, the same product or service could be offered to different customers at different prices. Such segmented marketing is not often used for consumer products but is quite frequent in large scale and business to business transactions.
U.S. Pat. No. 6,078,893 discloses a method for tuning a demand model in a manner that is stable with respect to fluctuations in the sales history used for the tuning. A market model is selected, which predicts how a subset of the parameters in the demand model depends upon information external to the sales history; this model may itself have a number of parameters. An effective figure-of-merit function is defined, consisting of a standard figure-of-merit function based upon the demand model and the sales history, plus a function that attains a minimum value when the parameters of the demand model are closest to the predictions of the market model. This effective figure-of-merit function is minimized with respect to the demand model and market model parameters. The resulting demand model parameters conform to the portions of the sales history data that show a strong trend, and conform to the external market information when the corresponding portions of the sales history data show noise.
Certain consumer products are generally customized. For example, in the case of insurance policies, the policy premium is determined by the actuarial risk of the customer, supplied by the actuarial models of the insurance company; and the specific gross margin required by the service provider. In this case the consumer only knows the price of the product or service offered to him, and not its breakdown into cost and margin. In an industry such as insurance, where the cost (actuarial risk) of the product or service is individualized, the consumer only knows the price quoted to him and is practically unable to compare it with the price of an identical product offered to somebody else.
A methodology for setting enterprise pricing is disclosed in U.S. Pat. No. 6,308,162, which discloses the collection of sales data and its automated optimization in the light of primary enterprise objectives such as maximization of profit and using secondary objectives such as retaining a certain market share. The methodology produces an overall result such as an optimal store price for a given product but is not intended for providing individual pricing.
Products such as insurance policies are not products that are sold once only, neither are they products that have a fixed price for all consumers, but rather are products that are renewed on a regular basis. Yet no automated methodology currently exists for taking renewal business into account in setting an optimal price. Furthermore no automated methodology exists for providing individualized pricing.
SUMMARY OF THE INVENTION
According to a first aspect of the present invention there is thus provided a method of automatically determining an optimum price for an offer by a first entity to a customer entity, comprising the steps of:
obtaining a demand function representative of said customer,
using said demand function and a product margin, building a goal function representative of goals of said first entity, and
automatically optimizing said goal function for said margin, therefrom to generate said offer.
Preferably, said demand function comprises expected behavior in respect of said offer together with expected behavior in respect of future offers, and wherein said automatically optimizing comprises taking into account said expected behaviors in respect of future offers.
Preferably, said automatically optimizing comprises iteratively optimizing backwardly from a furthest future offer to a present offer, in each iteration considering an offer respective to said iteration and an immediately previous offer.
Preferably, said building of said goal function comprises incorporating constraints into said goal function.
Preferably, said incorporating of said constraints comprises building an effective goal function using a lagrangian multiplier to represent said constraints.
The method may further comprise forming a set of non-linear equations from said Lagrangian multipliers and solving said non-linear equations.
Preferably, said solving of said non-linear equations comprises Newton Raphson iteration.
Preferably, said automatically optimizing comprises iteratively optimizing backwardly from a furthest future offer to a present offer, in each iteration considering an offer respective to said iteration and an immediately previous offer, in each stage using a lagrangian multiplier obtained by solution of said non-linear equations.
Preferably, said demand function representative of said customer is a demand function generated per customer.
Preferably, said goal function comprises a term for other income derived from products linked to a product being a subject of said offer.
Preferably, said building of said goal function comprises incorporating a time horizon therein.
Preferably, said automatically optimizing comprises using dynamic programming.
Preferably, said obtaining a demand function comprises applying logistic regression to a customer profile.
According to a second aspect of the present invention there is provided a method of automatically determining an optimum price for an offer by a first entity to a customer entity, comprising the steps of:
obtaining a demand function,
using said demand function and a product margin, building a goal function representative of goals of said first entity
including in said goal function a term for renewal by said customer, and
automatically optimizing said goal function for said margin, therefrom to generate said offer, said optimization including said term for renewal.
According to a third aspect of the present invention there is provided apparatus for automatically determining an optimum price for an offer by a first entity to a customer entity, comprising:
a demand function input for obtaining a demand function representative of said customer,
a goal function builder for using said demand function and a product margin, building a goal function representative of goals of said first entity, and
a goal function optimizer for automatically optimizing said goal function for said margin, therefrom to generate said offer.
Preferably, said demand function comprises expected behavior in respect of said offer together with expected behavior in respect of future offers, and wherein said optimizer is operable to take into account said expected behaviors in respect of future offers.
Preferably, said optimizer is operable to optimize said goal function backwardly from a furthest future offer to a present offer, in each iteration considering an offer respective to said iteration and an immediately previous offer.
Preferably, said goal function builder is further operable to incorporate constraints into said goal function.
Preferably, said incorporating of said constraints comprises building an effective goal function using a Lagrangian multiplier to represent said constraints.
Preferably, said goal function builder is further operable to form a set of non-linear equations from said Lagrangian multipliers to represent said constraints in said goal function, and wherein said apparatus further comprises a non-linear equation solver for solving said non-linear equations, thereby to obtain a set of values for said Lagrangian multipliers that allow said goal function to satisfy said constraints.
Preferably, said solving of said non-linear equations comprises Newton Raphson iteration.
Preferably, said optimizer is operable to iteratively optimize backwardly from a furthest future offer to a present offer, in each iteration considering an offer respective to said iteration and an immediately previous offer, in each stage using a lagrangian multiplier obtained by solution of said non-linear equations.
Preferably, said demand function representative of said customer is a demand function generated per customer.
Preferably, said goal function comprises a term for other income derived from products linked to a product being a subject of said offer.
Preferably, said building of said goal function comprises incorporating a time horizon therein.
Preferably, said goal function optimizer is operable to use dynamic programming in order to carry out said automatically optimizing.
Preferably, said demand function input is operable to apply logistic regression to a customer profile, therefrom to obtain said demand function representative of a respective customer.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention and to show how the same may be carried into effect, reference will now be made, purely by way of example, to the accompanying drawings.
With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice. In the accompanying drawings:
FIG. 1 is a simplified diagram showing the two-stage approach to price setting of the preferred embodiments of the present invention,
FIG. 2 is a simplified balloon diagram showing inputs and an output associated with the enterprise goal function,
FIG. 3 is a simplified flow diagram showing a procedure for optimizing a goal function over a series of time periods using dynamic programming,
FIG. 4 is a simplified flow diagram showing additional steps required prior to the procedure of FIG. 3 in the event of there being constraints, and
FIG. 5 is a simplified flow diagram showing an overall method for obtaining personalized optimized pricing and incorporating the procedures of FIGS. 3 and 4 therein.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present embodiments provide a method and apparatus for providing an optimized margin for offering a product or service. The optimization may take into account renewal business and/or may be personalized for individual customer or client profiles. It is noted that a sale price comprises a cost plus a margin, and therefore the concept of optimization of price, both in the description and claims, includes that of optimization of margin and vice versa.
Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is applicable to other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.
Reference is now made to FIG. 1 , which is a simplified conceptual flow diagram giving an overview of a first preferred embodiment of the present invention. The estimate of an optimized price for a particular product for a particular customer comprises two separate stages, the first of which 10 is the estimate of a demand function for each individual customer. The second stage, 12 is the optimization of an overall goal function to maximize profit over the enterprise. The demand function estimated in stage 10 is used as one of the inputs from which the goal function is established, so that the goal function relates the estimated demand behavior of the individual customer to the overall goals sought by the enterprise. Optimization of the goal function is thus able to provide a price that is optimized both for the needs of the enterprise per se and for the specific need of the enterprise to retain the present customer. As will be explained below, optimization is not based only on the probability of making a current sale to the customer but also on the probability of future sales, in particular regular, renewal type sales.
Reference is now made to FIG. 2 , which is a simplified balloon diagram showing inputs and outputs of the Enterprise goal function.
The goal function 20 is built up from a variable cost 22 of the product, a time horizon 24 for the product, constraints 26 , if there are any, income 28 from associated products, and the estimated customer demand function 30 . The above is not an exhaustive list as an individual enterprise may define its own goal function in any way it chooses.
Once the goal function is set up, then, again as will be described in greater detail below, it may be optimized to produce an optimized sale margin 32 .
Individual elements used in producing the goal function 20 are considered in greater detail below.
Demand Function
The price can be decomposed into two elements, variable cost (VC) and margin:
P t =VC t +M t
The variable cost represents all the direct costs that are incurred in the production process of a product or service and the costs that result from the selling of the product or service. For example, in the case of insurance premiums the main component of the variable cost is the expected claim (EC) imbedded in an insurance policy. But along with the expected claim, the post-selling service (S) and other expenses must also be considered as variable costs, to give:
VC t =EC t +S t,
For instances of t greater than the current time we may use the expected VC as an estimator and thereby treat it as fixed For example, we can assume that the future expected claims, in the absence of claims in previous years, are a function of the current expected claim and decay throughout the policy life span, as follows:
EC t =EC t-1 −K t ,
where EC t is the expected claim at year t, K t =αK t-1 where K 0 >0 and α is a constant (1≧α0), EC 0 is the initial actuarial cost. In non-recursive form:
EC
t
=
EC
0
-
K
0
1
-
α
t
1
-
α
.
The margin is to be determined by the present methodology given constraints provided by the enterprise, and represents the gross profit per product or service.
The present embodiments deal with demand functions at the individual level. In general, the demand function relates the probability of a consumer purchasing a product or service as a function of the price offered and other factors. The other factors may include for example, competitor's prices and socioeconomic factors. Estimating a demand function is not trivial, and one method of estimating a demand function that uses logistical regression, is discussed below. The demand function, however obtained, is provided as an input to the formation of a goal function for the enterprise. When dealing with products or services subject to a renewal process, one may denote the demand function at period t as:
Q t =D t ( P t ,M t ,X t ;β t ) t= 1
Q t =D t ( P t-l ,P t ,M t ,X t ;β t ) t=2,3,
where: 0≦Q t <1;
0≦P t ;
Q denotes the probability of a given purchase being made;
P is the product's price;
X represent the customer profile (covariates) which is to say it represents variables included in customer profiles; and
β the parameters of individual functions expressing customer differentiation.
The only assumption to be made regarding D t (·) is that it is a strictly monotonic decreasing function of P t . The period t denotes the first sale (t=1) or renewal instance (2≦t) in which an offer is given.
For the case of a renewal demand function the embodiments explicitly assume that one of the covariates is the price of the previous year's purchase P t-l . The embodiments include such a variable in order to formalize the observed decision process that a person undergoes at the moment of a renewal, which is to compare prices of the current and previous period.
The preferred embodiments assume that the variable costs are known, so that the margin alone determines the price. The embodiments present the price as a variable in the demand function for exposition purposes, but due to the inclusion of the margin, the price becomes redundant. However, in the following, the terms “margin” and “price” are used interchangeably.
As will be discussed in more detail below in respect of FIG. 5 , a preferred embodiment uses logistical regression in order to arrive at a personalized demand function. However the skilled person will appreciate that any kind of data mining is in principle usable.
Optimization Problem
At the moment of offering a product or service the enterprise has to select an offering price. Selection is achieved by optimization of the goal function, and the main component of the goal function which the embodiments seek to maximize is the expected profit of an offer:
Profit t =( P t −VC t +OI t ) D t ( P t-l ,P t ,M t ,X t ,β)
where OI denotes other income expected as a byproduct of the selling of the main product or service. For example, the profit contributed by a complementary product or service that is sold alongside the main product or service (e.g., compulsory insurance that goes with a comprehensive car insurance policy). It may also represent the expected profit of future cross selling of products or services offered by the enterprise to current customers.
The precise goal function may be varied according to circumstances. The following presents several preferred goal functions that an enterprise wishes to maximize, and the skilled person will understand how to provide the appropriate goal function for his particular enterprise.
As mentioned above, constraints 26 may be present. Constraints are goals other than overall profit that apply to the enterprise, and typically appear in the goal program as secondary goals or constraints. Two different cases are considered below, unconstrained cases and constrained cases.
Unconstrained Cases
1) Firstly an unconstrained case is considered in which the sole goal is profit maximization. More particularly, the goal function seeks, for each individual offer, to maximize not only the profit of the current offer, but, in addition the present value (PV) of future cash flows that may be generated by renewals.
PV
t
=
(
M
t
+
OI
t
)
D
t
(
P
t
-
1
,
P
t
,
M
t
,
.
)
+
∑
i
=
t
+
1
T
(
M
i
+
OI
i
)
∏
j
=
t
i
[
kD
j
(
P
j
-
1
,
P
j
,
M
i
,
.
)
]
(
1
+
r
)
i
-
t
where k denotes the probability that a product or service will end its life span without being canceled and that the enterprise wishes to keep the present customer. Such a goal function is suitable for a renewable product since renewal is taken into consideration by the future cash flows. Usually the time horizon T, that is taken into account is large, in order to cover all significant future cash flow. The discount factor r is the cost of capital of the enterprise.
In order to maximize the goal function, we need to determine a set of margins for the current and subsequent periods {M t , . . . ,M T } that maximizes the present value.
2) Although the above case is derived from an economic perspective, in realistic situations the enterprise managers set a relative short horizon for optimization purposes. Nevertheless, the embodiments assume that at each period the managers look forward to a horizon of the same length.
Constrained Cases
In the following the constrained case is considered. The constrained case is that in which profit maximization is constrained by other secondary goals. More particularly, the overall profit of the enterprise is the sum of each individual offer. If the enterprise's sole concern is maximizing its earnings, the maximization of each individual present value preferably gives the overall optimum. However, in practice the enterprise has secondary goals that are preferably to be considered in the optimization process. It is still preferable to seek to maximize the overall present value, but subject to constraints that incorporate the secondary goals. 1) The enterprise sets as a goal the need to attain a certain level of unit sales for each of the periods. For example, size of portfolio of insurance policies, number of magazines sold, etc. Formally:
MAX M nt { ∑ n ( ( M nt + OI nt ) D t ( P n , t - 1 , P n , t , M nt , . ) + ∑ i = t + 1 T ( M ni + OI ni ) ∏ j = t i [ kD j ( P n , j - 1 , P n , j , M nj , . ) ] ( 1 + r ) i - t ) }
Subject to:
∑ n D ( P n , t , M n , t , . ) = S t
for each t, where S is the size of the portfolio.
2) The enterprise sets as a goal the attainment of a certain level of revenues for each of the periods. Formally:
MAX
M
nt
{
∑
n
(
(
M
nt
+
OI
nt
)
D
t
(
P
n
,
t
-
1
,
P
n
,
t
,
M
nt
,
.
)
+
∑
i
=
t
+
1
T
(
M
ni
+
OI
ni
)
∏
j
=
t
i
[
kD
j
(
P
n
,
j
-
1
,
P
n
,
j
,
M
nj
,
.
)
]
(
1
+
r
)
i
-
t
)
}
Subject to:
∑ n P n , t D ( P n , t , M n , t , . ) = R t
for each period t, where R t is a targeted revenue level.
Optimization Methodology
In this section, optimization methods are discussed that solve the problems presented in the previous section.
Unconstrained Cases
For the unconstrained cases the embodiments apply a dynamic programming algorithm, which solves the problem in a more efficient way than exhaustive search.
1) The algorithm is based on the observation that the optimal margin at period t, M t , only depends on the price at period t-1, P t-1 , and not on previous prices. This dependency is the expression of an assumption that the demand function involves only the price of the last period and not previous prices.
Thus for any time t, it is possible to find the optimal M t for each P t-1 in a predefined range. Then iterating t down from T to 1, all mappings M t [P t-1 ] can be found. In this way, in the last iteration the embodiment obtains M 1 [P 0 ], which is the margin sought for the current period P 0 .
Reference is now made to FIG. 3 , which is a simplified flow chart showing the procedure for optimizing the goal function in the unconstrained case.
Formally, at each iteration, going backwards from a final period T to a first period 1, the following is executed by preprogrammed software and/or dedicated hardware:
1. Make a partition of P t-1 in the interval [C t-1 ,C t-1 +ΔN], where Δ is the step size and N is the number of the current period, ranging from one to the total number of periods (stage 40 in FIG. 3 ).
2. Perform the loop of Stages 42 - 48 in FIG. 3 until all periods are complete. For each period P t-1 , starting with the final period T, find the M t that maximizes the expression V(P t-1 ):
V ( P t-1 )= M t D ( P t-1 ,M t )+ kD ( P t-1 ,P t , M t ) V ( P t )/(1+ r )
and
V ( P T-1 )= M T D ( P T-1 ,P T ,M T )
The optimization of M t can be performed by exhaustive search on a fixed partitioned interval or by more efficient algorithms like golden section search (See W. Press et. al., Numerical Recipes in C, p. 397, the contents of which are incorporated herein by reference) ór parabolic-interpolation search (See W. Press et. al., Numerical Recipes in C, p. 402, the contents of which are hereby incorporated herein by reference.)
The above algorithm takes O(TΔN 2 ) iterations.
The algorithm may be written in sketch computer code as:
procedure LongTerm given M −1 , T, r, D( ) returns M 0 opt
for each t from T−1 down to 0
for each M t−1 in range [M min , M max ] with step M step
E t max = −∞
for each M t in range [M min , M max ] with step M prec
Q t = D(t, M t , M t−1 )
E t = Q t * (M t + Etable[t+1)[M t ] / (1+r))
if E t > E t max then
E t max = E t
M t opt = M t
Mtable[t][M t−1 ] = M t opt
Etable[t][M t−1 ] = E t max
return Mtable[0][M −1 ]
2) For the second case, namely unconstrained with short time horizon, we assume that the enterprise optimizes the NPV for a relatively short period h, typically 3 to 6 periods. However, such an optimization is preferably performed for each and every period.
The algorithm is similar to the previous one. It iterates backwards from T to 1, but optimizes:
V
t
h
(
P
t
-
1
)
=
Max
M
t
{
M
t
D
(
P
t
-
1
,
P
t
,
M
t
)
+
D
(
P
t
-
1
,
P
t
,
M
t
)
V
t
+
1
h
-
1
(
P
t
)
}
⟹
M
t
(
P
t
-
1
)
where
:
V
t
h
-
1
(
P
t
-
1
)
=
M
t
(
P
t
-
1
)
D
(
P
t
-
1
,
P
t
(
P
t
-
1
)
,
M
t
(
P
t
-
1
)
+
D
(
P
t
-
1
,
P
t
P
t
-
1
)
,
M
t
(
P
t
-
1
)
V
t
+
1
h
-
1
(
P
t
)
⋮
V
t
1
(
P
t
-
1
)
=
M
t
(
P
t
-
1
)
D
(
P
t
-
1
,
P
t
(
P
t
-
1
)
,
M
t
(
P
t
-
1
)
The algorithm may be written in sketch computer code as: procedure SlidingWindow given M 1 , P, T, r, D( ) returns M 0 opt
for each t from P−1 down to 0
for each M t−1 in range [M min , M max ] with step M step
E t max = −∞
for each M t in range [M min , M max ] with step M prec
Q accum = 1
E t = 0
m t−1 = M t−1
m t = M t
for each h from t to t+T−1
Q accum = Q accum * D(h, m t , m t−1 )
E t = E t + m t *Q accum /(1+r) h
m t−1 =m t
m t = Mtable[h+1][m t ]
if E t > E t max then
E t max = E t
M t opt = M t
Mtable[t][M t−1 ] = M t opt
return Mtable[0][M −1 ]
The algorithm requires O(ThΔN 2 ) iterations.
The algorithm may also be written in a recursive manner, which is more efficient:
procedure RecursionStart given M −1 , T, r, DF( ) returns M 0 opt
return RecursiveWindow(0, M −1 , T, r, DF, 1)
procedure RecursiveWindow given t, M t−1 , T, r, D( ), Q t returns M t opt
if exists Mtable[t][M t−1 ] then
//we already calculated the value
return Mtable[t][M t−1 ]
E t max = −∞
//maximal E t found until now
for each M t in range [M min , M max ] with step M prec //search for M t opt
Q accum = D(t, M t , M t−1 )
//accumulated renewal probability
E t = M t *Q accum /(1+r) t
//E t for the selected M t
m h−1 = M t
for each h from t+1 to t+T−1
//accumulating E t for T−1 years
if E t *Q t < NEGLIGIBLE then
//recursion termination
condition
break
// recursive step for optimal M h
m h = RecursiveWindow(h, m h−1 , T, r, DF, Q t *Q accum )
Q accum = Q accum * D(h, m h , m h−1 )
//updating Q accum
E t = E t + m h *Q accum /(1+r) h
//updating E t
m h−1 = m h
if E t > E t max then
//if the new E t is higher
E t max = E t
//update with the new E t
M t opt = M t
Mtable[t][M t−1 ] = M t opt
//save the optimal M t
return M t opt
Constrained Optimization
The two cases of constrained optimization can be solved in a manner similar to the above. There are several methodologies to optimize a function subject to constraints. In the preferred embodiments to be described below, a mixture is applied of the dynamic programming algorithm of the unconstrained cases above, together with use of the well-known Newton-Raphson iteration method for finding the roots of a non-linear set of equations.
It is assumed that a known set of individuals approach the enterprise and ask for a price quote on the product or service the enterprise offers. These individuals may be asking for a first offer or be current customers renewing their products or services. In the case of a purchase, all members of the set approach the enterprise at the following period for a renewal. At the following period it is also assumed that new clients approach the firm, and so on for each period.
Reference is now made to FIG. 4 , which illustrates in general terms the procedure for optimizing a goal function having constraints.
In order to solve the above-described constraint problem the embodiments build a Lagranian function, (stage 50 in FIG. 4 ) which comprises augmenting the goal function by the constraints, and thereby obtaining an effective goal function for subsequent optimization:
GoalFunction
=
∑
i
pv
1
(
M
1
)
-
∑
t
λ
t
(
∑
i
θ
t
(
M
t
)
-
R
t
)
Where,
M i denotes the set of all margins for individual i for period 1 to T.
λ t is the Lagrange multiplier for period t
∑ i θ t ( M 1 ) - R t = 0
is the secondary target goal (constraint) for each time period t=1 to T.
We note that for fixed λ t the margin set M i is optimized for each individual in the same manner as in the unconstrained case. Thus, local optimizations for individuals, when taken together, provide a global optimum of the goal function because each individual's demand function is not influenced by the prices given to other individuals. Thus, in order to achieve a global maximum income one may maximize each local demand function. However if there is a further constraint, for example a certain minimum number of customers, then one sets the offers to each individual so that the combined probabilities give the minimum number of customers.
The problem is to find those λ t for which the optimal margins M i also satisfy the constraints. Thus, the problem may be reduced to that of finding the roots of a non-linear set of equations:
ϕ
1
(
λ
1
,
…
,
λ
t
)
=
0
⋮
ϕ
t
(
λ
1
,
…
,
λ
t
)
=
0
The above problem is solved (stage 52 ) by the Newton-Rapshon method (W. Press, “Numerical Recipes in C”, p. 379). In order to use Newton-Raphson in cases in which analytical derivatives are unavailable, it is preferably to use Broyden's method (W. Press, “Numerical Recipes in C”, p. 389) to approximate the Jacobian matrix.
Finally, in a stage 54 , per period iteration is carried out as in the unconstrained case of FIG. 3 , using the values of λ obtained in stage 52 .
Reference is now made to FIG. 5 , which is a simplified flow chart showing operation of a methodology according to the present invention that utilizes the procedures described in respect of FIGS. 1-3 . In a first stage 60 , the user enters profiles for his various clients. The profiles preferably include any factors available to the user about the client that has to do with the probability of making a sale to the respective client of the product, and may include age, sex, and socioeconomic group, prices offered by competitors etc. For example, the user may feel that a major factor in selling a given product is age. In such a case he will make age, or a generalized age group a prominent part of the profile provided that he has the data available.
In a following stage, 62 , a generalized demand function is used with data from the profile to produce a specific demand function for the individual clients of interest. Typically a demand function is a function that describes probabilities of either purchasing or not purchasing a product, and is thus ideally suited to techniques such as logistical regression. For a series of i conditions Xi in a given client's profile, each condition can be given a weighting β. The weighted conditions can then be summed, and the summation used to determine the individual customer's demand. Thus
y
=
1
1
+
ⅇ
∑
i
β
i
z
i
In a following stage 64 , general parameters are entered, such as the product variable cost, the time horizon of interest, other income—that is likely income from sales of associated products) and other like parameters deemed to be relevant.
In stage 66 , constraints are entered if any. As discussed above, constraints are secondary goals that the enterprise wishes to take into account, and may include factors such as wishing to maintain a certain market share, or wishing to retain a certain price image.
Stage 68 is a decision stage in which the system determines whether constraints have been entered. If constraints have been entered then the method branches to stage 70 in which the procedure of FIG. 4 is carried out to set up an effective goal function, and the procedure of FIG. 3 is entered indirectly. If constraints have not been entered then the procedure of FIG. 3 is entered directly as stage 72 . Finally, in a stage 74 , results are presented. Preferably, the results include both overall results for the client database and individual results for each client profile. Thus each client can be offered the product at a personally tailored price.
It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination.
Unless otherwise defined, all technical and scientific terms used herein have the same meanings as are commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods are described herein.
All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the patent specification, including defintions, will prevail. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.
It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather the scope of the present invention is defined by the appended claims and includes both combinations and subcombinations of the various features described hereinabove as well as variations and modifications thereof which would occur to persons skilled in the art upon reading the foregoing description. | A method or apparatus for automatically determining an optimum price for an offer by a first entity to a customer entity, comprising: obtaining a demand function representative of the customer, using the demand function and other factors include an intended product margin, building a goal function representative of goals of said first entity, and automatically optimizing the goal function for the margin, therefrom to generate the offer. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a U.S. national stage application of International Application No. PCT/EP2005/054189 filed Aug. 25, 2005, which designates the United States of America, and claims priority to German application number DE 10 2004 042 488.8 filed Aug. 31, 2004, the contents of which are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] The invention relates to an electrical assembly comprising an integrated circuit, which has at least one power semiconductor element and further electronic components, which are connected to one another and to connections by conductors formed by a leadframe.
BACKGROUND
[0003] Electrical assemblies, which are to operate reliably and must be robust in relation to ambient influences, are often realized with the aid of leadframe structures to which active and passive electrical and electronic components are applied by welding. The assemblies are encapsulated with electrically insulating materials, so that they are hermetically sealed in relation to ambient influences and can withstand even large mechanical loadings (impact, vibration). Examples of such assemblies are rotational speed sensors or position sensors in motor vehicles.
[0004] When using power semiconductor elements, in particular field effect transistors, occasionally large power losses arise, however, which are difficult to dissipate in the case of the assemblies described.
SUMMARY
[0005] It is an object of the present invention to configure an electrical assembly according to the preamble in such a way that, whilst maintaining the positive properties and with minimum additional costs, good heat dissipation is possible and a construction by way of printed circuit board assemblies (epoxy printed circuit boards or ceramic boards using SO technology) with separate cooling elements is avoided.
[0006] In the case of the assembly according to an embodiment, this object is achieved by virtue of the fact that the leadframe has at least one cooling area, which is thermally conductively connected to a thermal contact area of the at least one integrated circuit, which has a larger area than the thermal contact area of the at least one integrated circuit and which is wider than the parts of the leadframe which are used for electrical conduction.
[0007] Thus, according to an embodiment, an electrical assembly may comprise an integrated circuit, which has at least one power semiconductor element and further electronic components, which are connected to one another and to connections by conductors formed by a leadframe, wherein the leadframe has at least one cooling area, which is thermally conductively connected to a thermal contact area of the at least one integrated circuit, which has a larger area than the thermal contact area of the at least one integrated circuit and which is wider than the parts of the leadframe which are used for electrical conduction, and wherein the cooling area is formed as a thermal contact plate with a connection lug, which is bent away from its plane at its end remote from the integrated circuit and at which one end of the contact area bears and is thermally conductively connected, wherein the thermal contact plate is injection-molded or cast into a component composed of an electrically insulating material, wherein the component has a receptacle, into which the integrated circuit can be inserted in a manner positioned in such a way that connection lug and mating connection lug bear on one another and signal connection lugs and signal mating connection lugs bear on one another.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention permits numerous embodiments. A plurality of these embodiments are illustrated schematically in the drawing on the basis of a plurality of figures and are described below. In the figures:
[0009] FIG. 1 shows a first view of an exemplary embodiment,
[0010] FIG. 2 shows a second view of parts of the exemplary embodiment according to FIG. 1 ,
[0011] FIG. 3 and FIG. 4 each show a cross section through a part of an exemplary embodiment in which, as a result of prior bending of the cooling area, a good thermal contact is obtained in a first phase during production and in the finished state,
[0012] FIG. 5 shows an exemplary embodiment with an encapsulation composed of plastic,
[0013] FIG. 6 shows a further exemplary embodiment with an encapsulation.
[0014] FIG. 7 shows a perspective view of a further exemplary embodiment,
[0015] FIG. 8 shows a perspective view of a further exemplary embodiment, and
[0016] FIG. 9 shows a perspective view of a further exemplary embodiment,
[0017] FIG. 10 shows a stylized plan view of a leadframe with connected circuit, motor and sensor.
DETAILED DESCRIPTION
[0018] According to an embodiment, the leadframe is preferably stamped out in one piece from a metal sheet. Parts of the leadframe serve for electrical connection, and other parts serve for cooling. According to an embodiment, the thermal connection between the contact area and the cooling area can be effected in various ways, for example by conductive adhesive, by welding or soldering. However, it is also possible for a spring-elastic clamping to be provided. According to an embodiment, the cooling area may in particular cases be connected to the ground or the negative pole of the operating voltage source.
[0019] In order to obtain a good thermal contact, in one embodiment of the assembly it is provided that the cooling area is fixedly connected to the contact area at least two opposite edges, and that the area region of the cooling area that bears on the contact area is prestressed against the contact area. It is assumed in this case that the thickness of the cooling plate is smaller than the thickness of the metal body of the integrated circuit that forms the contact area.
[0020] One advantageous configuration of the assembly consists in the fact that the assembly including the leadframe is encapsulated with an electrically insulating material. According to an embodiment, the assembly can be brought into contact with cooling air.
[0021] In order in this case to ensure a good heat dissipation from the cooling area to the surrounding medium, however, in this configuration it may be provided that the cooling area is at least partially not encapsulated, or that the cooling area is at least partially encapsulated with a thinner layer than the remaining parts of the assembly.
[0022] Another embodiment enables a universal use of the assembly by virtue of the fact that the further electronic components form an application specific integrated circuit.
[0023] Moreover, in the case of the assembly according to an embodiment it may be provided that a sensor, in particular a position detecting sensor, is connected with the aid of the conductors formed by the leadframe.
[0024] According to an embodiment, a particularly compact assembly is obtained by the application specific integrated circuit and the integrated circuits being integrated in a common housing.
[0025] Furthermore, the fact that the leadframe is mounted in an electrically insulating holding frame contributes to the stability in the manufacturing process, according to an embodiment.
[0026] For electrical connection to other assemblies and apparatuses, in accordance with one embodiment, it may be provided that parts of the leadframe are embodied as electrical plug connections.
[0027] In order to improve the heat dissipation, it may furthermore be provided that a thermally conductive intermediate layer is applied between the contact area and the region of the leadframe that touches said contact area, according to an embodiment.
[0028] If the cooling area is formed as a thermal contact plate with a connection lug, which is bent away from its plane at its end remote from the integrated circuit and at which one end of the contact area bears and is thermally conductively connected, then both simple mountability of the integrated circuit and simple diagnosis in the event of a defect of the assembly are possible.
[0029] Said simple mountability is also improved if the contact area has a mating connection lug, which bears on the connection lug of the thermal contact plate and is thermally conductively connected to the connection lug, according to an embodiment.
[0030] A welding may be effected e.g. in a simple manner after the completion of the component of the assembly, according to an embodiment.
[0031] According to an embodiment, the same advantages are furthermore achieved if the leadframe has signal-carrying conductors having signal connection lugs, which are bent away from their plane at their ends facing the integrated circuit and at which ends the signal-carrying conductors bear and are electrically conductively connected, and if the ends of the signal-carrying conductors have signal mating connection lugs, which bear and are electrically conductively connected at the signal connection lugs.
[0032] Both good thermal conduction and good electrical conduction are achieved by virtue of the fact that the connection lug is connected to the mating connection lug and/or the signal connection lugs are connected to the signal mating connection lugs by welding such as electrical resistance welding or laser welding or by soldering, according to an embodiment.
[0033] Good thermal conduction can be achieved in a simple manner also by virtue of the fact that the connection lug is connected to the mating connection lug by means of electrically and/or thermally conductive adhesive, according to an embodiment.
[0034] For good electrical conduction, in a simple manner, the signal connection lugs may be connected to the signal mating connection lugs by means of an electrically conductive adhesive, according to an embodiment.
[0035] If the thermal contact plate is injection-molded or cast into a component composed of an electrically insulating material, wherein the component has a receptacle, into which the integrated circuit can be inserted in a manner positioned in such a way that connection lug and mating connection lug bear on one another and signal connection lugs and signal mating connection lugs bear on one another, then as a result of the integrated circuit being inserted into the receptacle, at the same time connection lugs and mating connection lugs and also signal connection lugs and signal mating connection lugs bear on one another in a correctly assigned manner, which significantly simplifies the mounting operation, according to an embodiment.
[0036] For conductive connection, a good accessibility e.g. for welding is achieved if connection lug and mating connection lug and/or signal connection lugs and signal mating connection lugs are bent away in a manner directed away from the plane of a bottom of the receptacle, according to an embodiment.
[0037] If the thermal contact plate is injection-molded or cast into the component composed of electrically insulating material in such a way that at least 50% of the area of the contact plate is covered with a wall thickness of the electrically insulating material of <3 mm, in particular of <1.5 mm, then good heat dissipation from the thermal contact plate via the component composed of electrically insulating material is achieved in conjunction with good stability of the assembly, according to an embodiment.
[0038] If the signal-carrying conductors of the leadframe are injection-molded or cast into the component composed of electrically insulating material, and the integrated circuit can be inserted into the receptacle in a manner positioned in such a way that mutually assigned signal connection lugs and signal mating connection lugs bear on one another, then a simple exact positioning of the signal connection lugs with respect to the signal mating connection lugs during mounting is possible in this case, too, according to an embodiment.
[0039] For further dissipation of the heat generated by the integrated circuit, according to an embodiment, the integrated circuit may bear with a boundary wall on the bottom of the receptacle, in which case preferably the component composed of electrically insulating material has a wall thickness of <4 mm, in particular of <2 mm, in the region of the bottom of the receptacle. The smaller the wall thickness, the better the heat dissipation capability to the ambient air.
[0040] In this case, according to an embodiment, the integrated circuit may bear on the bottom of the receptacle via an intermediate layer.
[0041] For good heat transfer, it is possible for the intermediate layer to comprise a thermally conductive adhesive, a thermally conductive adhesive film or a thermally conductive paste, according to an embodiment.
[0042] If the thermal contact plate is provided with a cutout or a plurality, in particular a multiplicity of continuous cutouts in its region enclosed by the electrically insulating material, according to an embodiment, then an at least largely reliable bearing of the contact plate on the plastic is achieved, even in the event of temperature change, by means of the electrically insulating material filling the cutouts. Delaminations between these parts which might occur after a temperature change and might lead to an insulating layer of air between said parts are thus avoided in a simple manner.
[0043] According to an embodiment, the integrated circuit may be a plastic-encapsulated power semiconductor element or a hybrid circuit that is arranged on a substrate and has power semiconductor elements.
[0044] In this case, according to an embodiment, the substrate is preferably a ceramic substrate or an insulated metal substrate or an epoxy printed circuit board, on which the power semiconductor element and electronic components are arranged, in particular soldered or in particular thermally conductively adhesively bonded.
[0045] In the exemplary embodiment according to FIGS. 1 and 2 , conductors 1 of a leadframe connect a structural unit which is formed as an integrated circuit and comprises a plurality of power semiconductor elements 2 to an application specific integrated circuit 7 and a sensor 6 . Further conductors of the leadframe are led out from the assembly and serve as connection pins 9 , 9 ′. A wider conductor of the leadframe is extended areally and forms a cooling area 3 , which is in thermal contact with a thermal contact area 4 of the integrated circuit 2 . The connection pins 9 serve for connection to a motor, preferably via interference-suppression inductors, which are not illustrated in FIG. 1 . The conductors 1 ′ illustrated as broken off are intended to show that other components may additionally be present in the assembly according to an embodiment.
[0046] During production, a leadframe is firstly produced as one piece. Bridges present between the individual conductors 1 , 1 ′ are separated later. As a result, the leadframe can be handled as one piece up to a definition of the conductors. The separation is effected only when the individual conductors have been fixed, which is effected by a holding frame 8 in the exemplary embodiment according to FIG. 1 . A final fixing is effected when the entire assembly is encapsulated with electrically insulated material.
[0047] In the exemplary embodiment according to FIG. 3 , an area region 5 of a conductor of the leadframe is pre-bent on that area which is intended to touch the contact area 4 of the power semiconductor element 2 . During mounting, the area region 5 is pressed onto the contact area 4 and fixed there for example by means of a soldering or welding seam 10 or by suitable clips. By means of the prestress, the conductor bears fixedly on the entire contact area 4 in the area region 5 .
[0048] The exemplary embodiment according to FIG. 5 has an encapsulation 11 , which also encompasses the cooling area 3 and is illustrated in transparent fashion in order to provide a clear view of the components and conductors. In order to obtain higher heat dissipation, the cooling areas 3 are not enclosed by the encapsulation 12 in the case of the exemplary embodiment according to FIG. 6 .
[0049] The exemplary embodiments illustrated in FIGS. 7 to 9 show an approximately pot-like component 13 composed of an electrically insulating material, which is a plastic and may be an epoxy resin, a filler plastic or a thermosetting plastic.
[0050] The housing part 13 may be a housing cover of a housing of a butterfly valve for a motor vehicle.
[0051] A recessed cutout 15 having a rectangular cross section is formed at the base of the pot-like depression 14 of the component 13 .
[0052] A leadframe comprising thermal contact plates 16 , 16 ′ and signal-carrying conductors 17 , 17 ′ is concomitantly injection-molded into the plastic.
[0053] In the case of the exemplary embodiment in FIG. 9 , the leadframe was firstly provided with a preencapsulation 18 composed of plastic so as then to be encapsulated by injection-molding once again in a further work operation to form the component 13 .
[0054] In each case two contact plates 16 and two conductors 17 project in a manner lying alongside one another from the side wall of the depression 14 of the component 13 .
[0055] Opposite said two contact plates 16 and conductors 17 , likewise two contact plates 16 ′ and two conductors 17 ′ project from a side wall of the depression 14 of the component 13 .
[0056] The free ends of the contact plates 16 , 16 ′ which project into the depression 14 are bent away at right angles from the plane of the contact plates 16 , 16 ′ to form connection lugs 19 , 19 ′.
[0057] In the same way, the free ends of the conductors 17 , 17 ′ which project into the depression 14 are also bent away at right angles from the plane of the conductors 17 , 17 ′ to form signal connection lugs 20 , 20 ′.
[0058] Both the connection lugs 19 , 19 ′ and the signal connection lugs 20 , 20 ′ are directed toward the opening of the depression 14 .
[0059] An integrated circuit having approximately the same cross-sectional contour as the receptacle 15 is inserted into the receptacle 15 , and is connected to the bottom 27 of the receptacle 15 by means of a thermally conductive adhesive 26 in FIG. 9 .
[0060] In the case of the exemplary embodiments of FIGS. 7 and 9 , plate-like contact areas 4 are led out, parallel to the contact plates 16 , 16 ′, from the sides of the encapsulated integrated circuit 21 which face the contact plates 16 , 16 ′ and are bent away at right angles at their free ends in a manner directed toward the opening of the depression 14 to form mating connection lugs 22 , 22 ′.
[0061] Each connection lug 19 , 19 ′ is assigned a mating connection lug 22 , 22 ′. In this case, mutually assigned connection lugs 19 , 19 ′ and mating connection lugs 22 , 22 ′ have the same width, are directed in the same direction and bear on one another.
[0062] The mutually assigned connection lugs 19 , 19 ′ and mating connection lugs 22 , 22 ′ are electrically and thermally conductively connected to one another by a plurality of welding points 23 .
[0063] In the same way as the mating connection lugs 22 , 22 ′, plate-like signal conductors 24 , 24 ′ are also led out from the integrated circuit and bent away to form signal mating connection lugs 25 , 25 ′, which bear on the signal connection lugs 20 , 20 ′ and are electrically conductively connected thereto by welding points 23 ′.
[0064] In the case of the exemplary embodiment in FIG. 8 , plate-like contact areas 4 ′ are present, which are bent to form a “U” in a manner corresponding to the receptacle 15 and are inserted into the receptacle 15 .
[0065] The contact areas 4 ′ are fixed to the bottom 27 of the receptacle 15 by means of a thermally conductive adhesive 26 , a substrate 29 of the integrated circuit 21 ′ likewise being fixed on the inner side of the “U” of the contact area 4 ′ by means of a thermally conductive adhesive 28 .
[0066] In this case, that part of the contact area 4 ′ which bears on the bottom 27 forms an intermediate layer 30 .
[0067] The two parallel limbs of the contact areas 4 ′ form mating connection lugs 22 , 22 ′ which, as in the exemplary embodiments in FIGS. 7 and 9 , bear on the connection lugs 19 , 19 ′ and are thermally conductively connected thereto by welding points 23 , 23 ′.
[0068] Arranged on the substrate 29 is an integrated circuit 21 ′ in the form of a hybrid circuit with conductor tracks (not illustrated), which also has a power semiconductor element alongside further electronic components.
[0069] Some of the conductor tracks (not illustrated) lead to the edge regions of the substrate 29 which are opposite the signal connection lugs 20 , 20 ′. Plate-like signal conductors 24 , 24 ′ are soldered by one end thereof onto the ends of the conductor tracks of the substrate 29 which are respectively assigned to them.
[0070] The other ends of the signal conductors 24 , 24 ′ are bent away at right angles to form signal connection lugs 20 , 20 ′ and bear on the signal mating connection lugs 25 , 25 ′ which are respectively assigned to them and to which they are electrically conductively connected by welding points 23 , 23 ′.
[0071] In the case of the exemplary embodiments in FIGS. 7 to 9 , the regions of the contact plates 16 , 16 ′ which are arranged in the component 13 extend near the outer wall of the component 13 , with the result that the majority of their area is covered by the electrically insulating material having only a small wall thickness 32 of approximately 1 to 1.5 mm. Good heat emission toward the outside is thereby possible.
[0072] For good connection of the contact plates 16 , 16 ′ to the electrically insulating material, a multiplicity of continuous cutouts 31 which are filled by the electrically insulating material are formed in the contact plates 16 , 16 ′.
[0073] In the case of the exemplary embodiments in FIGS. 7 and 9 , the contact plates 16 , 16 ′ serve both for heat dissipation and as electrical connection to plug pins (not illustrated), while in the case of the exemplary embodiment in FIG. 8 , the contact plates 16 , 16 ′ serve only for heat dissipation.
[0074] FIG. 10 reveals the stylized plan view of a leadframe such as is used in the case of the exemplary embodiments in FIGS. 7 and 9 .
[0075] In this case, the contact plates 16 have plug pins 33 and one of the conductors 17 leads to a position detection sensor 34 .
[0076] A further conductor 17 leads to the voltage supply 35 .
[0077] A DC motor 36 can be driven by the integrated circuit via the contact plates 16 ′. | An electric sub-assembly has an integrated circuit, which contains at least one power semi-conductor component and additional electronic components, the latter being interconnected and linked to connections by the conductors of a lead frame ( 1, 2, 3 ). The lead frame ( 1, 2, 3 ) has at least one cooling surface ( 3 ), which is connected in a thermally conductive manner to a thermal contact ( 4 ) of the integrated circuit or circuits. The cooling surface has a greater surface area than the thermal contact surface ( 4 ) of the integrated circuit or circuits and is wider than the parts ( 1 ) of the lead frame that are used as electric conductors. | 7 |
The U.S. Government has rights in this invention as a result of the investigations leading to this invention being funded in part by contract number DAAA15-87-C-0066 from the U.S. Department of Defense.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to sorption of various substances from gases, and the fact that the humidity of the gas can impede and adversely affect this said sorption. We have discovered new and improved methods of treating and manufacturing activated carbon in order to convert it to a new, improved form for which the adverse effects of humidity on sorption are eliminated or reduced.
2. Brief Description of the Background
Activated carbon (hereinafter sometimes also referred to as active carbon or as AC) is a highly adsorbent, porous material manufactured from carbonaceous animal, mineral or vegetable matter. The specific surface area of AC is usually several hundred or more square meters per gram, as measured by the BET method. The BET method is named for its originators, Brunauer, Emmet and Teller [J. Amer. Chem. Soc. 60, 309 (1938)] and is explained in the book by J. M. Smith, "Chemical Engineering Kinetics", pp. 329-48, McGraw-Hill Inc., New York (1981). An early disclosure (U.S. Pat. No. 1,497,544 to Chaney) teaches a method of manufacturing AC by subjecting charcoal to differential oxidation to remove exposed hydrocarbons contained therein, followed by limited oxidation to develop high sorption capacity. In said patent Chaney also teaches a method starting with vegetable matter (e.g. coconut shells) and subjecting it first to low-temperature distillation to expel volatile components, then subjecting the residue to differential oxidation (activation) to eliminate exposed hydrocarbons and to develop high sorption capacity. The differential oxidation can be conducted at temperatures in the range of about 800° to 1200° C. using air, oxygen, CO 2 , steam or other suitable oxidizing reagents. In U.S. Pat. No. 3,876,505, Stoneburner discloses the manufacture of highly porous activated carbon of high specific surface area from coal by heating 30 min. to 18 hr. in air at a temperature between about 150° C. and 215° C., followed by activating the material in a controlled oxygen atmosphere at a temperature between about 1000° and 2000° F. In a very general way, the manufacture of AC usually involves a pyrolytic carbonization step in which the raw material is heated to convert it to carbon and expel volatile hydrocarbons and other compounds by distillation, followed by an activation step in which the carbon is partly oxidized, thereby converting it to a highly porous structural form that has a large specific surface area. Similarly, AC that has been saturated with an organic sorbent can be regenerated by various combinations of distillation, pyrolysis and activation steps.
Active carbons are highly effective sorbents for treating and removing impurities from gases and liquids, owing to the high porosity and high specific surface area of AC. Said high porosity and surface area are usually produced by an activation process in which tiny pores are burned into the carbons by oxidation with reactants such as steam, air, carbon dioxide or mixtures thereof. Activated carbon usually contains oxygen atoms chemically attached to its surface in the form of functional groups such as the lactones, quinones, phenols and carboxylates reported by Ishizaki and Marti [Carbon 19, 409-12(1981)]. As early as 1863 Smith [Proc. Royal Soc. 12, 424(1863)] found that charcoal binds oxygen chemically. The presence of such chemically bound surface oxygen on AC can originate, at least in part, from the activation process.
It is known that water vapor or humidity in gases, including air, can interfere with the sorption of organic compounds from those gases by activated carbons. Accounts of this adverse effect of humidity on sorption of organic compounds by activated carbon may be found in the following references:
Grant, Joyce & Urbanic, p.219 in "Fundamentals of Adsorption" Proceedings of Engineering Foundation Conference, Deutsche Vereinigung fuer Verfahrenstechnik, 1986.
Walker & Thomson, Naval Research Laboratories Memorandum Report 5791, 20 May 1986.
Nelson, Correia and Harder, Am. Indust. Hygiene Journal, pp. 280-288, May 1976.
Adams, et al, Carbon 26, No. 4, 451-59 (1988).
Generally, sorption of certain molecules by AC is known to be influenced by the chemically bound oxygen on the surface of the carbon. It may be speculated that water vapor in a humid gas adsorbs preferentially on AC by hydrogen bonding at surface oxygen sites on the carbon. It may be speculated further that clusters of water molecules form by hydrogen bonding at such sites and interfere, perhaps by physical blockage, with the adsorption of organic molecules by the carbon.
Another problem with AC arises when it is used to sorb organic substances such as solvents that need to be recovered. During the desorptive recovery process, many such substances degrade or polymerize and it is believed that these undesirable degradation or polymerization reactions are catalyzed by the chemisorbed oxygen groups on the AC. The surface oxygen groups on carbon can be acidic or basic.
A number of authors have discussed the influence of surface-bound oxygen on the sorptive and catalytic properties of activated carbon, including:
Coughlin, I & EC Product R & D 80, 12(1969).
Oda and Yokokawa, Carbon 21, 303-309(1983).
Coughlin, Ezra & Tan, Environ. Sci. & Tech. 2, 291 (1968).
Jankowska et al, Carbon 21, 117-120(1983).
Matsumura et al, Carbon 23, 263-271(1985).
Barton et al, Carbon 22, 265-272(1984).
Boehm and Knoetzinger cited in the following paragraph.
It is known [see for example p 151 of Boehm and Knoetzinger in Catal. Sci. & Tech. (ed. by Anderson & Boudart) 4, 39-207, Springer Verlag, Berlin (1983)] to remove surface oxides from carbons by heating them under vacuum. However, deoxygenating carbons by such outgassing produces a material with a highly reactive and unstable surface that, upon re-exposure to air or moisture or both, will react rapidly to reform surface oxides.
Matsumura et al [Carbon 23, pp 263-271 (1985)] treated activated carbons to remove hydrophilic structures by the following procedure: first, the AC was washed with concentrated hydrochloric acid and then with concentrated hydrofluoric acid to remove metallic ions and then thoroughly rinsed with water. It is likely that contacting the carbon with hydrofluoric acid caused chemical reaction between the surface oxygen groups on the carbon and the said acid, thereby producing additional changes in the carbon beyond the removal of metals. Subsequently, a 30-g sample was put in a quartz cell, evacuated and heated in a furnace at 1000° C. for 30 min, then put into contact with hydrogen of about 500 torr at 1000° C., and again evacuated. This treatment process was repeated a few times, and finally the product material was cooled slowly to room temperature in the hydrogen atmosphere. Matsumura et al found that their treatment decreased the adsorption affinities of their treated AC for methanol and water, but not for benzene. They did not study the influence of humidity upon sorption of organic molecules on AC treated by their method. Surprisingly, and in spite of the procedure described by Matsumura et al, we have found that their expensive, inconvenient and time-consuming steps of treatment with concentrated mineral acids to remove metal ions and then washing, are not necessary to desensitize activated carbons to the deleterious effects of humidity upon sorption of organic molecules. In fact, by our methods disclosed hereinbelow, we have been able successfully to reduce the adverse effects of humidity upon sorption of organic substances by active carbons which contain substantial concentrations of metal ions. Contrary to any implications of the teaching of Matsumura et al, we have not had to remove said metals in order to desensitize active carbons to the deleterious effects of humidity upon sorption of organic compounds.
Mazur et al [J. Am. Chem. Soc. 99, pp 3888-91 (1977)] freed synthetic carbon fibers of surface oxides by pyrolysis at 1020° C. in a vacuum of 10 -5 torr, a procedure called vacuum-outgassing. After cooling to room temperature, Mazur et al exposed their vacuum-outgassed samples of carbon fibers to vapors of a variety of substances including oxygen, propane, ethylene, propylene, isobutylene, allene, cyclopentadiene, methylacrylate, acrylyl chloride and vinyl bromide. All of these substances were found to adsorb irreversibly on the deoxygenated synthetic carbon fibers. Mazur et al did not work with activated carbons and did not investigate sorption.
Attar discloses in U.S. Pat. No. 4,597,769 a process for demineralizing coal in which the surface forces between organic and inorganic phases of the coal were reduced by exposing the coal to a mixture of alcohol and acidic gas at temperatures between 100° and 250° C. for up to 300 min.
It appears that the prior art does not teach the manufacture or preparation of activated carbons that resist the deleterious effect of humidity upon the sorption of organic substances. Neither does the prior art teach how to treat activated carbons to make them so resistant.
The prior art described above does not disclose any improved active carbon sorbent resistant to the deleterious effects of humidity on the sorption of organic molecules, nor teach any method of making such an improved activated-carbon sorbent. In spite of the above described prior art, there remains a need for improved activated carbon sorbents resistant to the adverse effects of humidity.
SUMMARY OF THE INVENTION
An object of the present invention is to provide improved activated carbon sorbents that are resistant to the deleterious effects of humidity upon the sorption of organic substances thereon.
It is another object of this invention to provide an improved activated carbon sorbent having been treated in a first step to remove surface oxides thereby forming a chemically active surface, said carbon having been also treated in a subsequent passivating step by reaction with certain substances; the latter passivating step stabilizes the carbon against further reaction with water or air and thereby also causes the carbon to resist better the deleterious effects of humidity upon sorption of organic substances on the carbon.
It is yet another object to provide improved AC sorbents diminished in surface oxides, and therefore also of diminished catalytic activity for undesirable reactions of organic compounds, expecially during desorptive recovery of organic compounds sorbed on the AC.
It is still another object of this invention to provide an improved, metal-containing activated carbon sorbent from which surface oxides have been removed and the resulting chemically active carbon passivated by reaction with certain substances, thereby stabilizing said carbon as in the object described above.
Yet another object of this invention is to provide a packed bed of improved active carbon of increased breakthrough time for the removal of organic compounds from humid air.
Still another object of this invention is to provide methods of treating activated carbon sorbents to make them more resistant to the deleterious effects of moisture or humidity upon sorption of organic compounds.
It is yet another object of this invention to provide methods of treating activated carbon sorbents to remove surface oxides and to passivate the resulting active surface thereby formed, by chemical reaction of the de-oxygenated carbon with molecules which stabilize it.
It is still another object of this invention to provide an improved manufacturing process for making activated carbon sorbents which are resistant to the deleterious effects of humidity upon sorption of organic compounds.
Another object of this invention is to provide an improved manufacturing process for making activated carbons which have reduced populations of chemisorbed oxygen on their surfaces, which surfaces have also been passivated in chemical reactivity after they have been de-oxygenated, by reacting them chemically with molecules which stabilize them.
According to the present invention, the above and other objects of this invention, which will hereinafter become more readily apparent, have been achieved by an activated carbon low in population of surface oxides and with its surface stabilized by reaction with certain passivating molecules. In an exemplary embodiment, the treatment comprises, first, an out-gassing step to remove chemically bound oxygen from the surface of the active carbon by maintaining the AC, at a temperature in the range of about 700° to about 1100° C. and at a total pressure in the range of about 0.1 to about 2.0 atmospheres, in a stream of a de-oxygenating gas such as nitrogen for a period of about several minutes to about several hours, followed by cooling in a de-oxygenating gas to the temperature of the next, passsivating step, followed in turn by a step in which chemical ,reaction with a passivating substance such as ethylene occurs at a total pressure of about one atmosphere and a temperature of about 50° to about 350°° C. for a period between about several minutes and several hours, in order to stabilize the highly active carbon surface produced by the first step. After the reaction with the passivating substance, the carbon is cooled to room temperature in a de-oxygenating gas such as nitrogen. Such treatment de-oxygenates the surface of the activated carbon and then passivates the surface to stabilize it so it will not readily react subsequently with water vapor or oxygen in air.
In another exemplary embodiment, activated carbon is manufactured by an improved process in which, after the usual carbonization and activation steps, the active carbon is maintained under a de-oxygenating gas such as nitrogen at about the same temperature as used in the activation step, at a pressure of about 0.1 to about 2.0 atmospheres, and for a period of about several minutes to about several hours, followed by cooling in a de-oxygenating gas to a temperature between about 50° and 350° C., followed by reaction of the carbon with a passivating substance such as ethylene for about several minutes to several hours in the approximate temperature range of 50° to 350° C. and the approximate pressure range of 0.1 to 2.0 atmospheres, followed by cooling to room temperature in a de-oxygenating gas.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to the present invention, activated carbon is first de-oxygenated by outgassing it in a suitably non-reactive or reducing atmosphere at elevated temperature, thereby producing an AC with a chemically very reactive surface that can react readily with many substances; after the outgassing step, the de-oxygenated active carbon is cooled in a de-oxygenating gas or an inert gas and then contacted in a second step with a passivating substance which reacts with the highly reactive, de-oxygenated carbon surface to stabilize it against further chemical reaction and to produce reaction products on the surface which are not hydrophilic. In a subsequent third step, the active carbon is cooled to room temperature in a non-oxidizing environment provided by a de-oxygenating gas or an inert gas.
In the prior art, de-oxygenation by outgassing is usually accomplished by heating carbon in a vacuum. We have found, however, that heating the carbon in a flowing stream of inert gas such as nitrogen, helium or argon is a more convenient alternative, especially when beds of carbon are to be treated. The gas employed for de-oxygenation need not be always entirely inert. Any gas which does not oxidize carbon and does not adversely react with carbon, and which promotes or permits removal of oxygen from the carbon, is suitable for this de-oxygenation step, e.g. nitrogen, argon, hydrogen, methane or mixtures thereof can be used in the de-oxygenation step. Such a gas is referred to herein as a de-oxygenating gas and includes inert, non-reacting gases such as helium or nitrogen as well as reducing gases such as hydrogen which promote de-oxygenation. Mixtures of such gases can also be used. De-oxygenation by outgassing is best performed at pressures ranging from a vacuum up to a few atmospheres and at temperatures ranging from about 600° to 200° C. and for times ranging from a few minutes to several hours.
Passivating or stabilizing the highly reactive surface of de-oxygenated carbon is best accomplished with a reactant which contains no or only very little oxygen so as not to re-introduce hydrophilic oxygen groups onto the carbon. However, this passivating reactant need not be completely free of oxygen as we have found that ethanol reacts effectively to passivate the surface of de-oxygenated carbons thereby de-sensitizing them to the adverse effect of humidity on the sorption of organic molecules. The passivating reactants should preferably not form hydrophilic groups on the surface of the carbon, or they should at least form fewer or more weakly interactive hydrophilic groups than were originally on the carbon. Moreover, passivating agents should not form large bulky molecular structures which could block pores of the active carbon. Suitable passivating reactants include olefinic monomers such as ethylene, propylene, butene, acrylonitrile, styrene and derivatives of olefins, ethanol and other alcohols up to a carbon number of about eight, hydrogen, di-enes such as butadiene, allene, alkyl amines, aldehydes, halides and the like, and mixtures thereof. Olefins, low-molecular-weight alcohols and hydrogen are preferred passivating reactants. During the passivating step the passivating reagents can also be mixed with an inert or a de-oxygenating gas. Air, water or CO 2 are not suitable passivating substances because they react to reform hydrophilic oxygen groups on the carbon. The best conditions of the stabilization reaction will vary, depending on the reactivities of the de-oxygenated carbon surface and of the stabilizing reagent employed. The following ranges of conditions are suitable for the stabilization reaction: temperatures from room temperature up to about 500° C., with room temperature to about 250° C. preferable; pressures from about a few torr to several atmospheres, with about 0.1 to 2.0 atmospheres preferred; times of reaction ranging from about a minute to about ten hours, with several minutes to several hours preferred. After the stabilization reaction, the activated carbon should be cooled in a non-oxidizing atmosphere to room temperature. A preferred non-oxidizing atmosphere is a stream of nitrogen at a total pressure in the range of about 0.1 to 2.0 atmospheres.
It is important not to conduct the stabilizing reaction for too long a time, or under extreme reaction condition, especially with reagents that can polymerize. We have found that if the stabilizing reaction conducted with olefins, for example, is allowed to proceed too extensively, this can adversely affect the adsorption properties of the active carbon product. Presumably, reactions carried out too extensively can lead to excessive accumulation (e.g. polymers) on the carbon which may block pores of the carbon to access by sorbate molecules.
The present invention is not limited only to the treatment of already manufactured activated carbons. It can be also introduced into the overall manufacturing process for activated carbons, or into regenerating processes, by adding a de-oxygenating step, a chemical stabilizing or passivating step and a cooling step in a non-oxidizing atmosphere formed by a de-oxygenating gas, after the activation step of prior art processes for manufacturing or regenerating activated carbon. Processes for manufacturing activated carbon are described in Active Carbon by M. Smisek and S. Cerny, pp 10-48, Elsevier Publishing Company, New York, 1970. Typical active-carbon manufacturing processes include those described in U.S. Pat. No. 3,876,505 to, Stoneburner and U.S. Pat. No. 1,497,544 to Chaney, both of which are hereby incorporated herein by reference. The activation step in manufacturing active carbon is usually accomplished by contacting the carbon at elevated temperature (e.g. 900°-1100° C.) with a stream of oxidizing gas such as oxygen, CO 2 or steam. The improvement in manufacturing activated carbon conferred by the present invention is achieved by appending the following sequence of steps after the activation step of a typical manufacturing process:
(a) switching from the flow of oxidizing gas after activation of the carbon is complete, to a flow of another, de-oxygenating gas (e.g. nitrogen or hydrogen) which contacts the carbon and thereby permits de-oxygenation of the carbon to occur, (b) maintaining the carbon in a de-oxygenating gas at temperatures in the range of about 700° to 1200° C. and pressures in the range of zero to about 2 atmospheres for a time of about a minute to a few hours, (c) cooling the carbon while in a de-oxygenating gas to a temperature in the range of about 30° to 500° C., or in the range of about 30° to 550° C. (d) reacting the carbon by contacting it, in the temperature range of about 30° to about 500° C., or in the range of about 30° to 550° C., with a stabilizing or passivating substance such as ethylene at a total pressure in the range of about 0.1 to 2 atmospheres for a time period in the range of a few minutes to a few hours, (e) cooling the carbon to room-temperature while in a de-oxygenating environment such as flowing nitrogen at about one atmosphere.
Activated carbon can be regenerated after use by thermal pyrolysis and, or, distillation of volatile matter from the carbon. This is sometimes followed by an oxidative re-activation step, similar to that in a typical manufacturing process for AC. The method of the present invention can be applied also as an improvement to a process for regenerating AC, by adding, after either the distillation, pyrolysis or re-activation step of the regeneration process, the steps of de-oxygenating by outgassing, passivating with a suitable passivating substance, and cooling to room temperature in a de-oxygenating gas. The latter types of step which constitute an improvement in a regenerating process, have been already described more fully above for treatment or manufacture of activated carbon.
In some cases it will be more favorable to modify the process for manufacturing active carbons by adding the improvement steps of the present invention as described in a foregoing paragraph, rather than to apply the present invention to already-manufactured activated carbon. The reason for this is that, by adding the de-oxygenation reaction step and the stabilization reaction step to the usual manufacturing process, one avoids the necessity of costly reheating of the active carbon and the need to convey and store the active carbon between its manufacture and a subsequent treatment process to desensitize it to the adverse effects of humidity.
Having now been generally described, the invention will be better understood by reference to the following experimental examples wherein specific procedures falling within the present claims are described.
EXAMPLES
Example No. 1
ASC whetlerite, an active carbon containing added silver, copper and chromium and manufactured by Calgon Carbon Company, was ground and the fraction used in this Example was that which passed through a 65 mesh U.S. Standard screen but was retained on a 170 mesh screen. Whetlerites are more fully described in U.S. Pat. No. 2,920,050 to F. E. Blacet et al. Several grams of this active carbon was placed in a quartz tube and held at about 700° C. for about 4 hours during which time pure nitrogen was passed through the tube at about 100 ml/min and at a total pressure of about one atmosphere. Thereafter, with the nitrogen still flowing, the temperature was reduced to about 200° C. over the course of a few minutes and then an ethylene flow (about 20 ml/min) was introduced into the nitrogen stream for one hour. Total pressure was about one atmosphere. After the ethylene had been turned off the carbon samples were cooled to room temperature in the stream of nitrogen, then transferred to stoppered glass tubes but no other measures were used to prevent the carbons from contacting air.
The treated and untreated ASC whetlerites were loaded into glass tubes to form packed beds with glass wool inserted at each end to hold the carbon in place. Each bed contained about 100 mg of the carbon and was about 0.5 cm in diameter and about 1.5 cm long. Air containing about 84 parts of toluene per million parts of air was passed through these carbon beds at a flow rate of 60 ml/min, and at room temperature and at one atmosphere total pressure. Toluene had been added to the flowing air from a diffusion tube upstream of the carbon beds. In some cases, the air had been prehumidified by bubbling it through temperature controlled water; in other cases dry air was used. The humidity of the air was measured by a hygrometer. Downstream of the carbon bed, the concentration of toluene in the effluent air leaving the carbon bed was monitored by a flame ionization detector.
Breakthrough curves were generated for each carbon sample by plotting as the ordinate the ratio of toluene concentration of the bed effluent divided by the toluene concentration in the feed gas; time was plotted as the abscissa. Breakthrough times were estimated by extrapolating the nearly straight central portions of the S-shaped breakthrough curves to the abscissa; the intersections of these extrapolated lines with the abscissa were recorded as breakthrough times. Sorption capacities of the carbon beds were also estimated from the breakthrough curves by integration. Estimation of breakthrough times and sorption capacities from breakthrough curves is explained in the above-cited Smisek and Cherny reference, pp 361-75, and will be familiar to those of ordinary skill in the art.
The measured sorption properties (breakthrough time and sorption capacity in % by weight) of the untreated and treated ASC whetlerites (ASC) were as follows:
IN HUMID AIR (relative humidity >95%)
______________________________________ Untreated ASC Treated ASC______________________________________Breakthrough time 7.8 hr 13.0 hrSorption Capacity 11.2 wt % 16.3 wt %______________________________________
IN DRY AIR (relative humidity >10%)
______________________________________ Untreated ASC Treated ASC______________________________________Breakthrough time 16.4 hr 24.3 hrSorption Capacity 21.8 wt % 28.8 wt %______________________________________
Example No. 2
The treatment of the ASC whetlerites was the same as in Example No. 1 except that, in place of ethylene, ethanol at a rate of 1 ml/hr was injected by a syringe pump into the nitrogen feed stream for four hours during the treatment passivation step at 200° C. The results of toluene breakthrough experiments conducted as in Example No. 1 with carbon treated by the present Example were as follows:
IN HUMID AIR (relative humidity >95%)
______________________________________ Untreated ASC Treated ASC______________________________________Breakthrough time 7.8 hr 13.4 hrSorption Capacity 11.2 wt % 16.6 wt % IN______________________________________
DRY AIR (relative humidity >10%)
______________________________________ Untreated ASC Treated ASC______________________________________Breakthrough time 16.4 hr 19.8 hrSorption Capacity 21.8 wt % 24.6 wt %______________________________________
Example No. 3
BPL activated carbon was obtained from Calgon Carbon Company crushed and sieved as in Example No. 1. It was then treated by the same method of Example No. 1 except that the time of exposure to ethylene during the passivation step was ten minutes instead of one hour. The results of toluene breakthrough experiments conducted as in Example No. 1 were as follows:
IN HUMID AIR (relative humidity >95%)
______________________________________ Untreated BPL Treated BPL______________________________________Breakthrough time 8.3 hr 13.4 hrSorption Capacity 20.0 wt % 19.5 wt %______________________________________
IN DRY AIR (relative humidity >10%)
______________________________________ Untreated BPL Treated BPL______________________________________Breakthrough time 20.2 hr 22.4 hrSorption Capacity 29.8 wt % 28.5 wt %______________________________________
When reaction with ethylene as in the present Example was increased to 2 hr there was no improvement in breakthrough time compared to the untreated BPL carbon, and a lowered sorption capacity was observed. When the reaction time with ethylene was increased to ten hours, essentially no improvement was observed compared to the untreated BPL carbon.
Example No. 4
BPL active carbon obtained from Calgon Carbon Company was crushed, sieved and subjected to treatment by outgassing in nitrogen, followed by reaction with ethanol according to the procedure of Example No. 2. The results of toluene breakthrough experiments conducted as in Example No. 1, but using the BPL treated as in the present Example, were as follows:
IN HUMID AIR(relative humidity >95%)
______________________________________ Untreated BPL Treated BPL______________________________________Breakthrough time 8.3 hr 13.2 hrSorption Capacity 20.0 wt % 19.2 wt %______________________________________
IN DRY AIR(relative humidity <10%)
______________________________________ Untreated BPL Treated BPL______________________________________Breakthrough time 20.0 hr 17.2 hrSorption Capacity 29.8 wt % 23.0 wt %______________________________________
Example No. 5
The carbons of the foregoing Examples were subjected to nitrogen adsorption in order to determine specific surface areas by the BET method, as well as specific microporosity. The results follow:
______________________________________ Surface Area Micropore Volume (m.sup.2 /g) (mL/g)______________________________________ASC untreated 960 0.36ASC treated in Ex. 1 1035 0.39ASC treated in Ex. 2 992 0.38BPL untreated 1048 0.39BPL treated in Ex. 3 1031 0.39BPL treated in Ex. 4 1059 0.40______________________________________
It is evident the treatments caused no substantial change in either specific surface area or specific microporosity.
Example No. 6
The carbons of the foregoing examples were held in a desiccator at room temperature and contacted for 24 to 48 hr with the vapors in equilibrium with a saturated solution of CuSO 4 .5H 2 O in the bottom of the desiccator. Samples of each carbon were then placed in the weighing pan of a thermogravimetric analyzer and heated in a flow of dry nitrogen at a rate of 5° C. per min from room temperature (RT) to 150° C. The weight lost (%) by each carbon during heating in this temperature interval was as follows:
______________________________________ Weight Loss (%)______________________________________ASC untreated 6.4ASC treated in Ex. 1 0.0ASC treated in Ex. 2 1.4BPL untreated 13.4BPL treated in Ex. 3 12.4BPL treated in Ex. 4 10.2______________________________________
Because the weight lost by the carbons from room temperature to 150° C. can be attributed to loss of water, it is evident from the data of this Example that the treated carbons bound significantly less water than did the untreated carbons. Thus the treatments of the present invention increased the hydrophobicity of the carbons.
Example No. 7
BPL carbon was treated as in Example #1 except that no passivation step was employed. The carbon was outgassed at 700° C. in flowing nitrogen and then cooled to room temperature in flowing nitrogen, but with no intervening passivation step. The result of breakthrough experiments conducted in humid air using the carbon of the present Example with toluene as in Example #1 produced a breakthrough time of about 8.5 hr (close to that of the untreated carbon) and a sorption capacity of only 14.7% (by weight) (substantially less than that of the untreated carbon). The present Example demonstrates the need for a passivation reaction step in addition to an outgassing step to obtain an active carbon of improved sorption properties in humid air.
The invention now being fully described, 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. | An activated carbon sorbent in which oxygen has been substantially removed from said carbon by outgassing and said oxygen has been replaced by subsequent reaction of the outgassed carbon with a passivating substance. | 2 |
TECHNICAL FIELD
The present invention relates to a seat track assembly. More particularly, the invention relates to a seat track assembly fixed to lower structure of seat and floor for moving the seat with respect to floor. The track assembly may be used in vehicle seats as well as seats or track structures of any kind.
BACKGROUND
The prior art describes various kinds of seat track assemblies used for securing a desirable position of seat with respect to floor for enhancing occupant's comfort. In most of such seat track mechanisms, an upper channel, fixed to seat, is slidable over a lower channel, fixed to floor and these channels are provided with locking mechanism to lock the seat in the desirable position. Whenever the occupant wants to adjust the seat, the seat has to be slided to a preferred position, where it gets locked by means of locking mechanism.
Generally, a seat track mechanism is complex in construction which is operated from near the floor and uses a conventional bearing for facilitating sliding motion of an upper channel fixed to the seat over lower channel. One of the prior art U.S. Pat. No. 6,354,553 B1 describes a seat track assembly with positive lock mechanism where a conventional bearing is used for providing a fine sliding motion. Now, the need has aroused to develop a simple, easy to operate seat track assembly where locking is simplex and intact and which renders a smooth sliding of seat.
The present invention provides a seat track assembly with a lower channel, upper channel, latch bracket, latch pins, lever and sliding assemblies wherein sliding assemblies provide a streamlined sliding to the upper channel and at the desirable position latch pin engages with the lower channel to lock the seat track mechanism from moving further forward or rearward.
SUMMARY OF THE INVENTION
According to an embodiment of the invention, a seat track assembly comprises: a lower channel fixed to a floor, said lower channel comprising: a lower surface having a plurality of spaced slots; an upper channel slidable over said lower channel, fixed to lower structure of a seat, said upper channel comprising: an upper surface having a plurality of spaced slots; a latch bracket fixed to said upper channel; two latch pins placed between said lower channel and said upper channel, each of said latch pins comprising: an extrusion, three pins for engaging into said slots of said lower channel, two side tongues for engaging into said slots of said upper channel, each tongue being provided with a spring thereon, a central tongue for engaging into said slot of said upper channel; a lever operably connected to said latch bracket and latch pins, said lever comprising: two extruded surfaces for pushing said extrusion of said latch pin, a lever handle protruding through the upper channel; whereby in a latching position, the said pins of one of the latch pins engage into said slots to prevent the upper channel from sliding over said lower channel, thereby disallowing movement of the seat and when the lever handle is pulled, the extruded surface of the lever and the pushes the extrusion of the engaged latch pin upwards against the spring pressure to disengage the pins from the slots in the lower channel and engage the tongues with the slots to achieve an unlatching position, thereby allowing the upper channel to slide over the lower channel to enable movement of the seat.
According to another embodiment of the invention, the seat track assembly is provided wherein: said lower channel comprises: two side surfaces having round corners at bottom, and inwardly tapered surfaces at top; said upper channel comprises: two side surfaces having round corners at top, and outwardly tapered surfaces at bottom; and wherein said outwardly tapered surfaces guide into said inwardly tapered surfaces of lower channel.
According to another embodiment of the invention, the seat track assembly comprises: two sliding assembly comprising a pair of sliders, each of said slider comprising: a spacer, two balls, one connected to one end of the spacer and other connected to other end of the spacer, two short spacers, one connected to one of said balls and other connected to other of said balls.
According to another embodiment of the invention, the seat track assembly comprises a pair of said sliding assemblies, a lower sliding assembly being placed between said round corners of the lower channel and said outwardly tapered surfaces of the upper channel, and an upper sliding assembly being placed between said inwardly tapered surfaces of the lower channel and round corners of the upper channel.
According to another embodiment of the invention, a stopper is provided at each end of the tapered surfaces in said lower channel and an upward bent tongue is provided at each end of said upper channel to prevent the upper sliding assembly from coming out of the seat track assembly.
According to another embodiment of the invention, a stopper is provided close to each end of the lower surface of said lower channel and a downward bent tongue is provided next to each of said upward bent tongue in said upper channel to prevent the lower sliding assembly from coming out of the seat track assembly.
According to another embodiment of the invention, said lower channel is provided with a stopper and said upper channel is provided with stopper at each end next to downward bent tongue to control travel of the seat; wherein a fully forward position is achieved when said stopper and said stopper engage to prevent further travel of the seat in a forward direction; and wherein a rearmost position is achieved when said stopper in the lower channel and said stopper in the upper channel engage to prevent further travel of the seat in a rearward direction.
According to another embodiment of the invention, said upper channel is provided with holes for fixing said latch bracket to the upper channel with rivets passing through holes provided in the latch bracket and said holes of said upper channel.
According to another embodiment of the invention, lower surface of said latch bracket is provided with slots through which said pins of the latch pin pass to vertically engage into said slots of the lower channel.
According to another embodiment of the invention, a track handle is provided at side of base of the seat and a cable extends from said cable knob to said lever handle for pulling said lever.
According to another embodiment of the invention, said slots of the lower channel, said slots of said latch bracket through which the pins of said latch pin traverse and said slots of said upper channel are rectangular in shape.
According to another embodiment of the invention, said extrusion is round in shape.
According to another embodiment of the invention, a seat is provided with a pair of the seat track secured on both sides underneath the seat and joined to cable knob through cable.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 illustrates an embodiment of present invention depicting the exploded view of the seat track assembly.
FIG. 2 depicts a lower channel with a top, side and cross sectional view.
FIG. 3 depicts an upper channel with a bottom, side and cross sectional view.
FIG. 4 depicts a latch bracket with a top, side and cross sectional view.
FIG. 5 depicts a latch pin and cross sectional view of the same.
FIG. 6 depicts a lever and lever handle which are used for engagement and disengagement of latch pin in the lower channel.
FIG. 7 depicts a lower sliding assembly and an upper sliding assembly.
FIG. 8 depicts a short spacer and cross sectional view of the same.
FIG. 9 depicts a ball and cross sectional view of the same.
FIG. 10 depicts a spacer of the lower channel and cross sectional view of the same.
FIG. 11 depicts a spacer of the upper channel and cross sectional view of the same.
FIG. 12 depicts a rivet.
FIG. 13 depicts a spring.
FIG. 14 shows the connection of cable within the seat track assembly.
FIG. 15 illustrates the seat with the seat track assembly.
FIG. 16 illustrates fully forward position achieved by seat.
FIG. 17 illustrates rearmost position achieved by seat.
FIG. 18 illustrates desired position achieved by seat.
FIG. 19 illustrates connection of two seat track assemblies with each other
Description of Elements
Reference numerals
Lower channel
1
Upper channel
2
Latch bracket
3
Latch pins
4
Lever
5
Short spacer
6
Ball
7
Spacer
8
Spacer
9
Rivet
10
Spring
11
Slots
21
Tapered surface
22
Holes
23
Stopper
24
Stopper
25
Round corner
26
Stopper
27
Slot
31
Round corner
32
Hole
33
Hole
34
Hole
35
Slot
36
Downward bent tongue
37
Upward bent tongue
38
Tapered surface
39
Stopper
40
Hole
41
Slot
42
Extrusion
45
Side tongue
46
Pin
47
Central tongue
48
Extruded surface
51
Lever handle
52
Slit
53
Cable
54
Lower sliding assembly
55
Upper sliding assembly
56
Cable knob
57
DETAILED DESCRIPTION OF THE INVENTION
The present invention can be more fully understood by reading the following detailed description of some of the embodiments, with reference made to the accompanying drawings.
FIG. 1 illustrates an exploded view of the assembly according to an embodiment of the present invention. A lower channel ( 1 ) as shown in the assembly is provided with plurality of slots at regular intervals in its lower surface. The lower channel ( 1 ) is fixed to a floor with the help of rivets ( 10 ) as shown in FIG. 12 . An upper channel ( 2 ), which is slidable over the lower channel ( 1 ) is fixed to lower structure of a seat with the help of rivets ( 10 ). The upper channel ( 2 ) comprises different holes and slots on its upper surface. A latch bracket ( 3 ), placed between the lower channel ( 1 ) and the upper channel ( 2 ), is fixed to the upper channel ( 2 ) with the help of rivets ( 10 ) passing through holes provided on the upper surface of latch bracket ( 3 ). Two latch pins ( 4 ), each of which is provided with three pins in its lower part for engaging into the slots on lower surface of the lower channel ( 1 ). Each of said latch pin ( 4 ) is also provided with side tongues and central tongue, in its upper part for engaging into the slots on the upper surface of the upper channel ( 2 ). In the latching position one of the two latch pins ( 4 ) is engaged into slots on lower surface of the lower channel ( 1 ) to prevent the upper channel ( 2 ) from sliding over the lower channel ( 1 ) and thus prohibit the movement of the seat. A lever ( 5 ), having two extruded surfaces and a lever handle is operably connected to said latch bracket ( 3 ) and latch pins ( 4 ) and helps the latch pin to engage and disengage into the slots on lower surface of the lower channel ( 1 ). Sliding assemblies ( 55 , 56 ) as shown in the figure are provided between lower channel ( 1 ) and upper channel ( 2 ). Said sliding assemblies ( 55 , 56 ) help in the smooth sliding of upper channel ( 2 ) over the lower channel ( 1 ), thereby allowing smooth movement of the seat. Each of sliding assemblies comprises a pair of sliders and each slider consists of a spacer ( 8 , 9 ), two balls ( 7 ), one connected to one end of the spacer ( 8 , 9 ) and other connected to other end of the spacer ( 8 , 9 ) and two short spacers ( 6 ), one connected to one of said balls ( 7 ) and other connected to other of said balls ( 7 ). Further, a spring ( 11 ) is provided on each of said side tongues on upper part of the latch pin ( 4 ). The spring ( 11 ) helps in engaging the said latch pin ( 4 ) into slots provided on lower surface of the lower channel ( 1 ).
FIG. 2 shows the lower channel ( 1 ) which is provided with holes ( 23 ) for fixing the lower channel ( 1 ) to floor with the help of rivets ( 10 ) passing through holes ( 23 ). The lower channel ( 1 ) being fixed to floor does not have any movement. This lower channel ( 1 ) is provided with plurality of equally spaced identical slots ( 21 ) wherein the pins provided on lower part of the latch pin ( 4 ) traverse in latching position. During unlatched position pins provided on lower part of the latch pin ( 4 ) are not engaged with the slots ( 21 ) of the lower channel ( 1 ). The slots ( 21 ) of the lower channel ( 1 ) can be provided with any shape consistent with the shape of pins provided on lower part of latch pins ( 4 ). However, in the present embodiment, the slots ( 21 ) are provided with rectangular shape. This rectangular shape of the slots ( 21 ) is in consistence with the pins provided in lower part of the latch pin ( 4 ). Two side surfaces of the lower channel ( 1 ) are having round corners ( 26 ) at bottom and inwardly tapered surfaces ( 22 ) at top. Said round corners ( 26 ) and inwardly tapered surfaces ( 22 ) provide lower channel ( 1 ) with the shape as shown in cross-sectional view of the FIG. 2 . Further, the lower channel ( 1 ) is provided with a stopper ( 27 ) at each end of the tapered surfaces ( 22 ) and a stopper ( 24 ) close to each end of the lower surface for controlling the movement of sliding assemblies ( 55 , 56 ). Stopper ( 25 A, 25 B) as shown in the figure is provided in the lower channel ( 1 ) to control travel of the seat.
FIG. 3 depicts the upper channel ( 2 ) which is provided with holes ( 33 ) in its upper surface, for fixing the upper channel ( 2 ) to lower structure of a seat with the help of rivets ( 10 ) passing through holes ( 33 ). As shown in the figure, holes ( 34 ) are provided in the upper surface of upper channel ( 2 ) for fixing latch bracket ( 3 ) to the upper channel ( 2 ) with rivets ( 10 ) passing through holes provided in the latch bracket ( 4 ) and holes ( 34 ) in the upper channel ( 2 ). Two side surfaces of upper channel ( 2 ) are having round corners ( 32 ) at top and outwardly tapered surfaces ( 39 ) at bottom as shown in the cross sectional view of the FIG. 3 . Said outwardly tapered surfaces ( 39 ) of the upper channel ( 2 ) guide into the inwardly tapered surfaces ( 22 ) of the lower channel ( 1 ), thus, making the upper channel ( 2 ) slidable over the lower channel ( 1 ). The upper surface of upper channel ( 2 ) is further provided with plurality of spaced slots ( 31 ) and slots ( 36 ) for engaging, side tongues and central tongue provided on upper part of latch pins ( 4 ). Said side tongues and central tongue engage in the slots ( 31 ) and slots ( 36 ) respectively, only when said pins ( 47 ) of the latch pin ( 4 ) are not engaged within the slots ( 21 ) of the lower channel ( 1 ). Further the upper surface of upper channel ( 2 ) is provided with a hole ( 35 ) through which lever handle of the lever ( 5 ) protrudes. The hole ( 35 ) in the upper channel ( 2 ) is having a rectangular shape in the present embodiment. As shown in the side view of the figure, an upward bent tongue ( 38 ) is provided at each end of said upper channel ( 2 ) and a downward bent tongue ( 37 ) is provided next to each of said upward bent tongue ( 38 ), for controlling the movement of sliding assemblies ( 55 , 56 ), with the help of stopper ( 24 ) and stopper ( 27 ) of the lower channel ( 1 ). A stopper ( 40 A, 40 B) next to the downward bent tongue ( 37 ) is provided which control travel of the seat by engaging itself with stopper ( 25 A, 25 B) of the lower channel ( 1 ).
A latch bracket ( 3 ) as shown in FIG. 4 is placed between upper channel ( 2 ) and lower channel ( 1 ) and fixed to upper channel ( 1 ). It is provided with holes ( 41 ) on its upper surface to fix the latch bracket ( 3 ) to the upper channel ( 2 ) with the help of rivets ( 10 ) passing through holes ( 34 ) of the upper channel ( 2 ) and the holes ( 41 ) of the latch bracket ( 3 ). The lower surface of latch bracket ( 3 ) is provided with slots ( 42 ) through which pins provided in the lower part of the latch pins ( 4 ) pass and get vertically engaged into the slots ( 21 ) of the lower channel ( 1 ) during latching.
FIG. 5 shows a latch pin ( 4 ) with three pins ( 47 ) in its lower part, which pass through slots ( 42 ) in the latch bracket ( 3 ) for engaging and disengaging from the slots ( 21 ) of the lower channel ( 1 ). Side tongues ( 46 ) are provided for engaging into slots ( 31 ) of the upper channel ( 2 ). A central tongue, wider than side tongues is provided for engaging into the slot ( 36 ) of the upper channel ( 2 ). The central tongue being wider than side tongues gives strength to the latch pin ( 4 ) and also helps in preventing the tilting of latch pin during latching and unlatching. The tongues ( 46 , 48 ) engage into slots ( 31 , 36 ) when the pins ( 47 ) of the latch pin ( 4 ) are not engaged with the slots ( 21 ) of the lower channel ( 1 ). An extrusion ( 45 ) is provided at the centre of the latch pin ( 4 ), which helps latch pin to engage and disengage from slots ( 21 ) in the lower channel ( 1 ). Said extrusion ( 45 ) is round in shape in the present embodiment. The latch pins ( 4 ) are two in number and help to attain the desired position of the seat. At one time only one latch pin is in operation and other latch pin is idle, i.e. at one time only the pins ( 47 ) of one latch pin ( 4 ) are engaged with the slots ( 21 ) of the lower channel ( 1 ) to disallow movement of the seat.
A lever ( 5 ) as shown in FIG. 6 is operably connected to the latch bracket ( 3 ) and latch pins ( 4 ). A lever handle ( 52 ) having a slit ( 53 ) protrudes through the hole ( 35 ) provided in the upper channel ( 2 ). Two extruded surfaces ( 51 ) are provided for pushing the extrusion ( 45 ) of latch pin ( 4 ) upward to disengage the latch pins ( 4 ) from the slots ( 21 ) of the lower channel ( 1 ). When the lever handle is pulled the extruded surface ( 51 ) of the lever ( 5 ) pushes the extrusion ( 45 ) of the engaged latch pin ( 4 ) upwards to disengage the pins ( 47 ) from the slots ( 21 ) in the lower channel ( 1 ) and engage the tongues ( 46 , 48 ) with the slots ( 31 , 36 ) to achieve an unlatching position, thereby allowing the upper channel ( 2 ) to slide over the lower channel ( 1 ) to enable movement of the seat.
FIG. 7 shows a lower sliding assembly ( 55 ) placed between the round corners ( 26 ) of the lower channel ( 1 ) and the outwardly tapered surfaces ( 39 ) of the upper channel ( 2 ). Further, FIG. 7 shows an upper sliding assembly ( 56 ) placed between said inwardly tapered surfaces ( 22 ) of the lower channel ( 1 ) and round corners ( 32 ) of the upper channel ( 2 ). These sliding assemblies act as a bearing to help in the smooth movement of the upper channel ( 2 ) over the lower channel ( 1 ). Each sliding assembly comprises a pair of sliders. Further, each slider is provided with a spacer ( 8 , 9 ), two balls ( 7 ), one connected to one end of the spacer ( 8 , 9 ) and other connected to other end of the spacer ( 8 , 9 ) and two short spacers ( 6 ), one connected to one of said balls ( 7 ) and other connected to other of said balls ( 7 ).
FIG. 8 shows a short spacer ( 6 ) which forms a part of lower and upper sliding assemblies. One end of short spacer ( 6 ) is connected to the ball ( 7 ) in the slider and other end is free. Short spacer ( 6 ) is provided to hold the ball intact within the sliding assembly.
FIG. 9 shows a ball ( 7 ), one end of which is connected to the short spacer ( 6 ) and other end to the spacer ( 8 ) in a slider. The ball ( 7 ) acts as a bearing to help upper channel ( 2 ) slide smoothly over the lower channel ( 1 ).
FIG. 10 shows the spacer ( 8 ) placed in the lower sliding assembly ( 55 ). One end of spacer ( 8 ) is connected to one ball ( 7 ) and the other end is connected to another ball ( 7 ), in a slider. The spacer ( 8 ) is provided to keep the balls ( 7 ) intact within the lower sliding assembly ( 55 ).
FIG. 11 shows the spacer ( 9 ) placed in the upper sliding assembly ( 56 ). One end of spacer ( 9 ) is connected to one ball ( 7 ) and the other end is connected to another ball ( 7 ). The spacer ( 9 ) is provided for keeping the balls ( 7 ) intact within the upper sliding assembly ( 56 ).
Rivet as shown in FIG. 12 attaches the latch bracket ( 3 ) to the upper channel ( 2 ). These rivets also fix the upper channel ( 2 ) to the lower structure of the seat and the lower channel ( 1 ) to floor.
FIG. 13 shows a spring ( 11 ) which is placed on each of the side tongues ( 46 ) of said latch pin ( 4 ). During unlatching the latch pin ( 4 ) moves upward against the spring pressure to engage side tongues and central tongue in the slots ( 31 ) and slot ( 36 ) of the upper channel ( 2 ) respectively. During latching, due to spring pressure, the latch pin gets into the slots ( 21 ) of the lower channel ( 1 ) vertically and the complete mechanism gets locked.
FIG. 14 shows that the cable ( 54 ) is connected to cable knob ( 57 ), fixed to seat lower structure and lever handle ( 52 ) extruding from the upper channel ( 2 ). The figure shows how the upper channel ( 2 ) is guided in the lower channel ( 1 ). When the cable knob ( 57 ) is pulled, the lever handle ( 52 ) gets pulled by means of the cable ( 54 ). This movement of lever handle ( 52 ) compels the extruded surfaces ( 51 ) of the lever ( 5 ) to push the extrusion ( 45 ) of engaged latch pin ( 4 ) upwards, thereby disengaging the pins ( 47 ) of the engaged latch pin ( 4 ) from the slots ( 21 ) in the lower channel ( 1 ) and engaging the side tongues ( 46 ) and central tongue ( 48 ) of said engaged latch pin ( 4 ) with the slots ( 31 ) and ( 36 ) respectively, so that the unlatching position is achieved.
FIG. 15 illustrates the attachment of seat track assembly comprising lower channel ( 1 ), upper channel ( 2 ), cable ( 54 ) and cable knob ( 57 ) with the seat.
FIG. 16 illustrates a fully forward position of the seat achieved by the seat track assembly. This fully forward position is achieved when the stopper ( 25 A) in the lower channel ( 1 ) gets engaged with the stopper ( 40 A) in the upper channel ( 2 ) to prohibit further movement of seat in forward direction.
FIG. 17 illustrates a rearmost position of the seat achieved by the seat track assembly. This rearmost position is achieved when the stopper ( 25 B) in the lower channel ( 1 ) gets engaged with the stopper ( 40 B) in the upper channel ( 2 ) to prohibit further movement of seat in rearward direction.
FIG. 18 illustrates a desired position of the seat achieved by the seat track assembly wherein the pins ( 47 ) of one of the latch pins ( 4 ) is engaged within the slots ( 21 ) in lower channel ( 1 ). This engagement of pins ( 47 ) with the slots ( 21 ) fixes seat in one position and disallow seat to move forward or rearward.
In an embodiment, a seat is provided with a pair of seat track assemblies which are secured to both sides of the seat. Both the seat track assemblies are identical to each other and connected to the cable knob ( 57 ) through their respective cables ( 54 ). Both the seat track assemblies work simultaneously in a harmonized way.
FIG. 19 illustrates the connection of cable with two seat track assemblies.
When the cable knob ( 57 ) is pulled, the lever handle ( 52 ), protruding through the upper channels ( 2 ) of both the seat track assemblies get pulled horizontally by means of the cable ( 54 ) connecting each lever handle ( 52 ) through cable knob ( 57 ). Both the seat track assemblies work in an identical fashion. Due to pulling of the lever handle ( 52 ), one of the extruded surfaces ( 51 ) of the lever ( 5 ) push the extrusion ( 45 ) of the latch pin ( 4 ), the pins ( 47 ) of which were engaged with the slots ( 21 ) of the lower channel ( 1 ), upwards, thereby disengaging the pins ( 47 ) of said engaged latch pin ( 4 ) from the slots ( 21 ) of the lower channel ( 1 ). The side tongues ( 46 ) and the central tongue ( 48 ) of said engaged latch pin ( 4 ) get engaged with the slots ( 31 ) and slot ( 36 ) of the upper channel ( 2 ) against the spring pressure, thereby unlatching the upper channel ( 2 ) with the lower channel ( 1 ). Thus said upper channel ( 2 ) becomes slidable over the lower channel ( 1 ). At this point, one can take the seat to one's desired position. Once the desired position is achieved, the cable knob is set free, which brings back the lever handle ( 52 ) protruding through the upper channels ( 2 ) to its normal position. Due to spring pressure the pins ( 47 ) of the latch pin ( 4 ) (which is just placed above the slots ( 21 ) of the lower channel ( 1 )) gets vertically engaged in the slots ( 21 ) of the lower channel ( 1 ), thereby latching the seat track assembly. Latching disallows seat to move either forward or rearward. Thus the desired position of seat can be achieved by the help of the seat track assembly. More particularly, said seat track assembly in used in vehicle seats. However said seat track assembly can be used in any other seat, where the seat is to be adjusted with respect to floor. | The problem to be solved is to provide a seat track assembly which is simple, easy to operate seat track assembly where locking is simplex and intact and which renders a smooth sliding of seat and the problem is solved by providing a seat track assembly with a lower channel, upper channel, latch bracket, latch pin, lever and sliding assemblies wherein sliding assemblies provide a streamlined sliding to the upper channel and at the desirable position latch pin engages with the lower channel to lock the seat track mechanism from moving further forward or rearward. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims benefit of and priority from the U.S. provisional patent application No. 62/101,667, filed on Jan. 9, 2015. The disclosure of this provisional application is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to a system and method for improving gun safety and, in particular, to a secondary safety feature preventing accidental or negligent discharge of a firearm.
BACKGROUND
[0003] Accidental discharge is the event of a firearm firing (discharging) at a time not intended by the user. Perhaps most commonly, accidental discharges (sometimes called ADs by military and police personnel and sometimes referred to as negligent discharges) occur when the trigger of the firearm is deliberately pulled for a purpose other than shooting (such as demonstration, function testing, or dry-fire practice, for example) while ammunition is present in the chamber. Another, second common cause of accidental discharges occurs when the gun-handler places his finger on the trigger before he has decided to shoot. With the finger being so positioned, many events may cause the finger to compress the trigger unintentionally. For example, if one attempts to holster the firearm with his finger on trigger, the holster edge will drive the finger onto the trigger, causing a likely discharge. If one stumbles or struggles (with an adversary) with his finger on the trigger, the grasping motion of both hands will likely cause the trigger finger to press the trigger.
[0004] On occasion, an accidental discharge can occur for a reason other than the finger pulling the trigger, such as dropping a loaded weapon (whether or not secured around the torso of the user with a sling). Because of this possibility, most of the recently produced pistols are designed with a “drop-safety” or firing pin block, a mechanism inhibiting or isolating the firing pin, preventing accidental discharge if the firearm is dropped. However, most long guns do not have drop-safety features. Another common incidence of accidental discharge of the firearm (in particular, assault rifles) occurs when the user lets the rifle go and, before the rifle hangs on a sling over the user's torso, the rifle rubs against the torso and the items of user's clothing on its way to the hanging position. Any item protruding from the clothing of the user can and often does depress the trigger upon interaction with the dropped firearm. While gun safety rules recognize these possibilities and aim to prevent them, it is the tangible safety features—such as, for example, a trigger lock (an example 110 of which is shown in FIG. 1A , depicting a firearm 112 ) and a mechanism often called a “safety” (such as an external safety lever or latch on the side of the firearm or a grip safety mechanism of a handgun, an example 120 of which is shown in FIG. 1B , depicting a portion 122 of a firearm)—that are relied on to prevent an accidental discharge.
[0005] However, in the heat of the moment or just because of the mundane inattention, the user often simply forgets to activate the firearm's external, manual safety such as the safety 120 (interchangeably referred to herein as an external safety latch, manual safety latch, primary safety, or a primary safety mechanism), thereby negating the very purpose of the primary safety.
[0006] As far as a trigger lock mechanism is concerned, generally, two pieces come together from either side behind the trigger and are locked in place to form a lock that is substantially immovable and not repositionable unless unlocked with a key or combination. This physically prevents the trigger from being pulled to discharge the weapon. Other types of trigger locks do not go behind the trigger, but encompass the full area behind the trigger guard making the trigger inaccessible. It is well recognized in the art, however, that trigger locks are not designed to be used on loaded guns (see, for example, discussion in “Hype Over Trigger Locks Provokes Fear of Firearm Accidents”, E. Slater, Los Angeles Times, Feb. 16, 1999), which makes them basically useless for preventing negligent discharges. It is also well understood that the existing safety measures, while effective in majority of situations, occasionally may fall short of being “fool-proof” and providing a peace of mind to a responsible armed citizen.
[0007] There remains an unmet need, therefore, for a firearm safety feature that compensates for the discharge accidents that are not prevented by the primary safety mechanism
SUMMARY
[0008] Embodiments of the invention provide an article of manufacture that includes a rigid bar having first and second ends, the rigid bar having first and second portions that form a spatial bend in the rigid bar, the first end corresponding to the first portion, the second end corresponding to the second portion, the spatial bend defined in a plane. The article also includes a spring mechanism affixed to the second portion in a spatial coordination that defines, in operation of the spring mechanism, a vector of spring force in said plane. The article is configured for use as a secondary safety mechanism with a firearm.
[0009] Embodiments also provide a method for locking a trigger of a firearm with a secondary safety mechanism. The method includes a step of positioning the secondary safety mechanism between a back side of the trigger and a grip of the firearm. The secondary safety mechanism contains (i) a rigid bar having first and second ends, the rigid bar having first and second portions forming a spatial bend in the rigid bar, the first end corresponding to the first portion, the second end corresponding to the second portion, the spatial bend defined in a first plane, and (ii) a spring mechanism affixed to the second portion, between the second portion and the body, in a spatial coordination that defines a vector of spring force in said first plane. The positioning of the secondary safety mechanism is carried out such that the first plane is parallel to a second plane, the second plane defined by a plane in which the trigger moves during operation of the firearm. The method additionally includes a step of attaching the secondary safety mechanism to a body of the firearm through a hinge to form, with said secondary safety mechanism, a lever pivoting about the hinge in the first plane between first and second angular positions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention will be more fully understood by referring to the following Detailed Description in conjunction with the generally not-to-scale Drawings, of which:
[0011] FIGS. 1A, 1B illustrate schematically a trigger lock and a manual (primary) safety latch, respectively, conventionally used with firearms;
[0012] FIGS. 2A, 2B, 2C, and 2D illustrate schematically an embodiment of the secondary safety mechanism in different side views;
[0013] FIG. 2E illustrates, in top view, a related embodiment of the secondary safety mechanism;
[0014] FIG. 3 illustrates, in side view, another related embodiment of the secondary safety mechanism;
[0015] FIG. 4 illustrates, in side view, yet another related embodiment of the secondary safety mechanism;
[0016] FIGS. 5A, 5B are schematic illustrations of the assembled embodiment of FIGS. 6A, 6B, 6C ;
[0017] FIGS. 6A, 6B, 6C provide different views of the alternative embodiment that is assembled from the constituent components of FIGS. 7A, 7B, 7C, 7D, and 7E ;
[0018] FIGS. 7A, 7B, 7C, 7D, 7E provide different views of constituent components of an alternative embodiment of the secondary safety mechanism;
[0019] FIG. 8A illustrates operable cooperation between the embodiment of the secondary safety of FIG. 2A and the firearm in the first angular position of the embodiment, in which the spring mechanism is in contact with the body of the firearm and exerts a first vectored force on the secondary safety, the first end of the secondary safety abuts against a back side of the trigger, and a position of the trigger is locked by such abutting due to the first vectored spring force transferred to the back side of the trigger through the secondary safety;
[0020] FIG. 8B illustrates operable cooperation between the embodiment of the secondary safety of FIG. 2A and the firearm in the second angular position of the embodiment, in which the spring mechanism is in contact with the body of the firearm and exerts a second vectored spring force on the secondary safety, the first end of the secondary safety is separated from the trigger to define a spatial gap between a tip of the trigger and the secondary safety, and the trigger is released to move from the position in which it was locked as shown in FIG. 8A ;
[0021] FIG. 9A is a top view of a related embodiment of the secondary safety configured to be attached to and detached from the firearm without a need to remove a trigger-guard pin.
[0022] FIG. 9B is a schematic diagram showing, in side view, the cooperation of the embodiment of FIG. 9A with a firearm;
[0023] FIG. 9C is a schematic top-view diagram of another related embodiment of the secondary safety.
DETAILED DESCRIPTION
[0024] A problem of accidental discharge of a firearm, occurring when the primary safety mechanism is left disengaged (“off”, leaving the trigger unlocked) or becomes disengaged due to external circumstances, is solved by providing a secondary safety (interchangeably referred to herein as a secondary safety mechanism). The activation (and re-activation) of the secondary safety mechanism (causing the locking of the trigger by the secondary safety mechanism) is automatic, occurs independently of volition of and does not require the input from the user of the firearm. An embodiment of the invention re-activates upon release of pressure of the natural hand grip on rifle, at which time the spring system of the embodiment reengages a trigger block portion of the secondary safety mechanism to go automatically behind the trigger. At the same time, the de-activation of the secondary safety mechanism (as a result of which the secondary safety mechanism does not lock the trigger anymore) requires a conscious mechanical input from the user. Accordingly, the trigger of the firearm requires two different inputs provided by the user.
Example 1
[0025] FIGS. 2A, 2B, 2C, and 2D illustrate schematically an example 200 of an article of manufacture embodying a secondary safety mechanism according to the idea of the invention. The article 200 includes a rigid bar 202 (made, for example, of metal or material the mechanical properties of which are comparable to or exceeding that of metal, such as specific ceramics or graphite, for example) having first and second ends 204 , 208 . The rigid bar includes first and second portions I, II that are united, abutted to one another such as to spatially extend one another and to form a spatial bend defined in a first plane (as shown—in the xz-plane). The internal curvature of the so-bent bar defines an inner surface 210 , while the outer surface of the bar is marked 214 . As shown, the portions I, II are made integrally with one another (for example, in one mold and from the same material); alternatively, these portions can be fabricated separately (optionally—from different materials) and then adjoined or integrated.
[0026] In reference to FIGS. 2B and 2C , the first portion I of the embodiment 200 includes two walls 218 , 222 separated from one another along an axis (as shown—along the y-axis) that is perpendicular to the first plane. These two walls, together with the remaining sections of the portion I, form a framed opening 226 in and through the rigid bar. The purpose of such configuration, as will be discussed below, is to accommodate the trigger guard of a firearm. In the article 200 , each of the walls 218 , 222 (forming part of the frame around the opening) contains a corresponding aperture. These apertures 218 A, 22 A are coaxial with one another and configured to accommodate a pin with the use of which in one implementation, the article 200 is cooperated with the firearm. In reference to FIGS. 2C and 2D , it is appreciated that the width W 1 of the frame of the opening 226 can be substantially equal to or larger than the width of the first end or prong 204 . In practice it may be preferred to make the first end or prong of the article 200 approximately as wide as the trigger of the firearm with which the article is used, and the width W 1 slightly wider than the trigger guard (for example, 10 to 50 percent wider). The width of the second end 208 (not marked) can be generally arbitrary, but for practical convenience it may be dimensioned somewhere between or about the values of W 1 and W 2 . In a specific case, the rigid bar 202 can be made symmetrical with respect to the first plane (xz-plane).
[0027] The article 200 is additionally equipped with a spring mechanism configured to generate, in operation and after the article 200 is cooperated with the firearm, a vectored force pushing the second portion II away from the body of the firearm, as discussed below. As shown in the example of FIGS. 2A through 2D , the spring mechanism includes a coil spring 230 attached to the second portion II at only one end of the spring. Provided that, in operation, the spring mechanism is configured to be abutting the body of the firearm, it may be advantageous to shape the coil spring 230 as a cone (as shown in FIG. 2D ). In this case, a diameter of a coil at the second (free) end of the spring 230 is bigger than that of a coil at the end that is affixed to the second portion II, and a surface tangential to the loops of the soil spring 230 is a conical surface. Such configuration is beneficial in that it increases the area of contact between the spring mechanism of the article 200 and the body of the firearm, in operation. Generally, a spring mechanism used in an embodiment of the present invention includes a combination of multiple and, optionally, different type springs, or a combination of at least one spring and a component biased against and moveable by such spring. In related embodiments, for example, the spring mechanism may include different contraptions such as, for example, a leaf spring configured as a cantilever spring (that is fixed to the second portion II at only one end), or a combination of a torsion spring with the spring base (as discussed below).
Example 2
[0028] It is appreciated that a particularly shaped perimeter of the article 200 , illustrated in FIGS. 2A, 2B, 2C, and 2D is not required for proper operation of the article 200 . For example, in a related asymmetric embodiment 250 (which is the modified embodiment 200 ), schematically shown in top view in FIG. 2E , the wall 222 (of the frame defining the opening 226 of embodiment 200 ) is not present. As a result, the opening 256 , which accommodates in operation the trigger guard of the firearm, is walled at only three sides. Such configuration may be of interest in some circumstances as it may simplify the installation of the secondary safety element onto the firearm.
Example 3
[0029] In another related embodiment 300 (shown schematically in side view in FIG. 3 ) that has the first and second ends 304 , 308 , the rigid bar 302 of the article 300 may be formed from the first and second portions joined such as to define inner and outer surfaces 310 , 314 the radii of curvatures of which are monotonically changing. The side view of FIG. 3 corresponds to the side view of FIG. 2A (the remaining views of the embodiment 300 being similar to those of FIGS. 2B, 2C , and 2 D). As shown, the embodiment 300 is equipped with a spring mechanism including a leaf cantilever spring 330 .
Example 4
[0030] In another related embodiment, shown as 400 in FIG. 4 , the portions I, II are configured to contain straight regions such as to form, when the portions I, II are united, not only the bent of the rigid bar 402 in the xz-plane, but also a dihedral angle A in the same plane in which the bent of the bar 402 is defined. The embodiment 400 is shown for simplicity of illustration without a spring mechanism.
[0031] In operation, embodiments of the secondary safety that were discussed above and similar embodiments are cooperated with a particular firearm such as to form a lever (i) that is configured to be pivoted about a point or an axis by a force applied by a finger of the user of the firearm to portion II of the embodiment of the secondary safety and (ii) that, as a result of such pivoting, locks a trigger of the firearm in an off position. While details of the installation of an embodiment of the secondary safety mechanism on the firearm can differ, the principle of the spatial cooperation between the embodiment and the firearm will be readily understood in reference to FIGS. 8A and 8B . FIGS. 8A, 8B illustrate the installation of the embodiment of FIG. 2A on a pin 804 of the guard 806 of the trigger 808 of the firearm 810 . In one case, the pin 804 is temporarily removed from the trigger guard 806 , and a plank of the guard 806 is tilted to open the guard 806 and to set the embodiment 200 onto the plank such that the plank passes through the opening 226 . Afterwards, the plank of the guard 806 is closed, and the pin 804 is re-installed in its original position—this time, both through the openings 218 A (and 222 A, if present) of the embodiment 200 and the pin-openings of the guard 806 . Such installation structurally results in a lever, formed by the embodiment 200 , that is biased with the spring mechanism (in this case—the coil spring 230 ) against the body of the firearm 850 and that is configured to operate by pivoting the embodiment 200 about the pin 804 . In operation, the pivoting of the secondary safety occurs between two different angular position, which are illustrated respectively in FIGS. 8A and 8B .
[0032] As shown in FIG. 8A , in the first angular position of the secondary safety mechanism (denoted by an angle A 1 formed between a line 850 , which is tangential to the outer surface of the first portion of the embodiment 200 at a chosen point of its first end 204 , and the z-axis in the xz-plane), the end of the spring mechanism 230 that is not affixed to the embodiment 200 is in contact with the body of the firearm 850 . At the same time, the first end 204 of the embodiment 200 is abutted (touches at the surface) against the back side of the trigger 808 at a point that is sufficiently distanced from the tip 852 of the trigger. The embodiment 200 and its spring mechanism are judiciously dimensioned, depending on the specific geometry of the firearm 810 , to ensure that in the configuration of FIG. 8A the spring mechanism is biased to exert a first vectored force onto the embodiment 200 such as to press the first end 204 against the back side of the trigger 806 to fix and lock the trigger 806 in the “off”, not depressed position.
[0033] Changing the mutual positioning of the elements shown in FIG. 8A —that is, unlocking the trigger 806 —requires the use to take a complex action that includes pivoting the embodiment 200 about the pin 804 . Specifically, the user has to press the second portion II of the embodiment at the inner surface 210 towards the body 850 (as shown—towards the grip of the firearm 810 ) such as to compress (or, in a different implementation, create a torsion in) the spring mechanism while the first end 204 slides along and under the trigger 808 towards the trigger guard 806 , such as create, at the second angular position of the embodiment 200 , a gap G between the trigger 808 and the embodiment 200 . The spatial cooperation between the firearm 810 and the embodiment 200 in the second angular position is shown in FIG. 8B , where the angle A 2 formed by the z-axis and the line 850 is different from A 1 and where the kinetic energy, stored in the spring mechanism as a result of the pressure on the second portion II by the user's finger, is illustrated by a shortened length of the coil spring 230 as compared to that of FIG. 8A . Once the secondary safety mechanism is in such second angular position, the trigger 808 is free to move from its locked-by-the-secondary-safety-mechanism position (of FIG. 8A ) and can be depressed by the user to discharge the firearm 810 .
Example 5
[0034] Another related embodiment 500 of the secondary safety mechanism is illustrated in FIGS. 5A and 5B and, in different views in FIGS. 6A, 6B, 6C . FIGS. 7A, 7B, 7C, 7D, and 7E illustrate some of the individual components of the mechanism 500 with examples of dimensions.
[0035] The embodiment 500 includes a rigid bar 502 and a spring mechanism 530 moveably cooperated with the rigid bar 502 . The bar 502 is structured by analogy with the rigid bar 202 of the embodiment 200 , in that it includes the first end or prong 504 , the second end 508 , the opening 526 framed in part by the walls 518 , 522 , and the co-axial apertures 518 A, 522 A in the walls 518 , 522 . The apertures 518 A, 522 A are dimensioned to accommodate a pin of the trigger guard of a particular firearm with which the embodiment 500 is intended to be used.
[0036] The spring mechanism 530 of this related embodiment, however, contains two portions: a spring base 530 A (which has a shape reciprocal to the shape of the second end 508 to facilitate the mechanical mating between the two), and the torsion spring element 530 B. The torsion spring element 530 B includes, in turn, a torsion spring (not shown) set on a pin that simultaneously connects the spring base 530 A and the second end 508 through the co-axially aligned cylindrical openings 540 , 542 . The openings 540 , 542 are made in the spring base 530 A and the second end 508 , respectively. As shown, the spring base 530 A includes two protrusions (each having a throughout opening 540 ) configured to “sandwich” the second end 508 therebetween when attached to the second end with the use of the torsion spring element 530 A. It is appreciated that in a related implementation, the situation may be reversed: the spring base 530 A can have only one protrusion that is fitted between the portions of the second end 508 , shaped like a dove-tail.
[0037] When assembled and cooperated with a firearm, the embodiment 500 is hingedly set on a pin of a trigger guard through the openings 518 A, 522 A (as discussed for the embodiment 200 in reference to FIGS. 8A and 8B ), while the spring base 530 B is constantly kept in contact with a grip of the firearm due to the force-bias created by the torsion spring. When the embodiment 500 is in a first angular position (similar to that shown in FIG. 8A ), the torsion force formed by the torsion spring is larger than that corresponding to the second angular position.
[0038] It is understood, therefore, that the (re-)activation of the secondary safety mechanism such as the mechanisms 200 , 500 , for example, causes locking of the trigger of the firearm and occurs automatically, due to the spring bias, each time when the finger of the user is removed from the trigger of the firearm, without any additional action from the user. An embodiment of the invention is configured to re-activate upon release of pressure of the natural hand grip on rifle, at which time the spring system or mechanism of the embodiment reengages a trigger block portion of the secondary safety to go automatically behind the trigger. In other words, even when the primary safety of the firearm is de-activated, the trigger will be locked (as shown in the example of FIG. 8A ) with the embodiment of the invention positioned in the first angular position. On the contrary, the de-activation of the secondary safety mechanism (as a result of which the trigger is no longer locked with the secondary safety mechanism) does not happen by occurrence as it requires a conscious effort and input on the part of the user to bring the mechanism from the first angular position to the second angular position (as shown in the example of FIG. 8B ). The secondary safety mechanism can be kept de-activated as long as required by simply keeping it depressed (in the second angular position) with a finger. Notably, the use of the secondary safety according to the invention does not require any additional training on the part of the user.
Example 6
[0039] Yet another related implementation 900 of the invention is illustrated in the views of FIGS. 9A, 9B . The cooperation of this embodiment with a firearm does not require a removal of the guard pin of the firearm, while its configuration facilitates the addition and removal of the embodiment to and from the firearm in real time, on the order of seconds. As will be appreciated by a person of ordinary skill in the art, the implementation 900 is structured around the contraption of FIGS. 6A, 6B, 6C , and FIGS. 7A and 7C through 7E , which is judiciously modified to facilitate the attachment of the implementation to and detachment of it from the firearm without requiring a removal of the guard pin.
[0040] Specifically, FIG. 9A shows in top view a portion of the embodiment 900 , in which the rigid bar 902 (shown partially, with the prong 904 ) is affixed to a clip portion 910 . The clip portion 910 is configured, in operation, to be snapped onto a firearm 810 and, in one case, onto a portion 912 of the trigger guard. By analogy with the embodiment 250 of FIG. 2E , portion I of the 902 includes an opening 902 A formed by three walls. One of the three walls—the side wall 918 —has an aperture 918 A dimensioned to accommodate a pin of the trigger guard of a particular firearm therethrough.
[0041] The clip 910 is formed by merging together first and second parts of the clip to form a “U”-shaped portion 912 . As shown in FIG. 9A , the first part of the clip is a plate member 910 A having a straight portion and a bent portion defining a hook at the end of the straight portion. The second part of the clip is a plate member 910 B, 910 C, which plate member is extended beyond the bent portion defining a hook of the plate member 910 A (such extension is indicated as 910 C).
[0042] The clip is preferably but not necessarily dimensioned to provide for a spring bias between the opposing sides 910 A, 910 B that form the “U” of the clip. So structured, the portions 910 A, 910 B apply a force to the portion of the firearm onto which the clip is attached, squeezing the portion of the firearm therebetween. In the simplest case, clip 910 is made of a metal plate, a ceramic plate, or a plate made of appropriate resilient plastic material. The portion 910 C of the plate member 910 B, 910 C contains a through hole 914 dimensioned to fit over the pin of the trigger guard (and, therefore, is dimensioned the same way as the aperture 918 A is dimensioned). In one embodiment, each of the through holes or apertures 914 , 918 A is cylindrical (defined by a corresponding cylindrical wall). In one embodiment, the affixation of the rigid bar to the clip portion 910 is permanent, by molding or soldering. However, regardless of whether the clip portion 910 and the rigid bar 902 are attached permanently or whether the embodiment 900 can be taken apart by separating the elements 902 and 910 , the cooperation between the elements 902 and 910 is such that the apertures 918 A and 914 are mutually aligned to be co-axial. In a schematic diagram of FIG. 9B , the clip 910 is indicated with a dashed line and is shown not-to-scale, with the width of the plate member indicates as W.
[0043] In order to attach the secondary safety 900 to the firearm, the article 900 in positioned such that one end of the pin of the trigger guard is passed through the openings 914 , 918 A to position the prong 904 behind and in contact with the trigger (in a fashion discussed above) while the clip 910 grasps a portion of the firearm to ensure that the arms 910 A, 910 B of the “U” 912 of the clip 910 fit over and onto the opposite sides of the firearm. The detachment of the secondary safety from the firearm is done in reverse order, and also without the removal of the trigger guard pin.
[0044] While constructing the clip 910 from the first and second portions each of which is structured as a plate may be preferred because it may provide a more reliable attachment of the embodiment 900 to the firearm, it is understood that in a related embodiment (not shown) the clip portion 910 can be formatted from a cylindrical rod of diameter W (and, in a specific case, from a wire) made of judiciously chosen material. In another related embodiment, the clip portion 910 ′ for use with the rigid bar 902 can be formed from first and second parts as shown in FIG. 9C . Here, the first part shown as 910 A′ defines the “U” 912 ′, while the second part is denoted as 910 B, 910 C. The corresponding wide surfaces (defined in the xz-plane) of the first and second parts are affixed to one another along the length L. The extension of the second part beyond the “U” 912 ′ is labeled 910 C. This extension 910 C has a through hole 914 (the axis of which is parallel to the y-axis) and is attached to the rigid bar 902 (schematically indicated with a dashed line), by analogy with the case shown in FIG. 9A .
[0045] In accordance with embodiments of the present invention, method and apparatus are disclosed for configuring a secondary safety for use with a firearm, which is necessitated by the first-hand experience of the inventor and the military. Embodiments of the secondary safety are configured and intended as a back-up mechanism, an addition to the primary safety latch the activation of which may be forgotten by the user of the firearm or which becomes inadvertently disengaged. The proposed secondary safety is structured to be compatible with most of common grips of the firearms such as HOGUE or Ergo grips, for example, and provides a field-ready firearm with a passive trigger-locking mechanism operating in addition to—and independently from—the primary safety mechanism.
[0046] Therefore, embodiments of the invention provide an article of manufacture that contains a rigid bar having first and second ends (the rigid bar including first and second portions forming a spatial bend in the rigid bar, the first end corresponding to the first portion, the second end corresponding to the second portion, the spatial bend defined in a plane) and a spring mechanism affixed to the second portion in such a spatial coordination as to define, in operation of the spring mechanism, a vector of spring force in the plane. The first and second portions may be configured to form a dihedral angle in the plane. The rigid bar has inner and outer surfaces, the inner surface corresponding to an inside curvature of the bend, the outer surface being opposite to the inner surface, and the spring mechanism may include a leaf spring attached to the outer surface at only one end of the spring and disposed in the plane. In a related implementation, the rigid bar has inner and outer surfaces, the inner surface corresponding to an inside curvature of the bend, the outer surface being opposite to the inner surface, while the spring mechanism may include a coil spring attached to the outer surface at only one end of the spring. Alternatively, the spring mechanism includes a rigid plate hingedly connected to the second end and a torsion spring one end of which abuts against the second portion and another end of which abuts against the rigid plate. An article of manufacture may additionally include a firearm connected to the rigid bar with a hinge such that to position the rigid bar to define a lever pivoting about the hinge in the plane between first and second angular positions. In the first angular position i) the spring mechanism is in contact with a body of the firearm to exert a first spring force on the rigid bar; ii) the first end abuts against a back side of a trigger of the firearm at a contact point, and iii) a position of the trigger is locked by the first end due to the first spring force applied to the back side at the contact point. In the second angular position a) the spring mechanism is in contact with the body of the firearm to exert a second spring force on the rigid bar, the second spring force being larger than the first spring force; b) the first end is separated from the trigger to define a spatial gap between a tip of the trigger and an outer surface; c) the trigger is released to move from the position. In the first angular position, the contact point may be spatially separated from the tip of the trigger and the first portion may be located between the back side of the trigger and a trigger guard. A first distance defined between the second portion and the body in the first angular position may be larger than a second distance defined between the second portion and the body in the second angular position.
[0047] The present invention also encompasses a method for locking a trigger of a firearm. The steps of the method include positioning a secondary safety mechanism between a back side of the trigger and a grip of the firearm (the secondary safety mechanism including (i) a rigid bar having first and second ends, the rigid bar having first and second portions forming a spatial bend in the rigid bar, the first end corresponding to the first portion, the second end corresponding to the second portion, the spatial bend defined in a first plane, and (ii) a spring mechanism affixed to the second portion between the second portion and the body, in a spatial coordination that defines a vector of spring force in the first plane) such that the first plane is parallel to a second plane, where the second plane is defined as a plane in which the trigger moves during operation of the firearm. The steps of the method additionally include attaching the secondary safety mechanism to a body of the firearm through a hinge to form, with said secondary safety mechanism, a lever that pivots about the hinge in the first plane between first and second angular positions. The process of attaching of the secondary safety mechanism to the body may include attaching the secondary safety mechanism to the trigger guard and, in a specific case, using a removable pin of the trigger guard as the hinge.
[0048] A method may further include a step of attaching a clip portion of the secondary safety to a body of the firearm such as to grasp a portion of the body with the clip and, optionally, compress such body portion with the clip. In a specific case, the clip is fixed about a trigger guard and/or a grip of the firearm.
[0049] A method may additionally include a step of pivoting the secondary safety mechanism to the first angular position to verify that in the first angular position a) the spring mechanism is in contact with the body and exerts a first spring force on the rigid bar; b) the first end abuts against a back side of the trigger at a contact point, and c) a position of the trigger is fixed by the first end due to the first spring force applied to the back side at the contact point. Here, pivoting may include pivoting the secondary safety mechanism to the first angular position to verify that, when the secondary safety mechanism is in the first angular position and a manual safety latch of the firearm is in off position (disengaged), the trigger cannot move. Alternatively or in addition, the method may include a step of pivoting the secondary safety mechanism to the second angular position to verify that in the second angular position a) the spring mechanism is in contact with the body and exerts a second spring force on the rigid bar, the second spring force being larger than the first spring force; b) the first end is separated from the trigger to define a spatial gap between a tip of the trigger and an outer surface; and c) the trigger is released to move from the position.
[0050] References made throughout this specification to “one embodiment,” “an embodiment,” “a related embodiment,” or similar language mean that a particular feature, structure, or characteristic described in connection with the referred to “embodiment” is included in at least one embodiment of the present invention. Thus, appearances of these phrases and terms may, but do not necessarily, refer to the same implementation. It is to be understood that no portion of disclosure, taken on its own and in possible connection with a figure, is intended to provide a complete description of all features of the invention.
[0051] It is also to be understood that no single drawing is intended to support a complete description of all features of the invention. In other words, a given drawing is generally descriptive of only some, and generally not all, features of the invention. A given drawing and an associated portion of the disclosure containing a description referencing such drawing do not, generally, contain all elements of a particular view or all features that can be presented is this view, for purposes of simplifying the given drawing and discussion, and to direct the discussion to particular elements that are featured in this drawing. A skilled artisan will recognize that the invention may possibly be practiced without one or more of the specific features, elements, components, structures, details, or characteristics, or with the use of other methods, components, materials, and so forth. Therefore, although a particular detail of an embodiment of the invention may not be necessarily shown in each and every drawing describing such embodiment, the presence of this detail in the drawing may be implied unless the context of the description requires otherwise. In other instances, well known structures, details, materials, or operations may be not shown in a given drawing or described in detail to avoid obscuring aspects of an embodiment of the invention that are being discussed.
[0052] The invention as recited in claims appended to this disclosure is intended to be assessed in light of the disclosure as a whole, including features disclosed in prior art to which reference is made. | Secondary safety for firearm and method for automatic locking firearm's trigger even with disengaged primary safety. The mechanism includes a rigid bar and a spring unit biasing the rigid bar against the firearm's body to transfer vectored force to the back of the trigger against the trigger's movement, and is cooperated with firearms using existing firearm's components. Secondary safety blocks trigger immediately each time the user's finger is taken off the trigger and can be disengaged only with user's input directed against the vectored force and increasing it. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to development of an electronic level sensor and timer based falling head soil permeameter.
BACKGROUND AND PRIOR ART OF THE INVENTION
[0002] Soil permeameter is a device in the field of hydraulics, used to measure the permeability property of soil/rock. Permeability is an index of interconnectivity of pores. The coefficient of permeability is a constant of proportionality relating to the ease with which fluid passes through a porous medium. This parameter is very critical in understanding the fluid flow process in porous media and has a wide application in hydraulic engineering and fluid transport modeling studies.
[0003] Soil hydraulic conductivity has been historically measured in the laboratory, utilizing a falling or constant head of water applied to soil core samples retrieved from the field or on remolded soil samples. Laboratory measurements are often significantly at variance with in-situ field measurements because of the differing methodologies and the inherent difficulty of obtaining undisturbed soil samples. The hydraulic conductivity of soils at different depths is highly variable due to heterogeneous textural arrangement of soil particles.
[0004] It is desirable to have the capability to conduct hydraulic conductivity tests in laboratory by having the undisturbed soil in the form of a core of any desired depth above the permanent water table. Such depths may range from zero to many meters below the ground surface. In addition, it is desirable to have adequate flow capacity for maintaining flow equilibrium in a wide range of soils. Clay soils often have low permeability, whereas sandy or gravelly soils often have high permeability and, therefore, a greater accuracy is necessary in the measurement of time in case of falling head permeameter where the time reflects the permeability characteristics of soil under testing.
[0005] Prior art instruments developed for measuring hydraulic conductivity of soils generally fall into two major categories, namely- the lab measurements and in-situ field measurements. In the first type, the soil is collected from the field and subjected to permeability measurement in the lab. The second type is of measuring the permeability of soil at in-situ condition. For the first category of lab measurements, two types of permeameters are available, out of which one applies a constant head and the other a falling head. Both these types apply in principle Darcy's Law for calculation of coefficient of permeability. The second category applied for in-situ measurement of permeability utilizes various methodologies, which include electrical resistivity procedures and gas or liquid injection into the soil through penetrating probes and measuring permeability of unsaturated & saturated regime and complex analysis procedures.
[0006] The laboratory measurement of permeability is simpler, but requires collection of soil from the site, safe transportation to the lab, careful setting of lab experiment, and accuracy of measurements and reproducibility of experimental results. Among these two methods of measuring the permeability, namely the constant head has been reported, to be suitable for measuring the permeability of higher ranges, i.e, for coarser soil of more than 200 microns, while the falling head permeameter is for soils less than 200 microns having lower permeability.
[0007] The continuing physico-chemical processes ultimately disintegrate the rock into a fine soil texture and deposit in a suitable environment. In most of the semi arid environmental conditions, witnessing regular monsoon cycle, quick removal of the disintegrated rock materials and transport them to places of farther away from place of origin making them further finer particles and gets deposited as low permeable soil layers.
[0008] Reference may be made to U.S. Pat. No. 4,072,044 (Farwell et al 1976), U.S. Pat. No. 4,099,406 (Fulkerson, et al 1977) and U.S. Pat. No. 4,969,111 (Merva et al 1990) and scientific literature cited, indicating that the falling head permeameter is preferable for low permeability ranges and several errors/constraints that could affect the test results as reported are:
[0009] air trapped in sample; accuracy on measuring the elapsed time of test; uniform supply of water at the head soil core sample; disturbed soil conditions while loading the sample in apparatus; measurement error in head at beginning and at the end of test and area of specimen.
OBJECTS OF THE INVENTION
[0010] The main object of the present invention is to develop an electronic level sensor and timer based falling head soil permeameter, which obviates the drawbacks as detailed above.
[0011] Another object of present invention is to collect the soil core samples from various depths without disturbing the natural condition, of the same size of permeameter soil core chamber through coring process using the soil recovery pipe made up of seamless carbon steel tubes of various lengths by hammering process for recovering the soil as a core of particular length and depth section.
[0012] Still another object of the present invention is to have an accurate head level of start and end of test by using optical level sensors, which is of front mounting type at pre-determined heights in the burette tube.
[0013] Yet another object of present invention is to have an electronic timer unit interfaced with the level sensor to monitor the elapsed time between two pre-set levels automatically and more precisely to a level of 1/100 th of a second.
[0014] Further object of present invention is to conduct permeability test effectively by applying water uniformly over the soil surface and collecting the soil drained water without any hindrance, achieved by designing a three tubular cylinders assembly.
[0015] Still further object of the present invention is that the levels of placement of liquid level sensor can be chosen prior to the experiment by drilling a hole in the burette and fixing dome of the sensor with water leak proof condition using suitable adhesive. In the present case, the top level sensor was fixed at ‘0’ and the bottom level sensor was fixed at 20 cm levels.
SUMMARY OF THE INVENTION
[0016] Accordingly, the present invention provides an electronic level sensor and timer based falling head soil permeameter for measuring precisely the soil permeability which comprises, a glass burette ( 7 ) with two liquid level sensors ( 8 ) fixed at 0 and 20 cm graduated positions attached to a burette stand ( 9 ) and connected to top cylinder of soil permeameter assembly through a rubber hose, the said stand further attached to an electronic timer ( 10 ) unit interfaced with the level sensor ( 8 ), the said burette ( 7 ) connected to three cylindrical copper tube chambers to receive water from burette by top chamber ( 5 ) with a perforated Teflon disc at the bottom chamber ( 3 ) and middle chamber ( 4 ), these chambers further connected to soil core recovery tubes ( 11 ), which is attached to a conical flask ( 2 ) with a discharge tube and a measuring jar ( 1 ).
[0017] In an embodiment of the present invention, the depth core soils from field sites are collected in an undisturbed condition using a carbon steel seamless tube of various lengths.
[0018] In another embodiment of the present invention, a glass burette with two liquid level sensors fixed at 0 and 20 cm graduated positions attached to a burette stand and connected to top cylinder of soil permeameter assembly through a rubber hose is used to achieve the precise detection of water level cross over at selected levels.
[0019] In a further embodiment of the present invention, the elapsed time between the liquid level-change from 0 to 20 cm is precisely measured to an accuracy of 1/100 th of a second.
[0020] In yet another embodiment of the present invention, the drained out water from the bottom cylindrical chamber is collected and a constant rate of discharge is achieved through the outlet of the conical flask during the course of experiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] In the drawings accompanying this specification
[0022] FIG. 1 represents complete setup of an Electronic level sensor and timer based falling head soil permeameter
[0023] FIG. 2 represents technical specifications of soil core recovery pipes
[0024] FIG. 3 represents optical sensor with front mounting type circuit diagram.
[0025] FIG. 4 represents circuit diagram of interface used for electronic timer.
[0026] FIG. 5 represents permeameter with three cylinders assembly.
[0027] FIG. 6 represents technical specifications of top chamber, which supplies water uniformly to the soil core surface
[0028] FIG. 7 represents technical specifications of middle chamber housing test soil core sample
[0029] FIG. 8 represents technical specifications of bottom chamber, which collects the drained water
DETAILED DESCRIPTION OF THE INVENTION
[0030] The present invention provides an electronic level sensor and timer based falling head soil permeameter for measuring precisely the soil permeability which comprises, soil core recovery tubes of various lengths for collecting the different depth core soils from field sites, a glass burette with two liquid level sensors fixed at 0 and 20 cm graduated positions attached to a burette stand and connected to top cylinder of soil permeameter assembly through a rubber hose to detect precisely the water level crossovers, an electronic timer unit interfaced with the level sensor to monitor the elapsed time between two preset levels automatically and more precisely to a level of 1/100 th of a second, three cylindrical copper tube chambers ( FIG. 5 ) to receive water from burette by top chamber ( FIG. 6 ) with a perforated Teflon disc at the bottom and middle chamber ( FIG. 7 ) to hold the soil core with a perforated Teflon disc at bottom and bottom chamber ( FIG. 8 ) to receive drained water with an outlet rubber hose to channel drain water, a conical flask with a discharge tube to receive the water draining through the rubber hose and a measuring jar to collect constant discharge coming out of outlet of conical flask.
[0031] In accordance with the embodiment of the present invention, an electronic level sensor and timer based falling head soil permeameter is developed for measuring precisely coefficient of permeability of soil.
[0032] In accordance with the embodiment of the present invention, a process is provided for collection of soil cores from various depths in an undisturbed condition, thus facilitating in determination of permeability to almost nearer to the natural physical condition of the soil.
[0033] In accordance with yet another embodiment of the present invention, water level crossing is detected at the chosen heights in burette by using electronic sensors and activating the timer. Two liquid level sensors fixed at ‘0’ and ‘20’ ml position to sense the water level crossing at these two fixed intervals and produce a pulse to the timer. The sensor uses an Opto-Schmitt trigger and principle of total internal reflection. An integral LED and photo-sensor are so arranged that when a liquid does not cover the sensor, a light path is established between them. These two components are housed in a polysulphone body for compatibility with any liquid. Total absence of any moving part in the sensor ensures high reliability even in fast cycling applications. The liquid level sensor used incorporates the principle of total internal reflection. An integral LED and photo-sensor are so arranged that when a liquid does not cover the sensor, a light path is established between them. LED and Opto-Schmitt chips are sealed into the base of a clear plastic dome in such a position that light normally totally internally reflected from the dome boundary to the Opto-Schmitt. When liquid covers the dome, the change in the refractive index occurs at the boundary and some of the light escapes into the liquid, thus less light reaches the Opto-Schmitt, which thus turns off. Direct current supply of 5 Volts is required to power the output amplifier and 30-50 mA is for the operation of internal Light Emitting Diode (LED), which is obtained by using a single current limiting resistor. The output from these two sensors is given to the interface circuit embedded in timer unit.
[0034] Sensor 1 and Sensor 2 are mounted on the burette as shown in the diagram at 0 and 20 cm mark. The counting in the electronic timer is initiated by the output of the Sensor 1 and later on the counting is stopped by the output of the Sensor 2 .
[0035] In still another embodiment of the present invention a Borosil glass burette of 10 mm dia fitted with optical sensors at ‘0’ and ‘20’ cm levels with a facility of controlling the flow through a knob at the bottom and end tip of the burette which is connected to the top chamber through a rubber hose tightly to avoid the air entry for monitoring falling head.
[0036] In accordance with the further embodiment of the present invention, an electronic timer is provided to receive signals from the level sensors and to register the elapsed time taken to a level of 1/100 th of a second for water to cross between chosen two preset levels. The electronic timer is used here for the function of a stopwatch. An interface circuit is used here to take the input from the sensors and initiate as well stop the counting of the electronic timer. The interface circuit consists of all CMOS ICs. The electronic timer is also a CMOS based LCD display unit. The time is displayed in units of 1/100 second, 1/10 second, seconds and minutes. As the water column crosses the Sensor 1 , a low-to-high level transition signal is obtained at the sensor output. This is given to a positive trigger input of a CMOS CD 4047(pin- 8 ), used as a mono-stable multi-vibrator. The output of this mono-stable is a pulse. This pulse is given to an EX-OR gate of a CMOS CD 4030 (pin- 1 ) as one of the input. The moment it receives the input pulse it transfers it to the output of this EX-OR gate, which in turn, is connected to the input of the electronic timer to start the counting process. The counting is instantly shown in the LCD display. The moment the water column crosses the Sensor 2 , a low-to-high level transition is obtained at the sensor output. This is given to a positive trigger input of a second CMOS CD 4047(pin- 8 ), used as a mono-stable multi-vibrator. The output of this mono-stable is a pulse, which is given to the second input of the EX-OR(pin- 2 ) gate. This is instantly transferred to the output, which in turn is connected to the electronic timer, to stop the counting process and to display the total time taken for the water column of 20 ml, which is preset. The second CMOS CD 4047 (pin- 10 ) output is connected to a buzzer circuit. The buzzer gives the tone output to indicate to the operator that the counting is over on the electronic timer. The power supply to CMOS ICs and the Electronic timer is derived from the Regulator IC 7805, giving a constant 5 Volt supply. The instrument runs on the 230 Volt line supply, hence a step-down transformer and a rectifier is used in the front end of the 5 volt regulator.
[0037] In accordance with a further embodiment of the present invention, a design is evolved facilitating to house soil core collected from the field in the middle chamber and fitting the same with top chamber of water supply and bottom chamber for collecting the drain water with provision of perforated Teflon discs above and below of soil chamber for application of water uniformly at top surface of soil core and collecting permeated water uniformly draining from the bottom of soil core.
[0038] The present invention of Electronic level sensor and timer based falling head soil permeameter setup is schematically shown in FIG. 1 .
[0039] The first step of the process is to collect soil core samples from different depths using carbon steel seamless tubes of various lengths used as per technical specifications mentioned in FIG. 2 . The tubes are marked with desired sampling interval of 5 cms and driven into soil by hammering process and soil cores of various depth ranges are retrieved from inner part of the tube and marked with an arrow indicating top end of the soil core and then packed in a polythene sample bag with labeling giving site name, depth range, date of collection and transported safely to the laboratory. The samples are preserved in the laboratory according to site numbers and arranged depth wise and due care being taken to prevent disturbance to the core and as well to avoid direct sunlight falling on sample bags. The soil cores of various depth ranges of a particular site are taken for permeability test using the present invention. Each core sample is taken out from polythene bag and measured for its length and inserted in to middle chamber and then dressed at top and bottom with a knife for leveling up to chamber length. In order to avoid movement of water through contact between the soil core wall and chamber wall, silicon grease is applied inside part of chamber wall before insertion of soil core. The middle chamber holding the soil core is fitted with top chamber and bottom chamber tightly and placed inside chamber holder assembly and obtained verticality nature of chamber assembly with respect to working bench through adjustment of nuts provided in holder assembly and spirit level. The entire assembly is placed over a foldable plastic stool with a hole at the center. The outlet of bottom chamber connected with a rubber hose passes through the hole of plastic stool to drain water in to the conical flask.
[0040] The burette with two optical sensors as per specifications mentioned in FIG. 3 is fixed at ‘0’ and ‘20’ Cm levels and burette assembly is clamped to a stand placed on a working bench in such a way that the outlet of burette is above inlet of the top chamber of soil core assembly. The outlet of burette is connected to inlet of top chamber through a rubber hose in such a way that connection is made airtight at both the ends. Similarly, outlet of bottom chamber is connected with a rubber hose and other end of rubber hose is let into the conical flask placed below plastic stool. The outlet of the conical flask is further connected through a rubber hose for carrying the overflow water from the conical flask to the measuring jar placed near the conical flask.
[0041] The output from optical liquid level sensor is connected to a housing unit of interface circuit and timer. The interface circuit and timer unit assembly as shown in FIG. 4 is connected to power supply of 230 Volts (AC).
[0042] Once the entire setup is made, the level of conical flask output with respect to ‘0’ mm level of the burette tube is measured in terms of height (h o ). De-ionized water or double distilled water is added continuously to the burette keeping full open of the control knob of burette enabling water to enter the top chamber to fill the volume and allow the water to saturate the soil core sample and start draining into the bottom chamber and comes into the conical flask. The addition of water into the burette is continued till the conical flask started draining excess water and then by adjusting outlet control knob of burette, the overflow from the conical flask remains constant, i.e., constant discharge with time. Once the level of constant outflow is achieved, the addition of water to the burette is stopped such that the water level in the burette is above the ‘0’ mm level and the timer unit is started simultaneously. When the water level in the burette crosses the ‘0’ mm level, timer unit starts the clock and the time count is seen on the liquid crystal diode display. As soon as the water level crossed ‘20’ mm level, timer stops and display total time elapsed from head falling from ‘0’ to ‘20’ mm. The elapsed time is recorded. Water is added to the burette to have a level more than ‘0’ mm and the timer unit is reset for making a repeat measurement. The experiment was repeated three to four times. The process is repeated for all soil core samples of a particular site, recorded and tabulated.
[0043] The calculation of coefficient of permeability (cm/sec) is done by using the following formula:
[0000]
k
=
a
·
L
A
·
t
·
ln
h
0
h
t
Where k=Coefficient of permeability (cm/sec)
a=area of burette standpipe (cm 2 ) L=length of specimen (cm) A=area of specimen (cm 2 ) t=elapsed time of test (sec) h 0 =head at beginning (time=0) of test (cm) h t =head at end (time=t) of test (cm)
[0051] The following examples are given by way of illustration and therefore should not be construed to limit the scope of the present invention:
[0052] In order to test the function of the designed soil permeameter, sieved sand samples of various ranges of size were subjected for permeability determination. Each sample was tested number of times and time elapsed between 0-20 cm of each test was considered for permeability calculation. After ascertaining the performance of permeameter, field samples collected to a depth of 8 m from alluvium at 0.5 m interval was subjected for determination of coefficient of permeability. The various experiments conducted are briefly illustrated as examples.
[0053] River sand was sieved to various sizes of 250, 500, 1000 and 2000 microns using sieve shaker. The sieved samples were collected representing samples of having sizes between 250-499 microns, 500-999 microns, 1000-1999 microns and above 2000 microns and then subjected for permeability test using the developed apparatus.
Example-1
[0054] The first test was carried out using the sand sample having 250-499 micron size and the test was repeated 5 times and for each test the time registered in the timer as elapsed time (t) for the head to drop or falling from ‘0’ to ‘20’ cm level was recorded. The height from ‘0’ level at the beginning of the test up to the conical flask over flow level (h 0 ) was measured and recorded. The head at the end time (t) was estimated by deducting 20 cm from h 0 and noted as (h t ). The length of specimen (L) and area of the specimen (A) measured with the help of middle soil sample holder. The area of burette (a) was calculated by finding the diameter of the burette with the help of Vernier Caliper.
[0055] Area of burette (a)=0.785 cm 2
[0056] Length of specimen (L)=6.0 cm
[0057] Area of specimen (A)=19.002 cm 2
[0058] Time elapsed (t)=(Refer Table-1)
[0059] Head at beginning of test (h 0 )=104.5 cm
[0060] Head at end of test (h t )=84.5 cm
[0000]
TABLE 1
Size of
Electronic Timer Reading
Coefficient of
sample in
1/100 th of
Permeability K
micron range
Minutes
Seconds
Seconds
In cm/sec
250-499
0
18
93
0.0027815
0
19
01
0.00276981
0
19
10
0.00275676
0
19
13
0.00272819
0
19
12
0.00275379
Example-2
[0061] The observed elapsed time and calculated Coefficient of Permeability for each test were tabulated and given in Table-2. The other parameters such as area of burette, area of specimen, length of specimen, Head at beginning and at the end being remained unchanged with that of the example 1. The same was used for estimation of coefficient of permeability.
[0000]
TABLE 2
Size of
Electronic Tinner Reading
Coefficient of
sample in
1/100 th of
Permeability K
micron range
Minutes
Seconds
Seconds
In cm/sec
500-999
0
15
34
0.00343247
0
15
50
0.00339704
0
15
41
0.00341688
0
15
54
0.00338829
0
15
19
0.00346637
0
15
18
0.00346865
0
15
15
0.00347552
Example-3
[0062] The permeability test was conducted for the sand specimen of size range 1000-1999 microns by loading the specimen in middle chamber without disturbing other set up. The experiment was conducted for four times and elapsed time for each test was noted and used in the calculation. The following tabulation provides the observed elapsed time for each test and permeability evaluated.
[0000]
TABLE 3
Size of
Electronic Timer Reading
Coefficient of
sample in
1/100 th of
Permeability K
micron range
Minutes
Seconds
Seconds
In cm/sec
1000-1999
0
10
25
0.00513699
0
10
22
0.00515207
0
10
20
0.00516217
0
10
23
0.00514703
Example-4
[0063] In order to validate the performance of soil permeameter designed, soils were collected from natural condition. Depth samples from 0-8 m with sampling interval of 0.5 m were collected from coastal alluvium using an auguring tool. As the coastal alluvium was loose we could not collect through soil recovery pipes and therefore auguring method was adopted and depth sample interval was kept at 0.5m. The collected samples were packed carefully and brought to the lab for testing. The following Table-4 presents the time elapsed and Coefficient of Permeability determined for all the depth samples.
[0000]
TABLE 4
Depth of soil
Electronic Timer Reading
Coefficient of
samples in
1/100 th of
Permeability ‘K’
cm range
Minutes
Seconds
Seconds
In cm/sec
0-50
0
17
59
0.002993
0
17
41
0.003024
50-100
0
26
33
0.001999
0
26
37
0.001997
100-150
0
13
56
0.003883
0
13
53
0.003892
150-200
0
19
56
0.002692
0
19
75
0.002666
200-250
0
12
15
0.004333
0
12
19
0.004319
250-300
0
08
48
0.006209
0
08
56
0.006151
300-350
0
34
75
0.001515
0
34
78
0.001514
350-400
0
29
56
0.001781
0
29
53
0.001783
400-450
0
08
12
0.006485
0
08
09
0.006509
450-500
0
14
06
0.003745
0
14
15
0.003721
500-550
0
19
23
0.002738
0
19
28
0.002731
550-600
0
18
32
0.002874
0
18
29
0.002879
600-650
0
18
45
0.002854
0
18
39
0.002863
650-700
01
05
00
0.00081
01
03
82
0.00082
700-750
01
38
05
0.000537
01
37
04
0.000542
750-800
01
16
45
0.000792
01
16
32
0.000793
[0064] In all the examples, repetitive measurement of Coefficient of Permeability did not vary and thus establishing the sensitivity of electronic level sensor and timer based falling head soil permeameter developed.
ADVANTAGES OF THE INVENTION
[0065] The main advantage of the present invention is that the permeability is measured to a maximum undisturbed condition of soil; the falling head level is monitored by an electronic eye avoiding human error; the time elapsed is accurately measured by timer activated by the incoming pulse from liquid level sensor and following a fixed head level change reduces the error in estimating head at beginning (h 0 ) and head at end (h t ). The present invention is capable of measuring all ranges of permeability.
[0066] The main advantages of the present invention are:
1. The falling water levels are sensed precisely 2. The elapsed time between two levels is measured accurately to a level of 1/100 th of a second 3. The application of water uniformly over the entire surface area of the soil core was achieved
REFERENCES
[0070] Amoozegar, A. W. Warrick, Hydraulic Conductivity of Saturated Soils: Field Methods, Soil Science Soc AM, Madison, Wis., 1986, pp 735-770.
[0071] Ankeny et al., 1991. Method for determining Unsaturated Hydraulic Conductivity. Soil Science Society of Americal Journal. 55:467-470
[0072] ASTM, 1998. Standard method D 5126-90-Standard Guide for Comparison of Field Methods of determining hydraulic conductivity in the vadose zone, Annual Book of ASTM Standards 2001, Section 4: Construction. Vol.04.08 Soil and Rock (1):D 420-D 5779, pp. 1055-1064.
[0073] R. Allan Freeze, J. A. Cherry, Groundwater, Prentice-Hall, Inc., Enalw. Cliffs, N.J., 1979 pp 15-77. | Determination of hydraulic properties such as porosity and permeability of soil is of paramount importance in hydrology and civil engineering. In order to achieve greater accuracy in determination of permeability of soil using falling head permeameter, the two important known constraints of human monitoring error in noting the falling water level between two selected levels and elapse time between these two levels had overcome through electronically sensing the levels between two selected points and activating the timer clock automatically by the pulses coming from senor. The precision in measurement of time lapse in 1/100 th a second enables greater accuracy in estimation of permeability. Provision of perforated Teflon disc above and below the soil core facilitates in application of water uniformly over the entire surface area of soil core at top and similar way permeated water leaving the soil core uniformly without any obstruction. The use of carbon steel seamless tube while collecting soil core facilitated in undisturbed soil core recovery from desired depth section. The permeability test was conducted for various sorted sands of different size ranges and each sample was subjected to repetitive tests and elapsed time for each test was recorded from timer unit. Coefficient of Permeability was calculated for each test. The lab experiment conducted for sorted and unsorted sediments has yielded a consistent performance of Electronic level sensor and timer based falling head soil permeameter. | 6 |
This application claims priority to provisional application Ser. No. 60/950,996, filed Jul. 20, 2007, entitled, “Separator Tank,” the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention generally relates to separator tanks adapted to receive rainwater from a storm sewer or drain, and, more particularly, to separator tanks having a high flow rate through their lower chambers, while achieving high levels of separation and removal efficiency.
2. Description of Related Art
In general, separator tanks are structures adapted to receive rainwater and runoff from a storm sewer or drain. The tanks separate and entrap free and floating oils, grease, hydrocarbon, petroleum products, and total suspended solids (TSS), as well as sorbed contaminants like nutrients, heavy metals, and hydrocarbon and petroleum products, that are transported as suspended solids. Once the various contaminants have been separated or entrapped, the semi-clarified water may be discharged into municipal receiving sewers or water courses. Examples of separator tanks are disclosed in U.S. Pat. Nos. 4,987,148; 5,498,331; 5,725,760; 5,753,115; and 6,068,765, the disclosures of which are incorporated by reference in their entireties.
SUMMARY OF THE INVENTION
A separator tank for separating and trapping contaminants in rainwater and runoff is disclosed. According to one embodiment of the present invention, the separator tank comprises a container having a bottom wall, side wall, and top wall defining an internal chamber; an insert located inside of the internal chamber, the insert comprising a weir defining an intake area between the weir and the side wall; and a round-edged orifice positioned within the intake area; an inlet conduit for introducing an influent liquid into the intake area; wherein the weir is positioned such that the weir induces the influent liquid to flow in a swirling motion within the intake area.
According to another embodiment of the present invention an insert for a separator tank is disclosed. The insert includes a weir defining an intake area for receiving an influent liquid; and a round-edged orifice positioned within the intake area.
According to another embodiment of the present invention, the insert includes a weir defining an intake area for receiving an influent liquid; an orifice positioned within the intake area; and a drop tube in fluid communication with the orifice, the drop tube comprising a base formed by two wings.
According to another embodiment of the present invention, the insert includes a weir defining an intake area for receiving an influent liquid; an orifice positioned within the intake area; and a drop tube in fluid communication with the orifice, the drop tube comprising at least one vertical vane.
According to another embodiment of the present invention, the insert includes a weir defining an intake area for receiving an influent liquid; an orifice positioned within the intake area; and a drop tube in fluid communication with the orifice, the drop tube comprising a base formed by two wings; a back wall; and a front wall.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, the objects and advantages thereof, reference is now made to the following descriptions taken in connection with the accompanying drawings:
FIG. 1 is a perspective view of a prior art separator tank.
FIG. 2 is a perspective view of the upper chamber of a prior art separator tank.
FIG. 3 is a perspective view of an insert for a prior art separator tank.
FIG. 4 is a cross-sectional view of a separator tank according to one embodiment of the present invention.
FIG. 5 is a perspective view of the insert for a separator tank according to one embodiment of the present invention.
FIG. 6 is a plan view of the insert for a separator tank according to one embodiment of the present invention.
FIG. 7A-7B is a plan and section view of an orifice plate located in the insert according to one embodiment of the present invention.
FIG. 8 is a perspective view of the drop tube according to one embodiment of the present invention.
FIG. 9 is a plan view of the drop tube according to one embodiment of the present invention.
FIG. 10 is a longitudinal cross-section view of the drop tube according to one embodiment of the present invention.
FIG. 11 is a front view of the drop tube according to one embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Disclosed embodiments of the present invention and their advantages may be understood by referring to FIGS. 1-11 , wherein like reference numerals refer to like elements.
Referring to FIG. 1 , a known separator tank, disclosed in U.S. Pat. No. 5,498,331, is illustrated. Separator tank 100 may generally be in the shape of container 102 having bottom wall 104 , side wall 106 , and top wall 108 . Bottom wall 104 and top wall 108 may generally be circular and flat. Side wall 106 may be substantially cylindrical. Bottom wall 104 , side wall 106 , and top wall 108 may define internal chamber 110 . In one embodiment, insert 112 may divide chamber 110 into upper chamber 114 above insert 112 , and lower chamber 116 below insert 112 .
Referring to FIG. 2 , insert 112 has top surface 208 . Top surface 208 may generally be said to lie in a single horizontal plane, except for weir 210 , which extends above top surface 208 . In one embodiment, side wall 106 has inlet opening 200 located adjacently above top surface 208 . Side wall 106 may also have outlet opening 206 located adjacently above top surface 208 and spaced peripherally away from inlet opening 200 . Conduit 118 may be connected to inlet opening 200 through which liquid may be introduced into the separator tank. Further, conduit 120 may be connected to outlet opening 206 . Conduit 120 permits liquid to flow out of the separator tank.
Insert 112 may include a first opening 202 . Opening 202 may be disposed between inlet opening 200 and weir 210 . A second opening 204 may be on the outlet side of weir 210 . Openings 202 and 204 are such that liquid, without having to overflow weir 210 , may flow through inlet opening 202 to outlet opening 204 . To do so, liquid first flows through inlet opening 202 into the lower chamber 116 , through lower chamber 116 , and then up through second opening 204 into upper chamber 114 .
Referring to FIG. 3 , insert 112 may include a drop pipe 300 and a riser pipe 304 . Drop pipe 300 may be connected to and extend downwardly from first opening 202 . Drop pipe 300 may have T-connection 302 . T-connection 302 may allow for distributing the entering liquid in opposite directions within lower chamber 116 . Riser pipe 304 may be connected to and extend downwardly from second opening 204 . Riser pipe 304 permits water from lower chamber 116 to flow upwardly into upper chamber 114 .
Referring now to FIGS. 4 and 5 , separator tank 400 is shown according to one embodiment of the present invention. In addition to the features described above, in one embodiment, separator tank 400 includes various modifications and enhancements. These modifications and enhancements may include, for example, offsetting the position of insert 112 relative to inlet 118 , increasing the height of weir 412 , modifying first opening 202 to drop tube 402 , providing at least one vertical vane 410 in drop tube 402 , modifying the base of drop tube 402 , and modifying the back wall of drop tube 402 . Each of these modifications may contribute to increasing the treatment flow rate through separator tank 400 , while still maintaining high levels of separation and/or removal efficiency. Each modification will be described below.
Referring to FIG. 5 , insert 112 is shown according to one embodiment of the present invention. In this embodiment, insert 112 may have a substantially circular outer perimeter, sized to fit within the cylindrical side wall of separator tank 400 . Insert 112 may include weir 412 , first opening 202 , orifice 502 , drop pipe 402 , riser pipe 404 , second opening 408 , and vent 406 . In another embodiment, one or more of these elements may be provided separately.
Referring to FIG. 6 , insert 112 may be positioned such that weir 412 may be located between inlet 118 on one side of separator tank 400 and outlet 120 on the other side. In one embodiment, weir 412 may define a substantially circular intake area for receiving influent liquid. In another embodiment, weir 412 may define a partially circular or semi-circular intake area. In still another embodiment, weir 412 may define a rectangular intake area. In still another embodiment, weir 412 may define a polygonal intake area. In one embodiment, insert 112 or weir 412 may be positioned such that weir 412 induces the influent liquid to flow in a swirling motion within the intake area. For example, weir 412 may be offset from the center line of inlet 118 to induce swirling. In one embodiment, weir 412 may be offset from the center line of inlet 118 by about 5°, as best shown in FIG. 6 . In this embodiment, as influent liquid enters the intake area, the influent liquid may have an angular momentum about orifice 502 causing the influent to swirl and form a controlled vortex. Further, in this embodiment, the influent liquid may form a controlled vortex consistently in the same direction during each flow event, which in turn may allow separator tank 400 to handle increased flow rates. Moreover, the controlled vortex may ensure that all floatables, such as oil, are forced down drop pipe 402 . Other degrees of offset or positions for weir 412 may be used as necessary and/or desired.
In another embodiment, inlet 118 may be tangential to separator tank 400 , thereby obviating the need to offset insert 112 . In this embodiment, the shape of weir 412 may be changed as necessary and/or desired to accommodate a tangential inlet.
In one embodiment, the height of weir 412 may be increased relative to prior art separator weirs. Increasing the height of weir 412 allows for the intake area to handle a greater flow rate. This embodiment leads to an increased pressure gradient, especially during high flow rates, that drives the liquid through separator tank 400 . Further, the increased height of weir 412 may allow for greater flow, which in turn may allow for the formation of a stronger and more controlled vortex.
Referring to FIGS. 7A and 7B , orifice 502 is shown according to one embodiment of the present invention. Orifice 502 may be located in the intake area between inlet 118 and weir 412 . Orifice 502 may be positioned anywhere within the intake area. In one embodiment, orifice 502 creates first opening 202 through which influent liquid may enter drop pipe 402 . In one embodiment, orifice 502 may be modified to have a rounded entrance, as shown in FIG. 7B . Orifice 502 may generally be said to have two diameters: an outside diameter 704 and an inside diameter 702 . Outside diameter 704 and inside diameter 702 may be sized appropriately for the environment in which separator tank 400 may be used. Outside diameter 704 may be equivalent to where the rounded edge of orifice 502 aligns with top surface 208 of insert 112 . The inside diameter 702 may be equivalent to where the rounded edge of orifice 502 aligns with the inside diameter of drop tube 402 . In another embodiment, the diameter of drop tube 402 may be larger than inside diameter 702 . The diameters of orifice 502 may be changed as necessary and/or desired.
Rounding the entrance of orifice 502 may increase the treatment flow rate to lower chamber 116 . This increase in flow rate may be achieved because rounding the entrance of orifice 502 reduces the pressure drop of the liquid as it flows from above insert 112 into drop pipe 402 . Further, rounding the edge of orifice 502 may prevent flow separation and resistance to flow. The radius of the rounded edge may be changed as necessary and/or desired.
Referring to FIGS. 8-11 , drop tube 402 is shown according to one embodiment. In this embodiment, drop tube 402 may have a modified base and include at least one vertical vane 410 . Drop tube 402 may be integrally formed with insert 112 and extend into the lower chamber 116 of separator tank 400 .
As shown in FIG. 9 , drop tube 402 may have a plurality of vertical vanes 410 protruding from the inside wall of drop tube 402 . Vertical vanes 410 serve to dissipate the vortex that is created in the intake area. As the influent liquid flows downward through drop tube 402 , vertical vanes 410 create mini-vortices off the end of each vane 410 that swirl in the opposite direction of the vortex. Thus, vertical vanes 410 dissipate the vortex and may create an equal distribution of flow within drop tube 402 . Vertical vanes 410 may also reduce the formation of eddies, which may lead to a more uniform velocity profile through drop tube 402 . Reducing the high velocity jets may thereby reduce the chance of re-entraining any contaminates that have already accumulated in lower chamber 116 . The shape, size, number, and/or location of vertical vanes 410 may be changed as necessary and/or desired.
Referring to FIG. 10 , drop tube 402 may be modified to terminate at a base that may be comprised of two wings 806 . Wings 806 extend outwardly from drop tube 402 and comprise the base for drop tube 402 . In one embodiment, wings 806 may extend in opposite directions. Drop tube 402 may have two openings 804 through which liquid exits drop tube 402 and enters lower chamber 116 . In one embodiment, wings 806 may be angled slightly downward to prevent solids from accumulated on the base. Wings 806 may also prevent resuspension of contaminants already inside lower chamber 116 . In one embodiment, wings 806 direct the flow of the influent liquid into lower chamber 116 in a perpendicular direction to that of the normal direction of flow in lower chamber 116 . By introducing the influent liquid into lower chamber 116 in this manner, the residence time of the liquid in lower chamber 116 may be increased, and therefore the liquid may have an increased settling and separation time.
Referring to FIGS. 10 and 11 , drop tube 402 may have back wall 810 and front wall 808 . In one embodiment, the arc length of back wall 810 may be greater than the arc length of front wall 808 . Modifying back wall 810 may prevent the influent liquid, as it exits drop tube 402 , from impinging the nearest separator tank wall, which may be directly behind drop tube 402 . In this embodiment, back wall 810 may reduce re-entrainment and excessive turbulence.
The following examples are included to demonstrate preferred embodiments of the claimed subject matter. It should be appreciated by those of skill in the art that the techniques disclosed in the examples which follow represent techniques discovered by the inventors to function well in the practice of the claimed subject matter, and thus can be considered to constitute preferred modes for its practice. However, those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments which are disclosed and still obtain a like or similar result without departing from the scope of the claimed subject matter
EXAMPLE
A separator tank with the modifications and enhancements described above was tested to illustrate the capture efficiency of sediment, for five (5) flows, at 100, 200 and 300 mg/L concentration per flow. The tested separator tank consisted of a 6-foot diameter by approximately 6-foot high upper receiving chamber and 8-foot diameter by approximately 6-foot high lower settling chamber. An insert was mounted within the separator tank. The insert incorporated a semi-circular weir, 11-inch orifice plate, 18-inch inlet drop tee, 24-inch vertical outlet riser-pipe and 6-inch oil port. The unit had a 24-inch diameter inlet and outlet pipes, with the inlet invert tangent to the insert floor and inlet to outlet differential of 1-inch. The inlet pipe was oriented with a 1% slope and both pipes are centered within the unit. The modifications and enhancements included offsetting the inlet by 5°, increasing the height of the weir, providing four vertical vanes in the drop tube, providing two wings at the base of the drop tube, and increasing the arc length of the back wall of the drop tube. The hydraulic capacity and sediment removal efficiency was evaluated for the separator tank.
To determine the hydraulic capacity, preliminary flow (gpm) and water level (inches) within the unit were measured for 3 flows ranging from 0 to 1347 gpm (3.0 cfs). The maximum flow attained prior to breaching the bypass weir was 1122 gpm (2.5 cfs). Sediment removal efficiency tests were conducted at five (5) flows ranging from 281 to 1,403 gpm (0.63 to 3.13 cfs) with influent sediment concentrations of 100, 200 and 300 mg/L. The results are detailed below.
During the testing, the sediment concentration in the influent was measured in two ways. First, the sediment concentration was measured directly by placing iso-kinetic samplers in the water stream and a sample was collected. Second, the sediment concentration was measured indirectly by weighing the mass of the sediment metered into the measured flow and a concentration was calculated. Effluent sediment concentration was measure using iso-kinetic samplers in the flow. Removal efficiency was calculated using the direct measurements for influent and effluent. Adjusted removal efficiency was calculated using the indirectly measure influent concentration and the directly measured effluent concentration.
Sediment Removal Efficiencies at 125% Design Flow (1,403 gpm, 3.13 cfs)
1. 300 mg/L
The average flow recorded for the entire test was 1400.7 gpm (3.12 cfs), with a standard deviation (SD) of 2.91. The recorded temperature for the test was 75.4 degrees F. The measured influent sample concentrations ranged from 253.8 mg/L to 349.1 mg/L, with a mean concentration of 284.9 mg/L and SD of 39.8. The effluent concentrations ranged from 162.9 mg/L to 182.6 mg/L, with a mean concentration of 174.1 mg/L and SD of 8.4. The average background concentration was 0.8 mg/L. The resulting sediment removal efficiency for the indirect method was 38.9%. The adjusted influent concentrations ranged from 300.1 mg/L to 311.5 mg/L, with a mean concentration of 304.2 mg/L and SD of 4.5. The corresponding adjusted removal efficiency was 42.8%.
2. 200 mg/L
The average flow recorded for the entire test was 1401.4 gpm (3.12 cfs), with a standard deviation (SD) of 6.4. The recorded temperature for the test was 75.4 degrees F. The measured influent sample concentrations ranged from 177.8 mg/L to 220.0 mg/L, with a mean concentration of 196.3 mg/L and SD of 18.6. The effluent concentrations ranged from 122.1 mg/L to 139.2 mg/L, with a mean concentration of 132.3 mg/L and SD of 7.1. The average background concentration was 5.54 mg/L. The resulting sediment removal efficiency for the indirect method was 32.6%. The adjusted influent concentrations ranged from 199.1 mg/L to 204.0 mg/L, with a mean concentration of 201.8 mg/L and SD of 2.2. The corresponding adjusted removal efficiency was 34.4%.
3. 100 mg/L
The average flow recorded for the entire test was 1401.1 gpm (3.12 cfs), with a standard deviation (SD) of 3.3. The recorded temperature for the test was 75.2 degrees F. The measured influent sample concentrations ranged from 78.3 mg/L to 115.1 mg/L, with a mean concentration of 97.1 mg/L and SD of 16.5. The effluent concentrations ranged from 79.8 mg/L to 88.9 mg/L, with a mean concentration of 84.0 mg/L and SD of 3.3. The average background concentration was 1.96 mg/L. The resulting sediment removal efficiency for the indirect method was 13.5%. The adjusted influent concentrations ranged from 98.1 mg/L to 98.7 mg/L, with a mean concentration of 98.4 mg/L and SD of 0.3. The corresponding adjusted removal efficiency was 14.6%.
Sediment Removal Efficiencies at 100% Design Flow (1,122 gpm, 2.50 cfs)
1. 300 mg/L
The average flow recorded for the entire test was 1122.0 gpm (2.50 cfs), with a standard deviation (SD) of 2.39. The recorded temperature for the test was 76.9 degrees F. The measured influent sample concentrations ranged from 241.5 mg/L to 368.0 mg/L, with a mean concentration of 297.5 mg/L and SD of 51.9. The effluent concentrations ranged from 105.5 mg/L to 132.6 mg/L, with a mean concentration of 120.4 mg/L and SD of 11.3. The average background concentration was negligible. The resulting sediment removal efficiency for the indirect method was 59.5%. The adjusted influent concentrations ranged from 98.5 mg/L to 306.8 mg/L, with a mean concentration of 304.2 mg/L and SD of 3.7. The corresponding adjusted removal efficiency was 60.4%.
2. 200 mg/L
The average flow recorded for the entire test was 1121.6 gpm (2.50 cfs), with a standard deviation (SD) of 3.51. The recorded temperature for the test was 76.7 degrees F. The measured influent sample concentrations ranged from 157.9 mg/L to 253.2 mg/L, with a mean concentration of 190.1 mg/L and SD of 38.2. The effluent concentrations ranged from 72.3 mg/L to 86.9 mg/L, with a mean concentration of 80.4 mg/L and SD of 6.1. The average background concentration was 3.5 mg/L. The resulting sediment removal efficiency for the indirect method was 57.7%. The adjusted influent concentrations ranged from 197.4 mg/L to 203.1 mg/L, with a mean concentration of 201.1 mg/L and SD of 2.3. The corresponding adjusted removal efficiency was 60.0%.
3. 100 mg/L
The average flow recorded for the entire test was 1118.3 gpm (2.49 cfs), with a standard deviation (SD) of 2.6. The recorded temperature for the test was 75.7 degrees F. The measured influent sample concentrations ranged from 100.8 mg/L to 121.8 mg/L, with a mean concentration of 110.3 mg/L and SD of 8.0. The effluent concentrations ranged from 46.8 mg/L to 62.0 mg/L, with a mean concentration of 55.9 mg/L and SD of 7.8. The average background concentration was negligible. The resulting sediment removal efficiency for the indirect method was 49.3%. The adjusted influent concentrations ranged from 98.5 mg/L to 99.4 mg/L, with a mean concentration of 99.0 mg/L and SD of 0.3. The corresponding adjusted removal efficiency was 43.5%.
Sediment Removal Efficiencies at 75% Design Flow (842 gpm, 1.88 cfs)
1. 300 mg/L
The average flow recorded for the entire test was 840.7 gpm (1.87 cfs), with a standard deviation (SD) of 2.2. The recorded temperature for the test was 77.9 degrees F. The measured influent sample concentrations ranged from 406.4 mg/L to 452.3 mg/L, with a mean concentration of 436.8 mg/L and SD of 18.9. The effluent concentrations ranged from 86.5 mg/L to 95.7 mg/L, with a mean concentration of 92.0 mg/L and SD of 3.4. The average background concentration was negligible. The resulting sediment removal efficiency for the indirect method was 78.9%. The adjusted influent concentrations ranged from 305.7 mg/L to 319.2 mg/L, with a mean concentration of 314.9 mg/L and SD of 4.9. The corresponding adjusted removal efficiency was 70.8%.
2. 200 mg/L
The average flow recorded for the entire test was 842.4 gpm (1.88 cfs), with a standard deviation (SD) of 2.2. The recorded temperature for the test was 78.7 degrees F. The measured influent sample concentrations ranged from 256.2 mg/L to 290.4 mg/L, with a mean concentration of 276.4 mg/L and SD of 13.4. The effluent concentrations ranged from 56.7 mg/L to 79.9 mg/L, with a mean concentration of 73.4 mg/L and SD of 9.5. The average background concentration was 1.5 mg/L. The resulting sediment removal efficiency for the indirect method was 73.4%. The adjusted influent concentrations ranged from 198.7 mg/L to 205.5 mg/L, with a mean concentration of 202.8 mg/L and SD of 2.6. The corresponding adjusted removal efficiency was 63.8%.
3. 100 mg/L
The average flow recorded for the entire test was 841.6 gpm (1.88 cfs), with a standard deviation (SD) of 2.03. The recorded temperature for the test was 76.5 degrees F. The measured influent sample concentrations ranged from 85.4 mg/L to 130.2 mg/L, with a mean concentration of 104.4 mg/L and SD of 18.7. The effluent concentrations ranged from 31.5 mg/L to 46.6 mg/L, with a mean concentration of 37.9 mg/L and SD of 6.4. The average background concentration was negligible. The resulting sediment removal efficiency for the indirect method was 63.7%. The adjusted influent concentrations ranged from 98.6 mg/L to 102.6 mg/L, with a mean concentration of 101.6 mg/L and SD of 1.5. The corresponding adjusted removal efficiency was 62.7%.
Sediment Removal Efficiencies at 50% Design Flow (561 gpm, 1.25 cfs)
1. 300 mg/L
The average flow recorded for the entire test was 560.2 gpm (1.25 cfs), with a standard deviation (SD) of 1.0. The recorded temperature for the test was 76.3 degrees F. The measured influent sample concentrations ranged from 287.1 mg/L to 375.5 mg/L, with a mean concentration of 339.6 mg/L and SD of 34.6. The effluent concentrations ranged from 82.8 mg/L to 97.9 mg/L, with a mean concentration of 91.5 mg/L and SD of 6.0. The average background concentration was negligible. The resulting sediment removal efficiency for the indirect method was 73.0%. The adjusted influent concentrations ranged from 298.7 mg/L to 317.0 mg/L, with a mean concentration of 311.7 mg/L and SD of 7.0. The corresponding adjusted removal efficiency was 70.6%.
2. 200 mg/L
The average flow recorded for the entire test was 560.4 gpm (1.25 cfs), with a standard deviation (SD) of 1.2. The recorded temperature for the test was 76.6 degrees F. The measured influent sample concentrations ranged from 200.7 mg/L to 246.2 mg/L, with a mean concentration of 224.7 mg/L and SD of 16.8. The effluent concentrations ranged from 48.6 mg/L to 64.3 mg/L, with a mean concentration of 55.6 mg/L and SD of 7.0. The average background concentration was negligible. The resulting sediment removal efficiency for the indirect method was 75.2%. The adjusted influent concentrations ranged from 196.9 mg/L to 205.3 mg/L, with a mean concentration of 202.7 mg/L and SD of 3.1. The corresponding adjusted removal efficiency was 72.6%.
3. 100 mg/L
The average flow recorded for the entire test was 558.3 gpm (1.24 cfs), with a standard deviation (SD) of 9.0. The recorded temperature for the test was 77.2 degrees F. The measured influent sample concentrations ranged from 100.8 mg/L to 122.4 mg/L, with a mean concentration of 114.8 mg/L and SD of 8.5. The effluent concentrations ranged from 25.9 mg/L to 29.4 mg/L, with a mean concentration of 28.1 mg/L and SD of 1.4. The average background concentration was negligible. The resulting sediment removal efficiency for the indirect method was 75.6%. The adjusted influent concentrations ranged from 100.8 mg/L to 102.5 mg/L, with a mean concentration of 101.5 mg/L and SD of 0.7. The corresponding adjusted removal efficiency was 72.4%.
Sediment Removal Efficiencies at 25% Design Flow (281 gpm, 0.63 cfs)
1. 300 mg/L
The average flow recorded for the entire test was 280.7 gpm (0.63 cfs), with a standard deviation (SD) of 0.4. The recorded temperature for the test was 75.6 degrees F. The measured influent sample concentrations ranged from 318.8 mg/L to 363.0 mg/L, with a mean concentration of 331.2 mg/L and SD of 18.3. The effluent concentrations ranged from 25.6 mg/L to 41.7 mg/L, with a mean concentration of 31.8 mg/L and SD of 7.4. The average background concentration was negligible. The resulting sediment removal efficiency for the indirect method was 90.4%. The adjusted influent concentrations ranged from 286.5 mg/L to 307.3 mg/L, with a mean concentration of 293.3 mg/L and SD of 9.2. The corresponding adjusted removal efficiency was 89.2%.
2. 200 mg/L
The average flow recorded for the entire test was 280.9 gpm (0.63 cfs), with a standard deviation (SD) of 0.4. The recorded temperature for the test was 75.5 degrees F. The measured influent sample concentrations ranged from 200.9 mg/L to 234.4 mg/L, with a mean concentration of 216.8 mg/L and SD of 15.5. The effluent concentrations ranged from 13.2 mg/L to 21.8 mg/L, with a mean concentration of 16.0 mg/L and SD of 3.4. The average background concentration was negligible. The resulting sediment removal efficiency for the indirect method was 92.6%. The adjusted influent concentrations ranged from 189.1 mg/L to 193.7 mg/L, with a mean concentration of 193.3 mg/L and SD of 1.9. The corresponding adjusted removal efficiency was 91.7%.
3. 100 mg/L
The average flow recorded for the entire test was 281.1 gpm (0.63 cfs), with a standard deviation (SD) of 0.4. The recorded temperature for the test was 75.4 degrees F. The measured influent sample concentrations ranged from 77.5 mg/L to 140.5 mg/L, with a mean concentration of 101.6 mg/L and SD of 24.4. The effluent concentrations ranged from 4.7 mg/L to 9.6 mg/L, with a mean concentration of 6.8 mg/L and SD of 2.2. The average background concentration was negligible. The resulting sediment removal efficiency for the indirect method was 93.3%. The adjusted influent concentrations ranged from 95.9 mg/L to 102.8 mg/L, with a mean concentration of 99.4 mg/L and SD of 3.2. The corresponding adjusted removal efficiency was 93.1%. | A separator tank for separating and trapping contaminants in rainwater and runoff is disclosed. According to one embodiment of the present invention, the separator tank comprises a container having a bottom wall, side wall, and top wall defining an internal chamber; an insert located inside of the internal chamber, the insert comprising a weir defining an intake area between the weir and the side wall; and a round-edged orifice positioned within the intake area; an inlet conduit for introducing an influent liquid into the intake area; wherein the weir is positioned such that the weir induces the influent liquid to flow in a swirling motion within the intake area. According to another embodiment of the present invention an insert for a separator tank is disclosed. The insert includes a weir defining an intake area for receiving an influent liquid; and a round-edged orifice positioned within the intake area. | 4 |
FIELD OF THE INVENTION
This invention pertains to wet flue gas desulfurization (FGD) systems incorporating a tray or grid therein and more particularly to saturating and humidifying the incoming flue gas by means other than through underspray headers.
BACKGROUND OF THE INVENTION
To date, all wet flue gas desulfurization systems having a tray or grid therein also incorporate an underspray header or other quencher, presaturator, or gas cooling device that is used to humidify the gas and to prevent the build-up of solids upon the underside of the tray or grid. In the past, it had been believed that the incoming flue gas needed to be sprayed via such an underspray header assembly in order to improve the operation of the FGD scrubber. To accommodate this belief, separate quench sections were added to the scrubber tower. However, after experimentation, it has now come to light that an underspray header in towers incorporating a tray or grid is no longer needed and that a wet scrubber tower without an underspray header operates equivalent to a tower which includes such a device.
Generally, in a wet FGD tower, the bottoms product or reagent slurry is recirculated between the under and over spray headers. Usually, about 10%-40% of the slurry is delivered to the underspray header for the purpose of saturating and humidifying the incoming gas while the remaining 60%-90% or so is delivered to the overspray header for the purpose of pollutant removal.
As previously indicated, the use of an underspray header was thought necessary so as to uniformly humidify the incoming flue gas and so that the flue gas reaching the tray or grid had a known moisture content. This control over the physical and chemical characteristics of the incoming flue gas was believed essential for proper operation of the scrubber tower and for proper chemical reaction above the tray or grid. Also, the underspray header was often used to continuously wash the bottom of the tray or grid so as to prevent any build-up from occurring at what is known as the wet/dry interface. This wet/dry interface is a zone in the system where the incoming dry flue gas mixes with the humidifying liquid. Unfortunately, the inclusion of an underspray header increases the height of the scrubber tower by as much as two feet or more. Such a scrubber tower requires more height and volume thereby consuming more space in a facility in which excess space adds significantly to the cost. Also, such an underspray header assembly increases the cost of constructing the tower since more piping, pumps, valves, nozzles, and the like are required. Additionally, an underspray header increases the cost of operating the tower due to a greater demand for power and energy. Furthermore, underspray headers increase the final elevation of the overspray headers thereby resulting in a proportionate increase in pump power necessary to supply the bottoms product or reagent slurry to the overspray headers.
By eliminating the underspray header, all of the bottoms product is now directed to the overspray header with the rain falling from the tray or grid under the overspray header being used to humidify and saturate the incoming flue gas, a step normally accomplished by the underspray header. Also, the tray evenly distributes the weeping rain across the tower thereby maintaining uniform gas distribution within the tower. Furthermore, the portion of rain from the tray falling upon an awning structure just above the flue gas inlet forms a continuous, generally uniform curtain of liquid across this inlet. This curtain provides the primary means of gas quenching while the awning protects the floor and walls of the flue gas inlet from any backflow of slurry into the inlet.
It is thus an object of the present invention to provide more reagent on top of the tray or grid where the contaminant removal efficiency is greater and more effective. Another object of the present invention is to provide a shorter tower that is less costly to build, furnish, and operate. Yet another object of the invention is to humidify and saturate the incoming flue gas by directing it through a continuous curtain of reagent falling from an awning shielding the inlet flue gas. Another object of the invention is to direct the gas through a continuous flow of rain from the tray or grid. Still another object of the present invention is to prevent any sideways swirl that may arise upon the entrance of the flue gas into the tower. Furthermore, an object of the present invention is to provide a scrubber tower having high removal efficiencies equivalent to those towers which incorporate an underspray header assembly with less liquid recirculation. Still another object of the invention is to prevent build-up from occurring upon the wet/dry interface at the bottom of the tray or grid. These and other objects and advantages of this invention will become obvious upon further investigation.
SUMMARY OF THE INVENTION
What is disclosed is a method of saturation and humidification for a flue gas contaminant removal process that incorporates an upflow scrubber tower having a flue gas inlet without the use of special means under the tray. A sulfur or other pollutant containing flue gas is discharged into this tower and passes upward through at least one tray or grid within the tower. Afterwards, a recycled bottoms product is sprayed onto the flue gas upon passing through this tray or grid. The improvement consists of the steps of quenching the incoming flue gas prior to its passage through the lowermost tray or grid by initially passing this flue gas through a continuous liquid curtain of bottoms product falling from an awning over the flue gas inlet. Afterwards, further humidification of the incoming flue gas, to the point of saturation, occurs prior to its passage through the lowermost tray or grid by causing the recycled bottoms product to fall or rain upon the incoming and evenly distributed flue gas from the overhead tray or grid. Finally, an unobstructed passageway is created between the flue gas inlet and the lowermost tray or grid for better gas distribution so that any underspray header between the flue gas inlet and the lowermost tray or grid becomes unnecessary or is eliminated.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic cross-sectional view of a typical scrubber tower without an underspray assembly therein.
FIG. 2 is a schematic view of the invention, partially cut away, illustrating the awning and related structure.
FIG. 3 is a sectional view, taken along lines 3--3 of FIG. 2, illustrating the awning structure in greater detail.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, there is shown scrubber tower 10, having a flue gas inlet 12 and a flue gas outlet 14, through which flue gas 16 passes. Within tower 10 is perforated tray or grid 18 positioned underneath overspray header assembly 20. Nozzles 22 within overspray assembly 20 spray a reagent slurry or bottoms product 24 onto the upward flowing flue gas 16. This reagent slurry or bottoms product 24 is shown as being recycled within tower 10 via pump 26 and recycle line 28. Mist eliminators 30 remove any last vestiqe of entrained moisture droplets from flue gas 16 prior to being discharged via outlet 14. An awning 32 over inlet 12 helps initially deflect the incoming flue gas 16 downward for more even flow or distribution through tower 10 and to prevent any slurry reagent 24 from entering flue gas inlet 12.
FIGS. 2 and 3 illustrate awning 32 located on top of inlet 12 in greater detail. Awning 32 is generally configured as a flat plate across the top 34 and sides 36 of inlet 12. Top plate 38 of awning 32 is adjustable or can be adjusted (by means not shown) so as to initially force the incoming flue gas 16 downward. The upper surface of top plate 38 is generally compartmented by a plurality of vertical dividers 40 so as to add stiffness to top plate 38 and to evenly distribute the falling slurry 24 across top plate 38. Additionally, an optional collection plate 42 can be used to form a dam at the tip of awning 32 if desired. The collected slurry 24 captured behind collection plate 42 would then either spill over collection plate 42 or leak through a slot or gap between top plate 38 and collection plate 42.
The various compartments or reservoirs 44 in top plate 38, which are formed by dividers 40, fill with reagent slurry 24 falling from tray or grid 18 above. This excess slurry 24 collects behind and pours either over or under (or both) collection plate 42 to thereby form an even curtain of liquid falling in front of inlet 12. This liquid curtain then quenches incoming flue gas 16 as it enters tower 12.
As shown in FIG. 1, there is no underspray header assembly underneath tray 18 or between tray 18 and flue gas inlet 12. Instead, the reagent 24 falling from tray 18 (and that portion of reagent 24 falling upon awning 32) quenches the incoming dry flue gas 16 prior to passage through tray 18. The use of such a weeping tray 18 provides a heavy shower of slurry 24 that performs the function of previous underspray headers. Most of this rain of reagent slurry or bottoms product 24 from tray 18 is evenly distributed across tower 10. The resistance of tray or grid 18 to flue gas 16 flowing upward therethrough helps evenly distribute flue gas 16 within tower 12 and provides an optimum gas-to-liquid ratio for complete saturation and optimum pollutant removal.
A portion of this rain or slurry or bottoms product 24 falling from tray 18 just above inlet 12 falls upon awning 32. Awning 32 and reservoirs 44 distribute the collected slurry 24 as a continuous, uniformly thick, curtain of liquid across inlet 12 thereby quenching and humidifying the incoming flue gas 16 very quickly.
Due to the elimination of underspray headers, the height of tower 10 is reduced a minimum of about two feet on the average thereby requiring a less costly structure. Additionally, the construction of tower 10 is made more efficient since it is now simplified by the elimination of the cutting and welding processes normally required to install an underspray header. Furthermore, the cost of equipping tower 10 is reduced since fewer pumps, piping, nozzles, valves, and the like are now required. Also, all of the recycled slurry 24 is delivered to overspray headers 20 rather than being split between over and under spray headers. This enables more of slurry 24 to be provided to the top of tray 18 where contaminant removal efficiency is greater as a result of contact both in the spray and the resultant froth on tray or grid 18. Finally, awning 32 directs the incoming flue gas 16 initially downward providing a downward swirl effect that intimately mixes the gas 16 and slurry 24.
From tests conducted on such a system, it has been shown that the availability and reliability of wet FGD systems without underspray headers is the same as those with such headers. Such data also shows that the performance or contaminant removal of such systems can be maintained by properly selecting the spray flow characteristics above tray 18. Additionally, there has been no increase or build-up of solids underneath tray 18.
The slurry flow falling from compartments 44 on awning 32 also provides for the quenching and humidifying of flue gas 16 and for even gas distribution within tower 10. Any side-to-side flow of flue gas 16 passing through the liquid curtain formed from the flow of slurry 24 from overspray headers 20 above will be reduced and/or eliminated. Side plates 46 of awning 32 provide resistance to correct any such side-to-side movement.
Alternatively, this improvement can also apply to grid or packed FGD systems that have sufficient liquid with adequate flow distribution above the packing or grid. Also, this improvement can apply to any absorption or quench system that incorporates a tray or gas distribution device with an overspray above. This includes aqueous scrubbers for such gaseous pollutants as HCl, HF, NO x , SO 2 , SO 3 , Hg, etc. and certain materials such as flyash.
In the tests performed, (a) the average fuel flow to the burners was 1.02 million pounds of coal per hour; (b) the inlet gas sulfur dioxide (SO 2 ) ranged from 1100 to 2155 parts per million at about 6% oxygen; and, (c) the fuel sulfur content ranged from about 1.99 to 4.00 on a dry basis. During this test, the total boiler full load gas flow averaged 3,772,884 actual cubic feet per minute (ACFM) split between five duplicate absorber towers. The gas velocity ranged from 8.3 to 9.4 feet per second based on the saturated gas volume. As a consequence, the liquid/gas (L/G) ratio for the tower lacking an operating underspray was less than the L/G ratio in the tower incorporating an underspray. Also, there was even skin temperature around inlet 12 which indicated that gas 16 was evenly quenched/humidified from the rain slurry 24 falling from tray 18 and onto awning 32. Follow up pressure drop measurements indicate a pressure profile similar to that found in towers with underspray headers. Thus, it was confirmed that the elimination of the underspray header has no adverse effect on the operation of tower 10. Also, no scaling or deposits were found on the underneath side of tray 18. Additionally, sulfur dioxide removal improved considering the drop in L/G.
In a repeat test, the following operating parameters were controlled: pH was set at 6.2 and total solids was set at about 10%. The gas flow for the follow-up test was determined from the average sulfur content, the inlet sulfur dioxide parts per million, and fuel flow with this gas flow being about 734,221 ACFM through a single absorber tower. Consequently, the saturated gas velocity through tower 10 based on outlet gas conditions was 9.5 ft/sec. The results of this follow-up test indicated similar contaminant removal capabilities despite the failure to utilize underspray headers within tower 10. | A method of saturating and humidifying the incoming flue gas of a flue gas desulfurization process without the need for underspray headers or the like. Initial humidification occurs by passing the incoming flue gas through a continuous liquid curtain of recycled bottoms product falling from an awning over the flue gas inlet. Further saturation and humidification occurs by causing recycled bottoms product to fall or rain from an overhead tray or grid onto the flue gas prior to passing through the tray or grid. In order to accomplish such humidification, there is an unobstructed passageway between the flue gas inlet and the lowermost tray or grid. | 1 |
REFERENCE TO EARLIER FILED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 13/388,056, filed Jan. 30, 2012, which is a 371 national phase of PCT/CN2010/075548, filed Jul. 29, 2010, and claims the benefit of Chinese Application No. 200910165559.9, filed Jul. 30, 2009, the disclosures of which are incorporated, in their entirety, by this reference.
FIELD OF THE INVENTION
This invention relates to analogues of the human Glucagon-like peptide-1 (GLP-1) and pharmaceutical salts thereof. The GLP-1 analogues provided in this invention have the function of the human GLP-1 peptide and a longer half-life in vivo compared with the native protein. The present invention also relates to the use of GLP-1 analogues, the pharmaceutical salts thereof, or use as a pharmaceutical composition thereof in the treatment of non-insulin-dependent diabetes, insulin-dependent diabetes and obesity.
BACKGROUND OF THE INVENTION
Diabetes mellitus is a global epidemic disease and is a metabolic disorder relating to glucose, protein and lipids due to the absolute or relative deficiency of insulin (See Chen Ruijie. Status of research on diabetes drugs. Academic journal of Guangdong College of Pharmacy, 2001, 7(2):131-133). Diabetes mellitus can be divided into type I diabetes mellitus and type II diabetes mellitus (Type 2 diabetes mellitus, T2DM, the same below) according to the pathogenesis thereof 90-95% of all the patients diagnosed with diabetes mellitus suffer from T2DM, and patients are often afflicted with obesity, a deficiency of physical activity. T2DM is most common in the aging population, or among those with family history of diabetes mellitus T2DM. It is also a progressive disease. According to statistical data in 2000, the World Health Organization estimated that there are about 171 million people worldwidely who suffer from diabetes mellitus. In 2005, the U.S. Centers for Disease Control and Prevention. estimated that 20.8 million Americans suffer from diabetes mellitus which is about 7% of the population of the United States. In 2006, the International Diabetes Federation, estimated that the global number of patients suffering from diabetes mellitus is about 246 million (about 5.9% of the totally global population) and indicated that 46% of the patients were 40-59 years old.
T2DM is characterized by the inhibition of the secration of insulin and pancreatic β-cell dysfunction which results in insulin deficiency and hyperglycemia. (See Ferrannini E. Insulin resistance versus insulin deficiency in non-insulin-dependent diabetes mellitus: problems and prospects. Endocr Rev. 1998, 19(4):477-490). T2DM patients typically suffer from a postprandial and fasting hyperglycemia (fasting glucose >125 mg/dL). Observed high blood sugar is the result of pancreatic β-cells failure to secrete enough insulin in the surrounding tissue. (See Weyer C., Bogardus C., Mott D M., et al. The natural history of insulin secretory dysfunction and insulin resistance in the pathogenesis of type 2 diabetes mellitus. J. Clin. Invest. 1999, 104(6): 787-794).
A major risk factor of T2DM is obesity, which is itself very harmful to human health. T2DM often co-exists with other high-risk diseases such as hypertension and dyslipidemia. 60% of T2DM patients are accompanied by microvascular complications, including retinopathy and neuropathy, and also are accompanied by cardiovascular morbidities, such as coronary heart disease, myocardial infarction, shock, and the like. In the U.S., cardiovascular diseases (CVD) is the major cause resulting in mortality, and T2DM is the major risk factor causing macrovascular complications such as an atherosclerosis, myocardial infarction, shock, and peripheral vascular diseases. The risk of death caused by heart diseases with diabetes is 2-4 times higher than that of a non-diabetes person. In addition, nearly 65% of people with diabetes die of heart disease.
In addition to the physical and physiological harm to patients, T2DM causes great economic burden on society. According to statistics, the cost of the treatment of complications associated with diabetes is about $ 22.9 billion; the total cost of the treatment of T2DM and complications thereof is nearly $ 57.1 billion every year in the U.S.
Drugs for the treatment of T2DM have been sought. These include the early oral hypoglycemic drugs of sulfonyl class and biguanide class and the recent insulin sensitizer and α-glucosidase inhibitors, the development of animal insulins and human insulins in a variety of new regimes and formulations, the research of new mechanisms of drug treatment by simply increasing insulin, and new ways acting on the insulin-producing cells. Weight gain is a common side-effect after the administration of oral or injection hypoglycemic agents, which may reduce compliance, and may increase the risk of developing cardiovascular disease. Therefore, developing new types of drugs for the treatment of T2DM which have high safety profiles, good patient compliance and low side-effects is desirable.
As early as 100 years ago, Moore proposed that the duodenum can secrete a “chemical stimulant” stimulating pancreatic secretion. Attempts to inject gut-extract to treat diabetes were undertaken. Subsequently it was discovered that humoral factors derived from intestinal secretion can enhance the function of the pancreas endocrine, and about 50% of insulin secretion induced by intravenous or oral glucose is derived from the stimulus of peptides produced in the gut. Therefore Zunz and Labarre described the concept of “incretin.” Two kinds of incretins have been isolated so far, namely glucose-dependent insulinotropic polypeptide (GIP) and glucagon-like peptide-1 (GLP-1). Both GIP and GLP-1 are secreted by specific intestinal nerve cells when a related nutrient is absorbed. GIP is secreted by the duodenum and proximal jejunal K cells. GLP-1 is synthesized in L cells and mainly exists in the distal small bowel and colon (See Drucker D J. Enhancing incretin action for the treatment of type 2 diabetes. Diabetes Care. 2003, 26(10):2929-2940).
GLP-1 exists in two bio-active forms in blood plasma, namely GLP-1 (7-37) and GLP-1 (7-36). The difference between the two forms resides in one amino acid residue, and their biological effects and in vivo half-life are the same. (See Drucker D J. Enhancing incretin action for the treatment of type 2 diabetes. Diabetes Care. 2003, 26(10):2929-2940).
GLP-1 is usually referred to as GLP-1 (7-37) and GLP-1 (7-36) amide. GIP and GLP-1 are degraded to inactive forms by dipeptidyl peptidase-IV (DPP-IV) quickly after released in the gastrointestinal tract, so that the in vivo half-life of GIP and GLP-1 is very short (in vivo half-life of GIP is about 5-7 minutes, in vivo half-life of GLP-1 is about 2 minutes). (See Drucker D J. Enhancing incretin action for the treatment of type 2 diabetes. Diabetes Care. 2003, 26(10):2929-2940). Researches show that most of the degradation process occurs when the GIP and GLP-1 enter into the blood vessels containing DPP-IV, and a small amount of GLP-1 and GIP which has not been degraded will enter into the pancreas and associate with binding sites to stimulate insulin release from β-cells. Different from the mechanism of sulfonylurea to directly promote functional β-cells to release insulin, most of the effects of incretin are glucose-dependent. In addition, some in vitro tests on animals and humans have shown that GLP-1 also functions to suppress α-cell and reduce glucagon hypersecretion.
Although plasma GIP levels in patients with T2DM are normal, when the function of incretin declines significantly, the GLP-1 levels in patients with T2DM decline. Thus, drugs based on GLP-1 contribute more to treatment of T2DM. Although the levels of both GLP-1 (7-37) and GLP-1 (7-36) amide will increase in several minutes after a meal, and the content of GLP-1 (7-36) amide is more, so the GLP-1 secretion might have been greatly increased by the double effect of endocrine and transmission of neural signal before the digested food enters the small intestine and colon. The plasma level of GLP-1 under a fasting state is very low (about 5-10 pmol/L), and is increased rapidly after eating (up to 15-50 pmol/L). Under the double function of DPP-IV and renal clearance, the level in vivo of GLP-1 in circulation is decreased rapidly. Other enzymes such as human neutral endopeptidase 24•11 may also play a vital role in inactivating clearacne of GLP-1. Because the second amino acid residue of GLP-1 is alanine, which is a good substrate of DPP-IV, GLP-1 is easily degraded into inactive peptide fragments. In fact, the DPP-IV in vivo is postulated as the key reason for loss of the activity of the incretin. Experiments show that GLP-1 levels in mice, in which DPP-IV gene has been silenced, is higher than in normal mice. Significantly, insulin secretion is increased, too. Just because the presence of DPP-IV, the content in vivo (except in plasma) of the nondegradaded and biologically active GLP-1 is only 10-20% of the total content of GLP-1 in plasma. (See Deacon C F, Nauck M A, Toft-Nielsen M, et al. Both subcutaneously and intravenously administered, glucagon-like peptide 1 is rapidly degraded from the NH 2 -terminus in type 2-diabetic patients and in healthy subjects. (See Diabetes. 1995, 44(9): 1126-1131).
GLP-1 and GIP play their respective roles through binding to different G-protein-coupled receptors (GPCRs). Most of GIP receptors are expressed by pancreatic β-cells, and a minor part of GIP receptors are expressed by adipose tissue and the central nervous system. In contrast, GLP-1 receptors are mainly expressed in the pancreatic α- and β-cells and peripheral tissues including the central and peripheral nervous systems, brain, kidney, lung and gastrointestinal tract and the like. The activation of two incretins in β-cells will result in the rapid increase of the level of cAMP and intracellular calcium, thereby rleading to their extracellular secretion in a glucose-dependent manner. The sustained signal transmission from incretin receptors is associated with protein kinase A, resulting in gene transcription, increasing insulin biosynthesis and stimulating β-cell proliferation. (See Gallwitz B. Glucagon-like peptide-1-based therapies for the treatment of type 2 diabetes mellitus. Treat Endocrinol. 2005, 4(6):361-370). The activation of GLP-1 receptor and GIP receptor can also inhibit the apoptosis of pancreatic β-cells of rodent and human, while increasing their survival (See Li Y, Hansotia T, Yusta B, et al. Glucagon-like peptide-1 receptor signaling modulates beta cell apoptosis. J Biol Chem. 2003, 278(1): 471-478). Consistent with the expression of GLP-1 receptor, GLP-1 can also inhibit glucagon secretion, gastric emptying and food intake, and enhance the degradation of glucose through the neural mechanism. It shall be noted that, as with other insulin secretion mechanisms, the role of GLP-1 to control the level of glucose is glucagon-dependent and the counter-regulatory release of glucagon caused by low blood sugar is fully retained even at the pharmacological level of GLP-1.
The important physiological role of endogenous GLP-1 and GIP in glucose homeostasis has been studied in-depth through using receptor antagonists or gene knockout mice. Acute antagonism of GLP-1 or GIP reduces insulin secretion in vivo of rodents and increases plasma glucose content. Similarly, the mutant mice, in which GIP or GLP-1 receptor is inactivated, also experience defective glucose-stimulated insulin secretion and damaged glucose tolerance. GLP-1 also has a function of regulating fasting blood glucose, because the acute antagonists or damage on the GLP-1 gene will cause the increase of fasting glucose level of rodents. At the same time, GLP-1 is the basis of glucose control in human bodies, and studies on the antagonist of Exendin (9-39) have shown that the destruction of GLP-1 function will result in defective glucose-stimulated insulin secretion, decreased glucose clearance rate, increased glucagon levels and accelerated gastric emptying. The physiological roles of GLP-1 (see Deacon C F. Therapeutic strategies based on glucagon-like peptide 1. Diabetes. 2004, 53(9):2181-2189) comprise: (1) helping to organize glucose absorption, mediate glucose-dependent insulin secretion; (2) inhibiting postprandial glucagon secretion, reducing hepatic glucose release; (3) regulating gastric emptying, preventing excessive circulating of glucose when the food is absorbed in the intestine; and (4) inhibiting food intake (such as appetite). Also, animal studies also showed a physiological role for stabilizing the number of pancreatic β-cells in vivo.
Due to the beneficial effects of GLP-1 and GIP in controlling blood sugar and many other aspects, especially their characteristics of not producing hypoglycemia and delaying gastric emptying to control weight, the compounds attract the interest of many scientists. Further studies of based on GLP-1 and GIP for the treatment of T2DM have been pursued. It is well known that T2DM patients lack or lose the incretin effect. One reason is that incretin effect of GIP in vivo in the T2DM patient is significantly reduced. Meanwhile, the level of GLP-1 in vivo in T2DM patients is very low, and the level of GLP-1 caused by dietary stimuli is significantly reduced. (See Toft-Nielsen M B, Damholt M B, Madsbad S, et al. Determinants of the impaired secretion of glucagon-like peptide-1 in type 2 diabetic patients. J Clin Endocrinol Metab. 2001, 86(8):3717-3723). Because the role of GLP-1 in vivo in patients with T2DM has been partially reserved, GLP-1 synergist is one of the research directions of the drugs designed to enhance the incretin effect in T2DM patients.
GLP-1 analogues, may act similarly to endogenous GLP, by inhibiting the release of glucagon and stimulate insulin secretion both in vivo in a glucose-dependent manner and thus its role for lowering blood glucose exhibit a self-limitation, which generally does not cause hypoglycemia in large doses. Some literature reports that GLP-1 can reduce blood sugar to a level below normal, and this effect is transient and considered a natural result of GLP-1 promoted insulin secretion. GLP-1 can temporarily reduce blood sugar to a level below normal level but does not cause serious and persistent hypoglycemia. Besides directly reducing blood glucose, GLP-1 can also reduce the quantity of food intake, which has been verified in rodents and humans. The level of blood glucose, therefore, can be controlled by reducing body weight indirectly. GLP-1 also has the potential role of inhibiting the secretion of gastrin and gastric acid stimulated by eating, and these functions show that GLP-1 may also have a role in the prevention of peptic ulcer. Mechanisms of action for GLP-1 make it an ideal drug for the treatment of patients with type 2 diabetes, but also the drug for the treatment of patients with obesity diabetes. GLP-1 can enhance the satiety of the patients, reduce food intake and maintain body weight or lose weight. Several studies suggest that GLP-1 can prevent the conversion from impaired glucose tolerance to diabetes, and some literature reports that the GLP-1 class of compounds has direct effect on the growth and proliferation of pancreatic β-cells in experimental animals. It was found by some experiments that GLP-1 can promote the differentiation from pancreatic stem cells to functional β-cells. These results suggest that GLP-1 has the function of protecting pancreatic islet and delaying the progression of diabetes, and can maintain the morphologies and functions of β-cells, while reduce the apoptosis of β-cells. Because some oral drugs and exogenous insulins can not inhibit or reduce the exorbitant glucagon secretion in patients with T2DM, GLP-1 analogues can affect glucagon hypersecretion through directly inhibiting glucagon release or inhibition of glucagon resulted from promoting insulin secretion. The postprandial hyperglycemia can be reduced effectively through these two mechanisms. Meanwhile, the maintaining of the function of β-cells may also play a role in controlling the long-term postprandial hyperglycemia.
GLP-1 analogues are administered through subcutaneous injection, which doesn't require calculation of the amount of carbohydrates to estimate the optimal drug dosage, and does not require self-monitoring the blood glucose. As a result, these kinds of drugs are easier for patient compliance than self-administered insulin.
A variety of effects of natural GLP-1 have been confirmed, which bring new hope for the treatment of T2DM. The natural human GLP-1 peptide is, however, very unstable and can be degraded by dipeptidyl peptidase IV (DPP-IV). Moreover, its half-life is only about 2 minutes. When using natural GLP-1 to lower blood sugar, continuous intravenous infusion or continuous subcutaneous injection is needed, resulting in its poor clinical feasibility. Faced with this situation, researchers continue to explore methods to extend the action time of GLP-1. Therefore, there is a need for the development of long-acting GLP-1 analogues or derivatives thereof.
Exenatide is a synthetic Exendin-4, which is developed by the Eli Lilly Company and Amylin Company, with the trade name Byetta®. Exenatide has been approved for the treatment of T2DM by FDA and EMEA. It has 50% homology with mammalian GLP-1 in sequence and has a similar affinity site of the receptor with GLP-1. (See Drucker D J, Nauck M A. The incretin system: glucagon-like peptide-1 receptor agonists and dipeptidyl peptidase-4 inhibitors in type 2 diabetes. Lancet. 2006, 368(9548):1696-1705). It is encoded by a lizard-specific gene. Compared with GLP-1, the second residue, alanine, in GLP-1 is replaced with glycine in Exenatide, which effectively inhibits the enzymolysis of DPP-IV enzyme, and its half-life in vivo is about 60-90 minutes. (See Kolterman O G, Kim D D, Shen L, et al. Pharmacokinetics, pharmacodynamics, and safety of exenatide in patients with type 2 diabetes mellitus. Am Health Syst Pharm. 2005, 62(2): 173-181). The in vivo concentration of Exenatide after a single subcutaneous injection is increased persistently and can arrive to the maximum plasma concentration after 2 h or so, which can be maintained for 4-6 hours. (See Nielsen L L, Baron A D. Pharmacology of exenatide (synthetic exendin-4) for the treatment of type 2 diabetes. Curr Opin Investig Drugs. 2003, 4(4):401-05). It should be noted that the metabolism of Exenatide does not occur in the liver, but is degraded mainly by protein protease after filtered by renal glomeruli.
Exenatide has special glucose-regulating activities, including glucose-dependent enhance of insulin secretion, glucose-dependent inhibition of wrong excessive glucagon secretion, slowing gastric emptying and decreasing food intake and the like. Studies in vitro and in vivo in the models of diabetes found that Exenatide also has the effects of storing the first stage (first-phase) insulin secretion, promoting the proliferation of β-cell and promoting the regeneration of insulin from its precursor cell.
In order to achieve better control of blood glucose, injections twice a day of Exenatide are needed. This is a major inconvenience to patients. Furthermore, Exenatide has unfortunate side effects including mild to moderate nausea (about 40% of patients will have this reaction), diarrhea and vomiting (less than 15% of patients have both reactions). In addition, about 50% of Exenatide-treated patients can generate antibodies, although these antibodies do not affect the efficacy or lead to other clinical effects. Recently it is found that six patients suffered hemorrhage or symptoms of necrotizing pancreatitis after taking Byetta®.
CJC-1131 is a GLP-1 analogue with peptidase resistance developed by ConjuChem Biotechnologies Inc., in which the alanine residue in the second position of GLP-1 is replaced with D-Ala to enhance resistance of DPP-IV enzymolysis. The structure contains an active reactive linker that can bind to serum albuminutes through a covalent, non-reversible manner. (See Kim J G, Baggio L L, Bridon D P, et al. Development and characterization of a glucagon-like peptide-1 albuminutes conjugate: the ability to activate the glucagon-like peptide 1 receptor in vivo. Diabetes 2003, 52(3):751-759). The GLP-1-serum albuminutes complex retains the activity of GLP-1, while increasing its stability to DPP-IV enzymolysis, thereby extending in vivo action. Its half-life in plasma is about 20 days.
A study has found that the Ki was approximate 12 nM (the Ki of GLP-1 is 5.2 nM) when CJC-1131-serum albuminutes complex is bound to Chinese hamster ovary cell transfected with recombinant human pancreatic GLP-1 receptor. Meanwhile the EC 50 of the complex activating cAMP is 11-13 nM, wherein the EC 50 is similar to GLP-1's EC 50 . Existing literature reports show that this complex can reduce postprandial blood glucose level of the mice whose blood sugar is normal or high, and tests show that this activity of CJC-1131 acts on a certain functional receptor of GLP-1. Meanwhile in mice, CJC-1131 also has an effect on slowing gastric emptying and inhibiting food intake and the like.
Part of a phase II clinical trial of CJC-1131 has been completed. In September 2005, ConjuChem concluded that CJC-1131 may not be suitable for chronic dosing regimens after analysis of test results and suspended further clinical study
Albugon (albumin-GLP-1) is a long-acting drug for the treatment of T2DM developed by GlaxoSmithKline authorized by Human Genome Sciences Inc., which is a fusion protein of GLP-1 (with mutations increasing the resistance to DDP-IV) and albumin. Its half-life in monkeys is 3 days. The basic idea of the development thereof is to couple the recombinant GLP-1 and serum albuminutes to form a complex, thereby its in vivo half-life is significantly increased. The administration of Albugon effectively reduces blood glucose level of mice, increases insulin secretion, slows gastric emptying and reduces food intake etc. (See Baggio L L, Huang Q, Brown T J, et al. A Recombinant Human Glucagon-Like Peptide (GLP)-1-Albuminutes Protein (Albugon) Mimics Peptidergic Activation of GLP-1Receptor-Dependent Pathways Coupled With Satiety, Gastrointestinal Motility, and Glucose Homeostasis. Diabetes 2004, 53(9):2492-2500). Currently Albugon is in phase III clinical trials.
WO9808871 discloses a GLP-1 derivative which is obtained through the modification on GLP-1(7-37) with fatty acid. The half life in vivo of GLP-1 is significantly enhanced. WO9943705 discloses a derivative of GLP-1, which is chemically modified at the N-terminus, but some literature reports that modification of the amino acids on the N-terminal will significantly decrease the activity of the entire GLP-1 derivative. (See J. Med. Chem. 2000, 43, 1664 1669). In addition, CN200680006362, CN200680006474, WO2007113205, CN200480004658, CN200810152147 and WO2006097538 etc also disclose a series of GLP-1 analogues or derivatives thereof produced by chemical modification or amino acid substitution, in which the most representative one is liraglutide developed by Novo Nordisk, the phase III clinical trial of which has been finished. Liraglutide is a derivative of GLP-1, whose structure contains a GLP-1 analogue of which the sequence is 97% homologous with human GLP-1, and this GLP-1 analogue is linked with palmitic acid covalently to form Liraglutide, wherein the palmitic acid of the structure of Liraglutide is linked to serum albuminutes non-covalently, and this structural characteristic affects a slower release from the injection site without changing the activity of GLP-1 thereby extending its in vivo half life Meanwhile, the palmitic acid in the structure will form a certain steric hindrance to prevent the degradation by DPP-IV and to reduce renal clearance. Because of the characteristics described above, the half-life of Liraglutide in the human body administered by subcutaneous injection is about 10-14 hours. In theory, it can be administered once on day and the daily dose is 0.6-1.8 mg. On Apr. 23, 2009, Novo Nordisk announced that Committee for Medicinal products for Human Use (CHMP) under the EMEA gave a positive evaluation on Liraglutide and recommended approval of its listing. Novo Nordisk hopes that European Commission would approve its application of listing within two months.
BRIEF SUMMARY OF THE INVENTION
The present invention describes GLP-1 analogues which have longer half-life in vivo. The GLP-1 analogues described have the same function as that of human GLP-1 and a longer half-life in vivo.
The present invention also includes pharmaceutical compositions comprising GLP-1 analogues and pharmaceutically acceptable salts thereof, for use in the treatment of non-insulin-dependent diabetes mellitus, insulin-dependent diabetes and obesity.
The aims of the present invention are achieved by the following technical solutions. The present invention provides GLP-1 analogues having amino acid sequence of formula (I) or a pharmaceutically acceptable salt thereof:
Formula (I) - SEQ ID NO: 238 Xl-X2-Glu-Gly-Thr-Phe-Thr-Ser-Asp-X10-Ser-X12-X13- X14-Glu-X16-X17-Ala-X19-X20-X21-Phe-Ile-X24-Trp- Leu-X27-X28-X29-X30-X31-X32-X33-X34-X35-X36-X37- X38-X39-Lys
wherein the GLP-1 analogues contain a lipophilic substituent of formula R 1 (CH 2 ) n —CO—, in which R 1 is selected from CH 3 — and HOOC—, n is an integer selected from 8-25, X1, X2, X10, X12, X13, X14, X16, X17, X19, X20, X21, X24, X27, X28, X29, X30, X31, X32, X33, X34, X35, X36, X37, X38 and X39 are independently selected from any natural or non-natural amino acid or the peptide segments consisting of any natural or non natural amino acid.
The GLP-1 analogues refer to a new GLP-1 peptide obtained by the partial amino acid substitution or the extension at the C terminal of human GLP-1 (7-37) peptide serving as a precursor, comprising GLP-1 (7-36) amide and GLP-1 (7-37), which has same function as that of human GLP-1.
The GLP-1 analogues may be modified so that amino acid residues have lipophilic substituents, wherein a typical modification is to form an amide or ester, preferably, to form an amide.
In a preferred embodiment of the invention, the lipophilic substituent of formula R 1 (CH 2 ) n —CO— and the amino group of the amino acid residues of the GLP-1 analogue are linked by an amide bond, in which R 1 is selected from CH 3 — and HOOC—, and n is an integer selected from 8-25.
In another preferred embodiment of the invention, the lipophilic substituent of formula R 1 (CH 2 ) n —CO— and the ε amino group of the Lys at the C-terminal of the GLP-1 analogue are linked by an amide bond, in which R 1 is selected from CH 3 — and HOOC—, and n is an integer selected from 8-25.
In yet another preferred embodiment of the invention, the lipophilic substituent of formula R 1 (CH 2 ) n —CO— and the α amino group of the Lys at the C-terminal of the GLP-1 analogue are linked by an amide bond, in which R 1 is selected from CH 3 — and HOOC—, and n is an integer selected from 8-25, and 14 is the most preferred.
In another preferred embodiment of the invention, X1 in the amino acid sequence of the GLP-1 analogue is selected from L-His and D-His; X2 is selected from Ala, D-Ala, Gly, Val, Leu, Ile, Lys and Aib; X10 is selected from Val and Leu; X12 is selected from Ser, Lys and Arg; X13 is selected from Tyr and Gln; X14 is selected from Leu and Met; X16 is selected from Gly, Glu and Aib; X17 is selected from Gln, Glu, Lys and Arg; X19 is selected from Ala and Val; X20 is selected from Lys, Glu and Arg; X21 is selected from Glu and Leu; X24 is selected from Val and Lys; X27 is selected from Val and Lys; X28 is selected from Lys, Glu, Asn and Arg; X29 is selected from Gly and Aib; X30 is selected from Arg, Gly and Lys; X31 is selected from Gly, Ala, Glu, Pro and Lys; X32 is selected from Lys and Ser; X33 is selected from Lys and Ser; X34 is selected from Gly, Ala and Sar; X35 is selected from Gly, Ala and Sar; X36 is selected from Pro and Gly; X37 is selected from Pro and Gly; X38 is selected from Pro and Gly; X39 is selected from Ser and Tyr.
In one more preferred embodiment of the present invention, the amino acid sequence of the GLP-1 analogue is selected from the group consisting of SEQ ID NO: 1 to SEQ ID NO: 238.
In another preferred embodiment of the present invention, the lipophilic substituent of formula R 1 (CH 2 ) n —CO— and the amino group of the amino acid residues of the GLP-1 analog, of which the sequence is selected from the group consisting of SEQ ID NO: 1 to SEQ ID NO: 238, are linked by an amide bond, in which R 1 is selected from CH 3 — and HOOC—, and n is an integer selected from 8-25.
In one more preferred embodiment of the present invention, the lipophilic substituent of formula R 1 (CH 2 ) n —CO— and the α amino group of the C-terminal Lys of the GLP-1 analog, selected from the group consisting of SEQ ID NO: 1 to SEQ ID NO: 238, are linked by an amide bond, in which R 1 is selected from CH 3 — and HOOC—, and n is an integer selected from 8-25.
In one more preferred embodiment of the present invention, the lipophilic substituent of formula R 1 (CH 2 ) n —CO— and the α amino group of the C-terminal Lys of the GLP-1 analog, selected from the group consisting of SEQ ID NO: 1 to SEQ ID NO: 238, are linked by an amide bond, in which R 1 is selected from CH 3 and HOOC—, and n is an integer selected from 8-25, preferably n is selected from 8, 10, 12, 14, 16, 18, 20 and 22, most preferably, n is 14.
In one more preferred embodiment of this invention, the lipophilic substituent of formula R 1 (CH 2 ) n —CO— and the α amino group of the C-terminal Lys of the GLP-1 analog, selected from the group consisting of SEQ ID NO: 1 to SEQ ID NO: 20 and/or SEQ ID NO: 121 to SEQ ID NO: 136 and/or SEQ ID NO: 237, are linked by an amide bond, in which R 1 is selected from CH 3 — and HOOC—, and n is an integer selected from 8-25, preferably n is selected from 8, 10, 12, 14, 16, 18, 20 and 22, most preferably, n is 14.
In another more preferred embodiment of this invention, the lipophilic substituent of formula R 1 (CH 2 ) n —CO— and the α amido of the C-terminal Lys of the GLP-1 analog, selected from the group consisting of SEQ ID NO: 1 to SEQ ID NO: 8 and/or SEQ ID NO: 121 to SEQ ID NO: 124, are linked by an amide bond, in which R 1 is CH 3 , and n is 14.
The GLP-1 analogues provided in this invention belong to amphoteric compounds and one skilled in the art can convert them into salts by using acid or alkaline compounds with known technologies, wherein acids usually used for the formation of acid addition salts are: hydrochloric acid, hydrobromic acid, hydriodic acid, sulfuric acid, phosphoric acid, p-toluenesulfonic acid, methanesulfonic acid, oxalic acid, p-bromophenyl sulfonic acid, carbonic acid, succinic acid, citric acid, benzoic acid, acetic acid; the salts comprise sulfate, pyrosulfate, trifluoroacetate, sulfite, bisulfate, phosphate, biphosphate, dihydric phosphate, metaphosphate, pyrophosphate, hydrochloride, bromide, iodide, acetate, propionate, octanoates, acrylate, formate, isobutyric acid, hexanoate, enanthates, propiolate, oxalate, malonate, succinate, suberate, fumarate, maleate, 1,4-butynedioate, 1,6-hexynedioate, benzoate, chloro-benzoate, methyl-benzoate, dinitro-benzoate, hydroxyl-benzoate, methoxy-benzoate, phenylacetate, phenpropionate, phenylbutyrate, citrate, lactate, γ-hydroxybutyrate, glycolate, tartrate, methanesulfonate, propanesulfonate, 1-naphthol-sulfonate, 2-naphthol-sulfonate, mandelate and the like, preferably trifluoro-acetate. Alkaline substances can also be turned into salts with GLP-1 analogues, wherein the alkaline substances comprise ammonium, hydroxides of alkali metals or alkaline earth metal, and carbonate, bicarbonate, typically sodium hydroxide, potassium hydroxide, ammonium hydroxide, sodium carbonate, potassium carbonate and the like.
The pharmaceutical compositions containing GLP-1 derivatives according to the invention can be used to treat patients who need this treatment by the way of parenteral administration. Parenteral administration can be chosed from subcutaneous, intramuscular or intravenous injections. The GLP-1 derivatives of the invention can also be administered by transdermal routes, such as administration via transdermal patch (iontophoresis patch and others) and administration through the mucosa.
The pharmaceutical compositions containing the GLP-1 derivatives of the invention can be prepared through common techniques in the art of pharmaceutical industry. These techniques comprise proper dissolving and mixing the components to obtain the desired final compositions. For instance, the GLP-1 derivatives are dissolved in a certain amount of water, wherein the volume of water is slightly less than the final volume of the obtained composition. Isotonic agents, preservatives, surfactants and buffers are added according to need, wherein said isotonic agents are sodium chloride, mannitol, glycerol, propylene glycol, sugar or alditol. Said preservatives are phenol, orthocresol, para-cresol, meta-cresol, methylparahydroxybenzoate ester, benzyl alcohol. Said appropriate buffering agents are sodium acetate, sodium carbonate, glycine, histidine, lysine, sodium dihydrogen phosphate, disodium hydrogen phosphate, sodium phosphate. Said surfactants are Poloxamer, Poloxamer-188, Poloxamer-407, Tween 80 and Tween-20. If necessary, the aqueous solutions of acids such as hydrochloric acid or alkali such as sodium hydroxide solution are added to adjust pH values of the solutions, and finally the solution volume is adjusted by adding water to obtain the required concentration. Besides said components, the pharmaceutical compositions of the invention also comprise enough basic amino acids or other alkaline reagents having the function to decrease the aggregates formed by the composition during storage, such as lysine, histidine, arginine, imidazole during storage.
The GLP-1 analogues of the invention can be synthesized manually, wherein the resin is HMPA-AM resin, the α-amino group of the amino acid derivatives is protected by the Fmoc (fluorene formyl carbonyl), the side-chain thiol of cysteine, the side-chain amido of glutamine, the side-chain imidazole of histidine are protected by Trt (triphenylmethyl), the side-chain guanidyl of arginine is protected by Pbf (2,2,4,6,7-pentamethyl-dihydrobenzofuran-5-sulfonyl). The side-chain indolyl of tryptophan and the side-chain amino group of lysine are protected by Boc (tert-Butoxycarbonyl) (the side-chain amino group of the Lys are protected by Mtt when the peptide backbone is formed through ε amino group of Lys), the side-chain hydroxyl of threonine, the side-chain phenylol of tyrosine, the side-chain hydroxyl of serine are protected by tBu (tert-butyl). The carboxyl of C-terminal amino acids of the peptide chain of the GLP-1 analogues which will be synthesized is connected with an insoluble high molecular resin (HMP-AM resin) through covalent bonds, and then, the amino acids bound to a solid phase carrier act as amino components, the amino protection group is removed by 20% Hexahydropyridine/DMF solution, and then reactes with excess amino acid derivatives to link a long peptide chain. The operation (Condensation→washing→deprotection→washing→next round of condensation) is repeated to achieve the peptide chain length desired. Finally, the peptide chain is cleaved down from the resins by using mixture of TFA:water:1,2-dithioglycol:triisopropylsilane (92.5:2.5:2.5:2.5), to obtain the crude GLP-1 analogues through precipitation in an ether. The crude products are purified through using C18 reversed-phase column, and thereby obtaining the desired GLP-1 analogues. The ninhydrin testing method was used to moniter the condensation and the deprotection steps—that is, when there are free aminos on the resin, the ninhydrin reagent will show blue and no color (or slightly yellow) will be shown when there are no free aminos on the resin (Ninhydrin reagent itself is yellow). Therefore, after the condensation reaction is completed, if it shows yellow through ninhydrin test (color of Ninhydrin reagent per se), then it suggests that the coupling step is completed and the deprotection operation before next amino acid coupling can be carried out. If the testing shows blue, it suggests that there are still some free aminos on the peptide chains, and it is needed to further repeat the coupling step or to change the existing condensing agent until the testing has no color or slightly yellow.
DETAILED DESCRIPTION OF THE INVENTION
To describe the present invention in more detail, the following examples are provided. However, the present invention should not be construed as limited to the embodiments set forth herein.
EXAMPLE 1
The Method for Solid-Phase Synthesis of HS-20001
1. Preparation of Fmoc-Lys (Mtt)-HMP-AM Resin
(1) Drying and Swelling of HMP-AM Resin
50 g (30 mmol) HMP-AM resin (0.6 mmol/g) was dried for 24 hours in vacuum and placed into a 2 L bubbling bottle. Resins were swelled with 500 mL N,N-dimethylformamide (DMF) for 30 minutes, then the DMF was drawn-off and the resins were washed with DMF for 1 minute. The washing step was repeated twice.
2. Preparation of Fmoc-Lys(Mtt)-HMP-AM Resin
(1) Coupling of Fmoc-Lys (Mtt)-OH with HMP-AM Resin
The resins were washed with 500 mL DCM and then the washing step was repeated twice. 56.2 g (90 mmol) Fmoc-Lys(Mtt)-OH and 11.4 g (90 mmol) DIC were dissolved in 1 L DCM and added into the swelled HMP-AM resin. 366 mg (3 mmol) DMAP were added to react for 24 hours.
(2) Washing of the Resin
After the reaction, the resin was washed alternately with DMF and IPA twice and washed with DMF 3 times.
(3) Capping of Hydroxyl
15.3 g (150 mmol) acetic anhydride and 19.4 g (150 mmol) DIEA were dissolved in 1 L DMF and added into the resin to react for 10 min.
(4) Washing of the Resin
The resin was washed twice with 1 L 50% MeOH/DMF, 50% DCM/DMF, and then washed three times with DCM and with dehydrated ethanol three times successively. The resin was then dried under vacuum to obtain the Fmoc-Lys(Mtt)-HMP-AM resin.
(5) Loading Assays of Fmoc-Lys(Mtt)-HMP-AM Resin
5˜10 mg resin were put into 1 mL 20% Hexahydropyridine/DMF solution and stirred for 20 minutes. 50 mL supernatant was removed with a pipet and diluted in 2.5 mL DMF.
Blank samples: 50 mL 20% Hexahydropyridine/DMF was taken with a pipet and is diluted in 2.5 mL DMF.
Degree of substitution is calculated as follows:
Sub=( A× 51)/(7.8× m )
wherein A is the absorption value of UV at 301 nm; m is the weight of the resin in mg.
2. Swelling of the Solid-Phase Synthesized Resin
50 g (20 mmol) Fmoc-Lys(Mtt)-HMPA-AM resin (0.4 mmol/g) was dried in vacuum for 24 hours and placed into a 2 L bubbling bottle. 500 mL N,N-dimethylformamide (DMF) were added to swell the resin for 30 minutes. The DMF solution was then drawn-off.
3. Removal of 4-Methyl Triphenylmethyl (Mtt) Protecting Group of Fmoc-Lys (Mtt)-HMPA-AM Resin
The resin was washed with 200 mL DCM twice followed by addition of 1200 mL 1% TFA/DCM (TFA is about 8-fold excess) to remove Mtt protecting group for 1 hour. The resin was alternately washed with 200 mL 5% N,N-diisopropyl ethylamine (DIEA)/DMF and DMF three times followed by DMF washing three times.
4. Palmitic Acid Condensation
50 mmol palmitic acid and 50 mmol 3-(diethoxyphosphoryloxy)-1,2,3-phentriazine-4-ketone (DEPBT) were dissolved in 400 mL DMF. Then 100 mmol DIEA were added and stirred for 3 minutes at room temperature. The solution was added to the resin, reacted in 37° C. water baths for 2 hours under N 2 . After the reaction, the reaction solution was drawn-off and the resin was washed with DMF, isopropyl alcohol (IPA), and DMF in turn.
5. \Removal of 9-Fmoc (Fluorenylmethyloxycarbonyl) Protecting Group of Fmoc-Lys (N-ε-Palmitic Acid)-HMPA-AM Resin
200 mL 20% piperidine/DMF solution were placed into a bubbling bottle filled with Fmoc-Lys (N-ε-palmitic acid)-HMPA-AM resin and reacted for 5 minutes and then is drawn out. Then 200 mL 20% piperidine/DMF solution were added to react for 20 minutes at room temperature. After the reaction, the resin was washed with 200 mL DMF four times.
6. Solid Phase Synthesis of Peptide Chain Part of HS-20001
(1) Condensation of Fmoc-Ser (tBu)-OH
50 mmol Fmoc-Ser(tBu)-OH were dissolved in 125 mL 0.4 M 1-hydroxybenzo triazole (HOBt)/DMF. Then 125 mL 0.4 M N,N′-diisopropyl carbodiimide (DIC)/DCM were added to activate and react for 10 minutes at room temperature. The solution was added into the resin, reacted under of nitrogen at room temperature. Ninhydrin was used to detect and control the degree of the reaction. After reaction, the reaction solution was removed, and the resin was washed with DMF, IPA and DMF in turn.
(2) Extension of the Peptide Chain
HS-20001 resin peptide was synthesized according to the sequence of the peptide chain of HS-20001 from the amino terminal (N-terminal) to the carboxy-terminal (C-terminal) (His-(D)-Ala-Glu-Gly-Thr-Phe-Thr-Ser-Asp-Leu-Ser-Lys-Gln-Nle-Glu-Glu-Glu-Ala-Val-Arg-Leu-Phe-Ile-Glu-Trp-Leu-Lys-Gln-Gly-Gly-Pro-Ser-Ser-Gly-Ala-Pro-Pro-Pro-Ser), wherein the amounts of amino acids and condensation reagents were the same as the amounts for Fmoc-Ser (tBu)-OH. Protected amino acids were Fmoc-Pro-OH, Fmoc-Ala-OH, Fmoc-Gly-OH, Fmoc-Ser(tBu)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Lys(Boc)-OH, Fmoc-Leu-OH, Fmoc-Trp(Boc)-OH, Fmoc-Glu(OtBu)-OH, Fmoc-Ile-OH, Fmoc-Phe-OH, Fmoc-Arg(Pbf)-OH, Fmoc-Val-OH, Fmoc-Nle-OH, Fmoc-Asp(OtBu)-OH, Fmoc-Thr(tBu)-OH, Fmoc-D-Ala-OH and Fmoc-His(Trt)-OH respectively, and condensation and deprotection reactions were repeated.
(3) Post-Processing of HS-20001 Resin Peptide
HS-20001 resin peptide obtained in step (2) was washed with DMF, IPA and DMF in turn, then washed with absolute ether twice, and dried under vacuum to obtain the HS-20001 resin peptide.
(4) Preparation of HS-20001 Crude Peptide
The dried HS-20001 peptide resin is reacted with fresh lysate), of trifluoroacetic acid (TFA):triisopropylsilane (TIS):water=95:2.5:2.5 (by volume and total 10 mL of lysate per gram of the dry resin) for 4 h at room temperature. The reaction solution was filtrated, and the resin was washed with TFA twice. The filtrate was collected, combined, and concentrated to ⅓ of the original volume through rotary evaporation. HS-20001 was precipitated and washed with cold absolute ether, after centrifugation and drying in vacuum, white crude HS-20001 was obtained.
(5) Preparation of HS-20001 with Reversed-Phase Liquid Chromatography
10 g crude HS-20001 was dissolved in a certain amount of water, filtrated with 0.45 μm membrane filter, then purified with reversed-phase high performance liquid chromatography (RP-HPLC), wherein the mobile phase is A 0.1% TFA/H 2 O, B 0.1% TFA/acetonitrile,
the column is Denali C-18 column (particle diameter 8.3 μm, 5×30 cm), column temperature is 45° C., detection wavelength is 220 nm, flow rate is 120 mL/min. The product peaks were collected and concentrated under vacuum to remove most of the acetonitrile. 2.25 g of the product (HS-20001) was obtained by lyophilization, of which the purity as 98.5%, and the yield was 22.5%.
EXAMPLE 2
The Solid-Phase Synthesis Method for HS-20002
1. Preparation of Fmoc-Lys (Mtt)-HMP-AM Resin
See Example 1.
2. Swelling of the Solid-Phase Synthesized Resin
50 g (20 mmol) Fmoc-Lys(Mtt)-HMPA-AM resin (0.4 mmol/g) was dried for 24 hours in vacuum and placed into a 2 L bubbling bottle. The resin was swelled with 500 mL DMF for 30 minutes, and then DMF solution was drawn-off.
3. Removal of Mtt Protecting Group of Fmoc-Lys(Mtt)-HMPA-AM Resin
The resin was washed with 200 mL DCM twice. Mtt protecting group was removed by adding 1200 mL 1% TFA/DCM (TFA is about 8-fold excess) for 1 hour, and then washed with 200 mL 5% DIEA/DMF and DMF alternately for three times followed by DCM washing three times.
4. Palmitic Acid Condensation
50 mmol palmitic acid and 50 mmol DEPBT were dissolved in 400 mL DMF, and then 100 mmol DIEA was added by stirring to react for 3 minutes at room temperature. The resulting solution was added to the resin and reacted in 37° C. water bath under N 2 for 2 hours. After the reaction, the reaction solution as removed, and the resin was washed with DMF, isopropyl alcohol (IPA), and DMF in turn.
5. Removal of Fmoc Protecting Group of Fmoc-Lys (N-ε-Palmitic Acid)-HMPA-AM Resin
200 mL 20% Piperidine/DMF solution was placed into a bubbling bottle filled with Fmoc-Lys(N-ε-palmitic acid)-HMPA-AM resin, and drawn-off after reacting for 5 minutes. 200 mL 20% Piperidine/DMF solution was added for reacting for 20 minutes at room temperature. After the completion, the resin was washed four times with 200 mL DMF.
6. Solid-Phase Synthesis Method for the Peptide Chain Part of HS-20002
(1) Condensation of Fmoc-Ser (tBu)-OH
50 mmol Fmoc-Ser(tBu)-OH were dissolved in 125 mL 0.4M HOBt/DMF, then 125 mL 0.4 M DIC/DCM were added to activate and react for 10 minutes at room temperature. The resulting solution was contacted with the resin and reacted under N 2 at room temperature. Ninhydrin was used to detect and control the degree of the reaction. After the reaction, the reaction solution as removed, and the resin was washed with DMF, IPA and DMF in turn.
(2) Extension of the Peptide Chain
HS-20002 resin peptide was synthesized according to the sequence of peptide chain of HS-20002 from the N-amino (N-terminal) to the carboxy-terminal (C-terminal) (His-Gly-Glu-Gly-Thr-Phe-Thr-Ser-Asp-Leu-Ser-Lys-Gln-Met-Glu-Glu-Glu-Ala-Val-Arg-Leu-Phe-Ile-Glu-Trp-Leu-Lys-Asn-Gly-Gly-Pro-Ser-Ser-Gly-Ala-Pro-Pro-Pro-Ser), wherein the amounts of amino acids and condensation reagents were the same as that of Fmoc-Ser (tBu)-OH, protected amino acids were Fmoc-Pro-OH, Fmoc-Ala-OH, Fmoc-Gly-OH, Fmoc-Ser(tBu)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Lys(Boc)-OH, Fmoc-Leu-OH, Fmoc-Trp(Boc)-OH, Fmoc-Glu(OtBu)-OH, Fmoc-Ile-OH, Fmoc-Phe-OH, Fmoc-Arg(Pbf)-OH, Fmoc-Val-OH, Fmoc-Met-OH, Fmoc-Gln(Trt)-OH, Fmoc-Asp(OtBu)-OH, Fmoc-Thr(tBu)-OH and Fmoc-His(Trt)-OH respectively, and condensation and deprotection reactions were repeated.
(3) Post-Processing of HS-20002 Resin Peptide
The HS-20002 resin peptide obtained in step (2) was washed with DMF, IPA and DMF in turn, then washed twice with absolute ether, then dried under vacuum. HS-20002 resin peptide was obtained therefrom.
(4) Preparation of HS-20002 Crude Peptide
The dried HS-20002 peptide resin was reacted with fresh lysate of trifluoroacetic acid (TFA):triisopropylsilane (TIS):water:1,2-ethanedithiol (EDT)=94:1:2.5:2.5 (by volume and total 10 mL of lysate per gram of the dry resin) for 4 hours at room temperature. The reaction solution was filtrated after the reaction. The resin was washed with TFA twice, and then filtrate was collected, combined, and concentrated to ⅓ of the original volume through rotary evaporation. HS-20002 was precipitated with cold absolute ether, after centrifugation and drying under vacuum. The resulting product was white crude HS-20002.
(5) Preparation of HS-20002 with Reversed-Phase Liquid Chromatography
10 g crude HS-20002 were dissolved in a certain amount of water, filtrated with 0.45 μm membrane filter, then purified with reversed-phase high performance liquid chromatography (RP-HPLC), with a mobile phase A was 0.1% TFA/H 2 O, B 0.1% TFA/acetonitrile, the column was a Denali C-18 column (particle diameter 8.3 μm, 5×30 cm), column temperature was 45° C., detection wavelength was 220 nm, flow rate was 120 mL/min. The product peaks were collected, concentrated under vacuum to remove most of acetonitrile. 2.1 g of HS-20002 was obtained by lyophilization, of which the purity was 98%, and the yield was 20.5%.
EXAMPLE 3
The Solid-Phase Synthesis Method for HS-20003
1. Preparation of Fmoc-Lys (Mtt)-HMP-AM Resin
See Example 1.
2. Swelling of the Solid-Phase Synthesized Resin
50 g (20 mmol) Fmoc-Lys(Mtt)-HMPA-AM resin (0.4 mmol/g) dried for 24 hours in vacuum were placed into a 2 L bubbling bottle. The resin was swelled with 500 mL DMF for 30 minutes, and then DMF solution was drawn-off.
3. Removal of Fmoc Protecting Group of Fmoc-Lys(Mtt)-HMPA-AM Resin
200 mL 20% piperidine/DMF solution were added into a bubbling bottle filled with Fmoc-Lys (Mtt)-HMPA-AM resin. Then the solution was drawn off after 5 minutes, and 200 mL 20% piperidine/DMF solution were added. The reaction continued for another 20 minutes at room temperature. After the reaction, the resin was washed four times with 200 mL DMF.
4. Palmitic Acid Condensation
50 mmol Palmitic acid and 50 mmol DEPBT were dissolved in 400 mL DMF. Then 100 mmol DIEA was added by stirring to react for 3 minutes at room temperature. The resulting solution was added to the resin, reacted in 37° C. water baths under N 2 for 2 hours. After the reaction, the reaction solution was removed, and the resin was washed with DMF, isopropyl alcohol (IPA), and DMF in turn.
5. Removal of Mtt Protecting Group of N-α-Palmitic Acid-Lys(Mtt)-HMPA-AM Resin
The resin was washed with 200 mL DCM twice. The Mtt protecting group was removed by adding 1200 mL 1% TFA/DCM (TFA is about 8-fold excess) for 1 hour. The resin was washed with 200 mL 5% DIEA/DMF and DMF alternately three times, then washed with DCM three times.
6. Solid-Phase Synthesis Method for the Peptide Chain Part of HS-20003
(1) Condensation of Fmoc-Ser (tBu)-OH
50 mmol Fmoc-Ser(tBu)-OH and 50 mmol DEPBT were dissolved in a certain amount of DCM. Then 100 mmol DIEA was added for activation for 3 minutes at room temperature. The solution was added to the resin, reacted under N 2 at room temperature, and ninhydrin was used to detect and control the degree of the reaction. After the reaction, the reaction solution was removed, and the resin was washed with DMF, IPA and DMF in turn.
(2) Extension of the Peptide Chain
HS-20003 resin peptide is synthesized according to the sequence of peptide chain of HS-20003 from the N-amino (N-terminal) to the carboxy-terminal (C-terminal) (His-(D)-Ala-Glu-Gly-Thr-Phe-Thr-Ser-Asp-Val-Ser-Ser-Tyr-Leu-Glu-Glu-Glu-Ala-Ala-Lys-Glu-Phe-Ile-Ala-Trp-Leu-Val-Arg-Gly-Gly-Pro-Ser-Ser-Gly-Ala-Pro-Pro-Pro-Ser), wherein the amounts of amino acids and condensation reagents were the same as that of Fmoc-Ser (tBu)-OH, protected amino acids were Fmoc-Pro-OH, Fmoc-Ala-OH, Fmoc-Gly-OH, Fmoc-Ser(tBu)-OH, Fmoc-Arg(Pbf)-OH, Fmoc-Val-OH, Fmoc-Leu-OH, Fmoc-Trp(Boc)-OH, Fmoc-Ile-OH, Fmoc-Phe-OH, Fmoc-Glu(OtBu)-OH, Fmoc-Lys(Boc)-OH, Fmoc-Tyr(tBu)-OH, Fmoc-Asp(OtBu)-OH, Fmoc-Thr(tBu)-OH respectively, and condensation and deprotection reactions were repeated.
(3) Post-Processing of HS-20003 Resin Peptide
The HS-20003 resin peptide obtained in step (2) was washed with DMF, IPA and DMF in turn, then washed twice with absolute ether, and dried under vacuum to obtain HS-20003 resin peptide.
(4) Preparation of HS-20003 Crude Peptide
The dried HS-20003 peptide resin was reacted with fresh lysate of trifluoroacetic acid (TFA):triisopropylsilane (TIS):water=95:2.5:2.5 (by volume and total 10 mL of lysate per gram of the dry resin) for 4 hours at room temperature. The reaction solution was filtrated after the reaction. The resin was twice washed with TFA. The filtrate was collected, combined, and concentrated to ⅓ of the original volume through rotary evaporation. HS-20003 was precipitated with cold ether under stirring. After centrifugation and drying in vacuum, white crude HS-20003 was obtained.
(5) Preparation of HS-20003 with Reversed-Phase Liquid Chromatography
10 g crude HS-20003 was dissolved in a certain amount of 20% acetic acid/water and stirred for at least 4 hours, then filtrated with 0.45 μm membrane filter, then purified with reversed-phase high performance liquid chromatography (RP-HPLC), wherein the mobile phase was A 0.1% TFA/H 2 O, B 0.1% TFA/acetonitrile, the column was Denali C-18 column (particle diameter 8.3 mm, 5×30 cm), column temperature was 45° C., detection wavelength was 220 nm, flow rate was 120 mL/min. The product peaks were collected, concentrated with vacuum to remove most of acetonitrile. 2.5 g of HS-20003 was obtained by lyophilization, of which the purity was 98.5%, and the yield was 25%.
EXAMPLE 4
The Solid-Phase Synthesis Method for HS-20004
1. Preparation of Fmoc-Lys (Mtt)-HMP-AM Resin
See Example 1.
2. Swelling of the Solid-Phase Synthesized Resin
50 g (20 mmol) Fmoc-Lys(Mtt)-HMPA-AM resin (0.4 mmol/g) dried for 24 hours under vacuum were placed into a 2 L bubbling bottle. 500 mL DMF was added to swell the resin for 30 minutes, followed by drawing off DMF solution.
3. Removal of Fmoc Protecting Group of Fmoc-Lys(Mtt)-HMPA-AM Resin
200 mL 20% piperidine/DMF solution were added into a bubbling bottle filled with Fmoc-Lys (Mtt)-HMPA-AM resin, and then drawn off after 5 minutes, and then 200 mL 20% piperidine/DMF solution was added for reacting for 20 minutes at room temperature. After the reaction, the resin was washed four times with 200 mL DMF.
4. Palmitic Acid Condensation
50 mmol palmitic acid and 50 mmol DEPBT were dissolved in 400 mL DMF, and then 100 mmol DIEA was added by stirring for 3 minutes at room temperature. The resulting solution was added to the resin, reacted in 37° C. water bath under N 2 for 2 hours. After the reaction, the reaction solution was removed, and the resin was washed with DMF, isopropyl alcohol (IPA) and DMF in turn.
5. Removal of Mtt Protecting Group of Palmitic Acid-Lys(Mtt)-HMPA-AM Resin
The resin was washed with 200 mL DCM twice. Mtt protecting group was removed by adding 1200 mL 1% TFA/DCM (TFA is about 8-fold excess) for reacting for 1 hour, then washed with 5% DIEA/DMF and DMF alternately for three times, then washed three time with DCM.
6. The Solid-Phase Synthesis Method for the Peptide Chain Part of HS-20004
(1) Condensation of Fmoc-Ser (tBu)-OH
50 mmol Fmoc-Ser(tBu)-OH and 50 mmol DEPBT were dissolved in a certain amount of DCM. Then 100 mmol DIEA was added for activation for 3 minutes at room temperature. The resulting solution was added to the resin, reacted under N 2 at room temperature, and ninhydrin was used to detect and control the degrees of the reaction. After the reaction, the reaction solution was removed, and the resin was washed with DMF, IPA and DMF in turn.
(2) Extension of the Peptide Chain
HS-20004 resin peptide was synthesized according to the sequence of the peptide chain of HS-20004 from the N-amino (N-terminal) to the carboxy-terminal (C-terminal) (His-Aib-Glu-Gly-Thr-Phe-Thr-Ser-Asp-Val-Ser-Ser-Tyr-Leu-Glu-Glu-Glu-Ala-Ala-Lys-Glu-Phe-Ile-Ala-Trp-Leu-Val-Arg-Gly-Gly-Pro-Ser-Ser-Gly-Ala-Pro-Pro-Pro-Ser), wherein the amounts of amino acids and condensation reagents were same as that of Fmoc-Ser (tBu)-OH. Protected amino acids were Fmoc-Pro-OH, Fmoc-Ala-OH, Fmoc-Gly-OH, Fmoc-Ser(tBu)-OH, Fmoc-Arg(Pbf)-OH, Fmoc-Val-OH, Fmoc-Leu-OH, Fmoc-Trp(Boc)-OH, Fmoc-Ile-OH, Fmoc-Phe-OH, Fmoc-Glu(OtBu)-OH, Fmoc-Lys(Boc)-OH, Fmoc-Tyr(tBu)-OH, Fmoc-Asp(OtBu)-OH, Fmoc-Thr(tBu)-OH, Fmoc-Aib-OH and Fmoc-His(Trt)-OH respectively, and the condensation and deprotection reactions were repeated.
(3) Post-Processing for HS-20004 Resin Peptide
HS-20004 resin peptide obtained in step (2) was washed with DMF, IPA and DMF in turn, then washed twice with absolute ether, followed by drying under vacuum to obtain HS-20004 resin peptide.
(4) Preparation of Crude HS-20004 Peptide
The dried HS-20004 resin peptide was reacted with fresh lysate of trifluoroacetic acid (TFA):triisopropylsilane (TIS):water=95:2.5:2.5 (by volume and total 10 mL of lysate per gram of the dry resin) for 4 hours at room temperature. The reaction solution was filtrated, and the resin was washed twice with TFA. The filtrate was collected, combined, and concentrated to ⅓ of the original volume through rotary evaporation. HS-20004 was precipitated with cold ether under stirring. After centrifugation and drying in vacuum, white crude HS-20004 was obtained.
(5) Preparation of HS-20004 with Reversed-Phase Liquid Chromatography
10 g crude HS-20002 was dissolved in a certain amount of 20% acetic acid/water and stirred for at least 4 hours, then filtrated with 0.45 μm membrane filter, and purified with reversed-phase high performance liquid chromatography (RP-HPLC), wherein mobile phase was A 0.1% TFA/H 2 O, B 0.1% TFA/acetonitrile, the column was Denali C-18 column (particle diameter 8.3 μm, 5×30 cm), column temperature was 45° C., detection wavelength was 220 nm, flow rate was 120 mL/min. The product peaks were collected, concentrated with under vacuum to remove most of acetonitrile. 2.25 g of HS-20004 was obtained by lyophilization, of which the purity was 98.5%, and the yield was 22.5%.
EXAMPLE 5
The Solid-Phase Synthesis Method for HS-20005
The preparation method of HS-20005 is as same as that described in example 4, wherein the difference is that the amino acid sequence is replaced with SEQ ID NO: 5, and 2.5 g HS-20005 product was obtained, the purity of which was 98.5%, and the yield was 25%.
EXAMPLE 6
The Solid-Phase Synthesis Method for HS-20006
The preparation method of HS-20006 was the same as that described in example 4, wherein the difference was that the amino acid sequence was replaced with SEQ ID NO: 6. 2.25 g of HS-20006 product was obtained, the purity of which is 98.5%, and the yield is 22.5%.
EXAMPLE 7
The Solid-Phase Synthesis Method for HS-20007
The preparation method of HS-20007 was the same as that described in example 4, wherein the difference is that the amino acid sequence was replaced with SEQ ID NO: 7. 2.1 g of HS-20007 product was obtained, the purity of which was 98%, and the yield was 20.5%.
EXAMPLE 8
The Solid-Phase Synthesis Method for HS-20008
The preparation method of HS-20008 was the same as that described in example 4, wherein the difference is that the amino acid sequence was replaced with SEQ ID NO: 8. 2.5 g of HS-20008 product was obtained, the purity of which was 98.5%, and the yield was 25%.
REFERENCE EXAMPLE
Solid-Phase Synthesis Method for Liraglutide
1. Preparation of Fmoc-Lys(Mtt)-HMP-AM Resin
(1) Drying and Swelling of HMP-AM Resin
50 g (30 mmol) HMP-AM resin (0.6 mmol/g) was dried for 24 hours in vacuum and placed into a 2 L bubbling bottle. 500 mL N,N-dimethylformamide (DMF) was added to swell therein for 30 minutes. The DMF solution was drawn-off, and DMF was added to wash the resin for 1 minute. This washing step was repeated twice.
(2) Preparation of Fmoc-Lys(Mtt)-HMP-AM Resin
{circle around (1)} Coupling of Fmoc-Lys (Mtt)-OH and HMP-AM Resin
The resin was washed three times with 500 mL DCM/56.2 g (90 mmol) Fmoc-Lys(Mtt)-OH and 11.4 g (90 mmol) DIC were dissolved in 1 L DCM, and then added into the swelled HMP-AM resin. 366 mg (3 mmol) DMAP was added and reaction proceeded for 24 hours.
{circle around (2)} Washing of the Resin
After the reaction, the resin was washed twice alternately with DMF and IPA and then washed three times with DMF.
{circle around (3)} Capping of Hydroxyl
15.3 g (150 mmol) acetic anhydride and 19.4 g (150 mmol) DIEA were dissolved in 1 L DMF and added to the resin for reacting for 10 minutes.
{circle around (4)} Washing of the Resin
The resin was washed twice with 1 L 50% MeOH/DMF, 50% DCM/DMF, three times with DCM, and was washed three times with absolute ethanol. It was then dried under vacuum to obtain the Fmoc-Lys(Mtt)-HMP-AM resin.
(3) Loading Assays of Fmoc-Lys(Mtt)-HMP-AM Resin
5˜10 mg resin were put into 1 mL 20% Hexahydropyridine/DMF solution and stirred for 20 minutes. 50 μL supernatant is taken with a pipet and diluted in 2.5 mL DMF.
Blank samples: 50 μL 20% Hexahydropyridine/DMF was taken with a pipet and is diluted in 2.5 mL DMF.
Degree of substitution is calculated as follows:
Sub=( A× 51)/(7.8× m )
wherein A is the absorption value of UV at 301 nm; m is the weight of the resin in mg.
2. Swelling the Resin of the Solid-Phase Synthesis
50 g (20 mmol) Fmoc-Gly-HMP-AM resin (0.4 mmol/g) dried for 24 hours in vacuum were placed into a 2 L bubbling bottle, and then 500 mL N,N-dimethylformamide (DMF) was added to swell the resin for 30 minutes. Thereafter, the DMF solution was drawn-off.
3. The Solid Phase Synthesis Method of the Peptide Chain Part of Liraglutide
{circle around (1)} Condensation of Fmoc-Arg(Pbf)-OH
50 mmol Fmoc-Arg(Pbf)-OH were dissolved in 125 mL 0.4M 1-hydroxybenzotriazole (HOBt)/DMF, then 125 mL 0.4M N,N′-diisopropylcarbodiimide (DIC)/DCM were added to activate and react for 10 minutes at room temperature. The resulting solution was added to the resin, reacted under N 2 at room temperature, and ninhydrin was used to detect and control the degrees of the reaction. After the reaction, the reaction solution was drawn off, and the resin was washed with DMF, IPA and DMF in turn.
{circle around (2)} Extension of the Peptide Chain
Precursor peptide of Liraglutide was synthesized according to the sequence of the peptide chain of Liraglutide from the N-amido (N-terminal) to the carboxy-terminal (C-terminal)
(His-Ala-Glu-Gly-Thr-Phe-Thr-Ser-Asp-Val-Ser-Ser-Tyr-Leu-Glu-Gly-Gln-Ala-Ala-Lys-Glu-Phe-Ile-Ala-Trp-Leu-Val-Arg-Gly-Arg-Gly), wherein the amounts of amino acids and condensation reagents were the same as that of Fmoc-Arg(Pbf)-OH, protected amino acids were Fmoc-Arg(Pbf)-OH, Fmoc-Val-OH, Fmoc-Leu-OH, Fmoc-Trp(Boc)-OH, Fmoc-Ala-OH, Fmoc-Ile-OH, Fmoc-Phe-OH, Fmoc-Glu(OtBu)-OH, Fmoc-Lys(Mtt)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Tyr(tBu)-OH, Fmoc-Ser(tBu)-OH, Fmoc-Asp(OtBu)-OH, Fmoc-Thr(tBu)-OH, Fmoc-His(Trt)-OH respectively, and the condensation and deprotection reactions were repeated.
{circle around (3)} Removal of Mtt Protecting Group of the Precursor Peptide of Liraglutide
The resin was twice washed with 200 mL DCM. The Mtt protecting group was removed twice by adding 1200 mL 1% TFA/DCM (TFA is about 8-fold excess) to react for 1 hour. The resin was washed alternately with 200 mL 5% N,N-diisopropylethylamine (DIEA)/DMF and DMF for three times, and washed 3 times with DMF.
{circle around (4)} Modification of Precursor Peptide of Liraglutide with Palmitic Acid
50 mmol Fmoc-Glu-OtBu were dissolved in 125 mL 0.4 M 1-hydroxybenzo triazole (HOBt)/DMF. Then 125 mL 0.4M N,N′-diisopropylcarbodiimide (DIC)/DCM was added to activate and react for 10 minutes at room temperature. The solution was added to the resin from step {circle around (3)}, and allowed to react under N 2 at room temperature. Ninhydrin was used to detect and control the degree of the reaction or reaction progress. After the reaction, the reaction solution was drawn-off, and the resin is washed with DMF, IPA and DMF in turn.
1 L 20% PIP/DMF was added to remove Fmoc protecting group for 5 minutes, then drawn off. 1 L of 20% PIP/DMF was added to remove Fmoc protecting group for 20 minutes, then are drawn off. The resulting resin was wased four times with DMF.
50 mmol palmitic acid and 50 mmol 3-(diethoxyphosphoryloxy)-1,2,3-phentriazine-4-ketone (DEPBT) was dissolved in 400 mL DMF. Then 100 mmol DIEA was added to react for 3 minutes under stirring at room temperature. The solution was added to the resin, reacted in 37° C. water bath under N 2 for 2 hours. After the reaction, the reaction solution was drawn-off, and the resin was washed with DMF, isopropyl alcohol (IPA), and DMF in turn.
4. Post-Processing of the Resin Peptide of Liraglutide
The resin peptide of Liraglutide obtained in step (2) was washed with DMF, IPA and DMF in turn, and then washed three times with DCM, washed twice with absolute ether, and dried in vacuum, to give the resin peptide of Liraglutide.
5. Preparation of Crude Peptide of Liraglutide
The dried peptide resin of Liraglutide was reacted with fresh lysate of trifluoroacetic acid (TFA):triisopropylsilane (TIS):water=95:2.5:2.5 (by volume and total 10 mL of lysate per gram of the dry resin) for 4 hours at room temperature. The reaction solution was filtrated after the reaction, and the resin was twice washed with TFA. The filtrate was collected, combined, and concentrated to ⅓ of the original volume through rotary evaporation. Liraglutide was precipitated with cold absolute ether, after centrifugation and drying under vacuum as white crude HS-20001 is obtained.
{circle around (5)} Preparation of Liraglutide with Reversed-Phase Liquid Chromatography
10 g of crude Liraglutide as dissolved in a certain amount of NH 4 HCO 3 solution, filtrated with 0.45 μm membrane filter, then purified with reverse-phase high performance liquid chromotagraphy (RP-HPLC), wherein mobile phase was A 0.1% TFA/H 2 O, B 0.1% TFA/acetonitrile, the column was Denali C-18 column (particle diameter 8.3 μm, 5×30 cm), column temperature was 45° C., detection wavelength was 220 nm, flow rate was 120 mL/min. The product peaks were collected, concentrated with vacuum to remove most of acetonitrile. 2.25 g of Liraglutide product was obtained by lyophilizatiom, the purity of which was 98%, and the yield was 12.5%.
Experimental Example 1
Testing the Agonist Activity of the Compounds on Glucagon-Like Peptide-1 Receptor (GLP1R)
GLP1R is a receptor coupled with Gs protein, of which the binding with the agonists will result in an increase of intracellular cAMP concentration. In the present experiment, GLP1R and the luciferase reporter gene plasmid regulated by cAMP response elements are co-transfected into HEK293 cells. When the compound binds to the receptor and activates the receptors, the expression of the luciferase will increase. The activation status of the compound to GLP1R can be learned by testing the activity of the luciferase.
No. of the test
Final concentration
drug:
amount (mg)
DMSO (μl)
(mM)
Liraglutide
2
53.31556
10
HS-20001
2
43.81871
10
HS-20002
2
43.91502
10
HS-20003
2
44.99387
10
HS-20004
2
44.8526
10
HS-20005
2
43.81871
10
HS-20006
2
43.91502
10
HS-20007
2
44.99387
10
HS-20008
2
44.8526
10
Experimental Procedures:
1. HEK293 cells stably transfected with GLP1R and pCRE-Luc plasmid were implanted in 96 well plate with the amount 40000 cells/well/100 μl, and incubated at 37° C. for 24 hours.
2. The compounds or positive drugs having a certain concentration gradient were added (3 wells per concentration) and incubated at 37° C. for 5 hours. The negative control was solvent DMSO.
3. 50 μl culture medium was taken from each well, and 50 μl of the luciferase substrate were added and vortexed for 10 minutes.
4. 80 μl reaction solution was taken and transferred to a white 96 well plate, then detected on the Invision microplate reader (enzyme-labelling measuring instrument).
The experimental results: compared with positive compounds liraglutide, the activity of the compound HS-20001 is approximately equal to that of the positive compounds, but HS-20002-20008 show much better agonist activity.
TABLE 1
EC50 Values of the series of compounds:
Maximum
Compounds
EC50 (nM)
95% CI (nM)
reaction rate (%)
Liraglutide
0.014707
9.726e−012 to
96.84616
2.223e−011
HS-20001
0.013552
7.6757e−012 to
98.11013
2.3963e−011
HS-20002
0.0014145
1.2036e−012 to
87.99447
1.6623e−012
HS-20003
0.00071876
4.9657e−013 to
87.86082
1.0404e−012
HS-20004
0.00037259
2.1453e−013 to
90.81368
6.4710e−013
HS-20005
0.00023552
7.3567e−012 to
89.13468
2.2346e−011
HS-20006
0.00064358
1.3581e−012 to
87.4281
1.4523e−012
HS-20007
0.00054921
4.1354e−013 to
87.0389
1.2514e−012
HS-20008
0.00021002
2.2436e−013 to
88.4628
6.0245e−013
Experimental Example 2
Test In Vivo Activity
db/db mice with type 2 diabetes were divided into six groups based on a random blood glucose and body weight (8 per group). Physiological saline, 3 or 10 μg/kg HS series new compounds (Liraglutide, 20001, 20002, 20003, 20004, 20005, 20006, 20007, 20008) are administered by single subcutaneous injection. The random blood glucose of the mice is determined at differete time after administration.
The animals used in the experiment are db/db mice, which are products of a U.S. corporation named Jackson and are conserved and reproduced by Shanghai Institute of Materia Medica of Chinese Academy of Science, of which the Certificate of Conformity is: SCXK(HU)2008-0017, Body Weight: 35-50 g; Gender: Male 85, female 86, bred in SPF-grade animal room; Temperature: 22-24° C.; Humidity: 45-80%; Light: 150-300Lx, 12 h day alternates with night.
The test candidates of the experiment are HS-20001, HS-20002, HS-20003, HS-20004, HS-20005, HS-20006, HS-20007, HS-20008, liraglutide (developed by Novo Nordisk, as Positive control).
Preparation method: 1 bottle of the compound (2 mg/bottle) was dissolved with double-distilled water to prepare a colorless and transparent solution of which the concentration is 2 mg/mL. Then the solution was diluted to 0.6 μg/mL and 2 μg/mL with physiological saline (Sodium chloride injection, Double-Crane Pharmaceutical Co., Ltd. Anhui, batch number: 080728 6C). “ACCU-CHEK® Advantage” blood glucose meter form Roche was used to determine the blood glucose.
Dose Setting and Group
Test Group 1:
Control group: physiological saline
Liraglutide group 3 μg/kg
HS-20001group: 3 μg/kg
HS-20002group: 3 μg/kg
HS-20003group: 3 μg/kg
HS-20004group: 3 μg/kg
HS-20005group: 3 μg/kg
HS-20006group: 3 μg/kg
HS-20007group: 3 μg/kg
HS-20008group: 3 μg/kg
Test Group 2:
Control group: physiological saline
Liraglutide group: 10 μg/kg
HS-20001group: 10 μg/kg
HS-20002group: 10 μg/kg
HS-20003group: 10 μg/kg
HS-20004group: 10 μg/kg
HS-20005group: 10 μg/kg
HS-20006group: 10 μg/kg
HS-20007group: 10 μg/kg
HS-20008group: 10 μg/kg
Route and volume of administration: Single subcutaneous injection dose, dose volume was 5 mL/kg.
Test Method
Screening, Grouping, and Administration for db/db Mice with Type 2 Diabetes
Test Group 1:
171 db/db mice (male 85, female 86) were single-cage reared after weaning, fed with high fat diet. The random and fasting blood glucoses were measured after the db/db mice were seven weeks old. 80 db/db mice which fall ill were picked out and divided into 10 groups according to random blood glucose. Fasting blood glucose and body weight as follows: model control group, Liraglutide group-3 μg/kg, HS-20001 group-3 μg/kg, HS-20002 group-3 μg/kg, HS-20003 group-3 μg/kg, HS-20004 group-3 μg/kg, HS-20005 group-3 μg/kg, HS-20006 group-3 μg/kg, HS-20007 group-3 μg/kg and HS-20008 group-3 μg/kg.
Test Group 2:
The random blood glucoses of db/db mice were measured. 80 db/db mice which fall ill were picked out and are divided into 10 groups according to random blood glucose and body weight as follows: model control group, Liraglutide group-10 μg/kg, HS-20001 group-10 μg/kg, HS-20002 group-10 μg/kg, HS-20003 group-10 μg/kg, HS-20004 group-10 μg/kg, HS-20005 group-10 μg/kg, HS-20006 group-10 μg/kg, HS-20007 group-10 μg/kg and HS-20008 group-10 μg/kg.
Each group has 8 mice, half male and half female. The animals of each group were administered with the test compounds or solvent control respectively through single subcutaneous injection. The random blood glucose was determined at 1 h, 2 h, 4 h, 8 h and 24 h after administration, and the decrease rate of blood glucose as calculated as follows:
Decrease rate of blood glucose=(blood glucose of contro group1−blood glucose of treatment group)/blood glucose of control group*100%.
The Experimental Results
Test 1: Effect of the low-dose new compounds administered by singe dose on random blood glucose of db/db mice
The results can be seen in Tables 2 and 3. db/db mice were administered with 3 μg/kg HS-20002, 20004, 20005, 20006, 20007, or 20008 through single subcutaneous injection. After one hour, random blood glucose values of the mice were decreased significantly compared with those of the control group (P<0.05). Decrease rates are 24.51%, 15.00%, 14.00%, 14.25%, 13.98% and 13.90% respectively. After 2 h and 4 h from administration, random blood glucose values kept a lower level and had significant difference from those of the control group (P<0.05). After 8 hours from administration, random blood glucose values had no significant difference from those of the control group. The mice were administered with 3 μg/kg HS-20003 through subcutaneous injection. After one hour, random blood glucose values were decreased significantly compared with those of the control group (P<0.05); up to 17.33%, after 2 h, 4 h and 8 h from the administration, random blood glucose values showed no significant difference from those of the control group. After administered with 3 μg/kg HS-20001 for db/db mice through single subcutaneous injection, random blood glucose values decreased and were compared to those of the control group No significant difference was observed. The values of random blood glucose of the group of mice administered with liraglutide had no significant decrease.
TABLE 2
Effect of the administration of the new compounds (mmol/L, X ± s,
n = 8) through single dose on random blood glucose of db/db mice in the same day.
Before
Time after administration (h)
groups
administration
1
2
4
8
control
25.14 ± 1.09
23.66 ± 0.73
22.63 ± 0.97
22.00 ± 1.00
25.39 ± 1.08
Liraglutide-
25.11 ± 2.33
21.78 ± 2.31
23.15 ± 2.62
21.56 ± 1.37
23.93 ± 2.09
3 μg/kg
HS-20001-3 μg/kg
25.21 ± 1.44
20.34 ± 2.29
19.84 ± 1.76
20.74 ± 2.51
24.29 ± 1.60
HS-20002-3 μg/kg
25.25 ± 1.57
17.86 ± 1.90*
19.56 ± 0.90*
18.10 ± 0.79**
24.19 ± 1.79
HS-20003-3 μg/kg
25.16 ± 1.49
19.56 ± 1.19*
19.44 ± 1.48
19.63 ± 1.12
22.59 ± 1.05
HS-20004-3 μg/kg
25.11 ± 1.63
20.11 ± 1.28*
18.81 ± 1.50*
17.98 ± 1.38*
23.30 ± 1.47
HS-20005-3 μg/kg
25.21 ± 1.56
20.11 ± 1.19*
18.96 ± 1.50*
18.98 ± 1.48*
22.36 ± 1.67
HS-20006-3 μg/kg
25.11 ± 1.49
20.36 ± 1.25*
19.91 ± 1.70*
19.58 ± 1.54*
24.30 ± 1.50
HS-20007-3 μg/kg
25.16 ± 1.63
20.43 ± 1.19*
19.81 ± 1.610*
20.98 ± 2.38*
23.42 ± 1.38
HS-20008-3 μg/kg
25.11 ± 1.58
20.56 ± 1.30*
20.81 ± 1.70*
19.30 ± 2.02*
22.41 ± 1.51
*P < 0.05,
**P < 0.01, Compared with those of the control group
TABLE 3
The decrease rate of random blood glucose (%, n = 8) of db/db
mice administered with the new compounds through single dose in the
same day
Time after administration (h)
group
1
2
4
8
Liraglutide-3 μg/kg
7.98%
−2.32%
1.99%
5.76%
HS-20001-3 μg/kg
14.05%
12.32%
5.74%
4.33%
HS-20002-3 μg/kg
24.51%
13.54%
17.73%
4.73%
HS-20003-3 μg/kg
17.33%
14.09%
10.80%
11.03%
HS-20004-3 μg/kg
15.00%
16.85%
18.30%
8.22%
HS-20005-3 μg/kg
14.00%
12.87%
10.53%
8.02%
HS-20006-3 μg/kg
14.25%
13.12%
10.86%
8.14%
HS-20007-3 μg/kg
13.98%
11.85%
9.30%
6.54%
HS-20008-3 μg/kg
13.90%
11.62%
8.90%
6.25%
Test 2: Effect of the high-dose new compounds administered by single dose on random blood glucose of db/db mice
The results can be seen in Tables 4 and 5. db/db mice were administered with 10 μg/kg HS-20002 through single subcutaneous injection. After one hour, the random blood glucose values of the mice decreased significantly compared with those of the control group (P<0.01). After 2 h, 4 h and 8 h from the administration, the random blood glucose values kept a lower level, wherein the values at 4 h after administration were most obvious, of which the decrease rate is up to 40.67% and is significantly different from that of the control group (P<0.001), until 24 hours after administration, the random blood glucose values were still significantly lower than those of the control group. The mice were administered with 10 μg/kg HS-20003 through single subcutaneous injection. After one hour, the random blood glucose values were decreased significantly compared with those of the control group (P<0.01) and is up to 23.62% decreasing, after 2 h, 4 h and 8 h from the administration. The random blood glucose values still keep at a lower level. After 24 hours from administration, there was no significant difference compared with the control group. db/db mice are administered with 10 μg/kg HS-20001 through single subcutaneous injection, after 2 h, the random blood glucose values are decreased significantly compared with those of the control group, after 4 h and 8 h from the administration, the random blood glucose values still keep at a lower level. After 24 hours from administration, the random blood glucose values showed no significant difference from those of the control group. HS-20002, HS-20004, HS-20005, HS-20006, HS-20007 or HS-20008 were administered to mice through single subcutaneous injection and the random blood glucose values are decreased immediately and significantly. The decrease rate is up to 36.20%, after 2 hours. After 4 and 8 hours from the administration, the blood glucose values still kept at a lower level. After 24 hours from the administration, blood glucose was not significantly different compared with those of the control group. The values of random blood glucose of mice of group administered with liraglutide have no significant decrease.
TABLE 4
Effect of the new compounds administered through single dose (mmol/L, ±
s, n = 8) on the random blood glucose of db/db mice in the same day.
Before
Time after administration (h)
Group
administration
1
2
4
8
24
Control
23.08 ± 1.37
27.15 ± 1.51
28.49 ± 1.58
30.76 ± 1.15
29.96 ± 0.88
27.75 ± 1.64
liraglutide-
23.19 ± 1.35
28.59 ± 1.50
28.89 ± 1.17
28.55 ± 1.31
31.84 ± 0.65
27.78 ± 1.14
10 μg/kg
HS-20001-
23.16 ± 1.57
23.90 ± 1.79
20.94 ± 1.57**
20.20 ± 1.78***
23.86 ± 1.87*
24.60 ± 1.92
10 μg/kg
HS-20002-
23.15 ± 1.32
19.74 ± 1.16**
20.31 ± 2.01**
18.25 ± 1.98***
22.55 ± 2.20**
22.60 ± 1.46*
10 μg/kg
HS-20003-
23.20 ± 1.36
20.74 ± 0.98**
21.10 ± 0.80***
19.54 ± 1.80***
22.14 ± 2.16**
24.45 ± 1.55
10 μg/kg
control
23.08 ± 1.37
30.76 ± 1.15
30.29 ± 0.98
29.90 ± 0.89
31.04 ± 0.94
28.98 ± 1.62
HS-20004-
23.18 ± 1.65
19.63 ± 1.81***
21.86 ± 1.66***
21.44 ± 1.68***
23.80 ± 1.46***
25.64 ± 1.85
10 μg/kg
HS-20005-
23.64 ± 1.35
19.39 ± 1.61***
21.56 ± 1.56***
21.49 ± 1.34***
23.46 ± 1.51***
25.52 ± 1.68
10 μg/kg
HS-20006-
23.54 ± 1.39
19.52 ± 1.72***
21.43 ± 1.49***
21.53 ± 1.67***
23.39 ± 1.55***
25.59 ± 1.74
10 μg/kg
HS-20007-
23.56 ± 1.42
19.41 ± 1.54***
21.84 ± 1.57***
21.64 ± 1.56***
23.81 ± 1.67***
25.51 ± 1.53
10 μg/kg
HS-20008-
23.49 ± 1.49
19.38 ± 1.83***
21.61 ± 1.68***
21.72 ± 1.63***
23.56 ± 1.80***
25.72 ± 1.69
10 μg/kg
*P < 0.05,
**P < 0.01,
***P < 0.001, Compared with the control group
TABLE 5
The decrease rate of the random blood glucose (%, n = 8) of db/db
mice administered with the new compounds through single dose in the
same day.
Time after administration (h)
group
1
2
4
8
24
liraglutide-10 μg/kg
−5.29%
−1.40%
7.19%
−6.26%
−0.09%
HS-20001-10 μg/kg
11.97%
26.50%
34.34%
20.36%
11.35%
HS-20002-10 μg/kg
27.30%
28.71%
40.67%
24.74%
18.56%
HS-20003-10 μg/kg
23.62%
25.93%
36.49%
26.12%
11.89%
HS-20004-10 μg/kg
36.20%
27.82%
28.30%
23.32%
11.52%
HS-20005-10 μg/kg
37.58%
28.32%
29.12%
24.10%
12.46%
HS-20006-10 μg/kg
38.12%
27.66%
29.78%
23.72%
13.66%
HS-20007-10 μg/kg
36.72%
25.43%
26.54%
23.03%
12.16%
HS-20008-10 μg/kg
35.49%
25.79%
27.33%
22.57%
14.58%
Test Conclusions:
The random blood glucose of db/db mice administered with series of the new compounds of the invention through single subcutaneous injection decreased significantly. The random blood glucose level decreased obviously by HS-20002, HS-20003, HS-20004, HS-20005, HS-20006, HS-20007 and HS-20008 in a dose of 3 g/kg. Where, HS-20002 and HS-20004 show a much better effect on reducing random blood glucose, the duration of the hypoglycemic effect after single subcutaneous injection was dose-related. The duration of the effect of HS-20002 and HS-20004 on decreasing random blood glucose in the dose of 3 g/kg was more than 4 hours. The duration of the effect of HS-20001, HS-20002, HS-20003, HS-20004, HS-20005, HS-20006, HS-20007 and HS-20008 on decreasing random blood glucose in the dose of 10 g/kg was more than 8 hours. | This invention discloses GLP-1 analogues and their pharmaceutical salts, wherein the GLP-1 analogue comprises an amino acid sequence of general formula (I), wherein Lys represents a modified lysine with a lipophilic acid. The GLP-1 analogues provided by this invention have the function of human GLP-1, and a longer half-life in vivo compared with the human GLP-1. Uses of such compounds and compositions include treating non-insulin-dependent diabetes, insulin-dependent diabetes, and obesity.
X 1 -X 2 -Glu-Gly-Thr-Phe-Thr-Ser-Asp-X 10 -Ser-X 12 -X 13 -X 14 -Glu-X 16 -X 17 -Ala-X 19 -X 20 -X 21 -Phe-Ile-X 24 -Trp-Leu-X 27 -X 28 -X 29 -X 30 -X 31 -X 32 -X 33 -X 34 -X 35 -X 36 -X 37 -X 38 -X 39 -Lys Formula (I)—SEQ ID NO: 238 | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for manufacturing barium-strontium titanate fine powder which is known as one of dielectric materials.
2. Description of the Prior Art
Recently, a method for forming ceramic material, which is a functional electronic material, into fine powder has been studied from various angles. As one of the applications of such fine powder of the ceramic material, there is such application that the fine powder is used to produce a capacitor. As electronic products are made small in size and high in density, the capacitor is also requested to be made small in size, light in weight, large in capacitance and improved in high frequency characteristic similarly to other electronic parts. For this reason, in a ceramic capacitor, in order to make its thickness thin and uniform, the ceramic material must be formed into fine powder.
As one of such ceramic materials, there is known barium-strontium titanate Ba 1-x Sr x TiO 3 (0<x<1). As a prior art method for manufacturing such fine powder, there is a solid phase reaction method which uses BaCO 3 , SrCO 3 and TiO 2 as the raw material. In this solid phase reaction method, BaCO 3 , SrCO 3 and TiO 2 are weighted so as to make a desired composition, ground in a ball mill and then mixed to one another. Thereafter, the product is subjected to pressmolding, calcined at high temperature of 1300° to 1500° C., ground in the ball mill and the like and then subjected to to the sieving or screening treatment, thus fine powder being obtained. However, according to this solid phase reaction method, it takes a long time to grind the materials in the ball mill and in addition impurity and powder of large size are inevitably mixed to the product. Further, there is a defect that a particle size distribution grows worse and so on. As other synthesizing method, there is an oxalate method. In this method, complex metal oxalate is synthesized and then roasted to thereby make fine powder of Ba 1-x Sr x TiO 3 . According to this method, a process for synthesizing uniform complex metal oxalate is complicated and in addition, organic compound is used so that the manufacturing cost becomes high. Further, although the desired fine powder is obtained, the powder is essentially succeeding the original oxalate powder. To avoid the formation of the powder having the original oxalate structure a problem of the sintering between the powders occurs so that this method does not yet reach the industrial production stage at present. Furthermore, a method in which metal alkoxide is used to produce complex metal titanate fine powder of barium-strontium titanate Ba 1-x Sr.sub. x TiO 3 has recently been studied and developed. This method must use special organic compound such as metal alkoxide so that the manufacturing cost thereof becomes considerably high as compared with the oxalate method.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to provide an improved method for manufacturing dielectric fine powder of Ba 1-x Sr x TiO 3 wherein 0<x<1.
Another object of this invention is to provide a method for manufacturing dielectric fine powder of Ba 1-x Sr x TiO 3 which can produce a fine powder which is very small in diameter and uniform in particle size.
A further object of this invention is to provide a method for manufacturing dielectric fine powder of Ba 1-x Sr x TiO 3 , by which dielectric fine powder can be manufactured at low cost and with ease.
A yet further object of this invention is to provide an improved method for manufacturing dielectric fine powder of Ba 1-x Sr x TiO 3 capable of producing a dielectric material having the maximum value of the dielectric constant with respect temperature at a desired temperature (not higher then 135° C.).
According to one aspect of this invention, there is provided a method for manufacturing dielectric titanate fine powder having the formula Ba 1-x Sr x TiO 3 wherein 0<x<1 comprising the steps of:
preparing a hydrolysis product of an inorganic titanium compound TiO 2 .xH 2 O by dissolving said inorganic titanium compound in a neutral or alkaline aqueous solution;
reacting said hydrolysis product with a water soluble salt of Ba and a water soluble salt of Sr in an aqueous alkaline solution having a pH not less than 13.0 to thereby obtain said dielectric fine powder having the formula Ba 1-x Sr x TiO 3 wherein 0<x<1; and
filtering said fine powder from the remaining solution.
The other objects, features and advantages of the present invention will become apparent from the following description taken in conjunction with the accompanying drawings through which the like references designate the same elements and parts.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are respectively diagrams showing X-ray diffraction patterns of barium-strontium titanate fine powder made in accordance with a manufacturing method of this invention;
FIG. 3 is photograph of the fine powder manufactured by the method of this invention taken by a transmission electron microscope;
FIG. 4 is a characteristic graph showing the measured capacitance of a disc made of fine powder manufactured by this invention;
FIG. 5 is a characteristic graph showing a relation between a lattice constant and content of Sr; and
FIG. 6 is a characteristic graph showing a relation between Curie temperature and content of Sr.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the manufacturing method of this invention, a hydrolyzed compound of Ti compound, a water soluble salt of Ba and a water soluble salt of Sr are reacted with one another in a strong alkaline aqueous solution at a temperature of approximately the boiling point thereof. The resultant precipitate is filtered, rinsed by water and then dried, thus complex metal titanate fine powder of barium-strontium titanate Ba 1-x Sr x TiO 3 (0<x<1) being made.
As the hydrolyzed compound of Ti compound, there can be used such one which is provided by hydrolyzing an aqueous solution such as TiCl 4 , Ti(SO 4 ) 2 and the like by an alkaline solution such as NH 4 OH, NaOH and so on. However, when Ti(SO 4 ) 2 is used, it is necessary that the hydrolyzed solution is repeatedly subjected to decantation and filtering so as to remove therefrom a sulfate group SO 4 2- .
As the water soluble salt of Ba, there can be used Ba(NO 3 ) 2 , Ba(OH) 2 , BaCl 2 , Ba(CH 3 COO) 2 and so on. Also, the hydrolyzed product of them can be used.
As the water soluble salt of Sr, there can be used SrO, Sr(OH) 2 , Sr(OH) 2 .8H 2 O, SrCl 2 , Sr(NO 3 ) 2 , Sr(CH 3 COO) 2 and the like.
As the reaction conditions for synthesizing barium-strontium titanate fine powder, pH is selected to be not less than 13.0, the molar ratio of (Ba+Sr)/Ti is selected in a range from 0.5 to 5.0 and the reaction temperature is selected in a range from 15° C. to the boiling point thereof.
As described above, according to this invention, the complex metal titanate fine powder of barium-strontium titanate can be synthesized directly by a wet synthesizing method under normal pressure. The fine powder made by this invention has the following excellent features that the diameter of the powder is very small and uniform and in addition this fine powder has less impurity mixed thereto. As compared with the dry method such as the solid phase reaction method, the method of this invention is superior in that a better fine powder can be obtained and that the manufacturing process thereof is very simple. Further, as compared with the oxalate method and the metal alkoxide method, in addition to the fact that the size of the fine powder thus made is substantially the same as those of the above oxalate and metal alkoxide methods, no organic compound is used and hence the fine powder can be manufactured by the simple manufacturing process. As a result, the present invention is further superior in decreasing the manufacturing cost by two to three digits. Furthermore, when the fine powder made by this invention is used as the dielectric material, it is possible to make the dielectric material having Curie temperature, namely, the maximum value of the dielectric constant at a desired temperature.
The present invention will hereinafter be described with reference to examples.
EXAMPLE 1
50 g of TiCl 4 was dissolved into 50 ml of an iced water while being stirred so as to make a Ti aqueous solution. Then, water was added thereto to prepare the Ti aqueous solution of 500 ml. Next, 55.11 g of Ba(NO 3 ) 2 and 11.16 g of Sr(NO 3 ) 2 were added and dissolved into this aqueous solution. Thereafter, the aqueous solution was adjusted to have pH 14 by adding a KOH solution thereto and then added with water so as to be 1 l in total volume. While being stirred, this solution was reacted at 100° C. for four hours. After the reaction, the resultant precipitate was rinsed by water by decantation treatment, filtered and further rinsed by water. Thereafter, the resultant product was dried at 100° C. for all day long, to thereby obtain fine powder.
FIG. 1 shows the results in which the fine powder made by the above treatment was analyzed by an X-ray analysis (Cu target and Ni filter). From this X-ray diffraction pattern, it was confirmed that this fine powder was a single phase Ba 0 .8 Sr 0 .2 TiO 3 of cubic perovskite structure (x=0.2 is based on the result of chemical analysis). The lattice constant a 0 of this fine powder was 4.004 Å.
FIG. 3 shows a photograph of this fine powder taken by a transmission electron microscope. From this photograph, it was understood that this powder was made of fine powders which have a diameter of about 500 Å and were very uniform in size.
EXAMPLE 2
50 g of TiCl 4 was dissolved into 50 ml of an iced water while being stirred so as to make a Ti aqueous solution. Thereafter, water was added thereto so as to prepare the aqueous solution of 500 ml. Next, 45.92 g of Ba(NO 3 ) 2 and 18.59 g of Sr(NO 3 ) 2 were added and dissolved into this aqueous solution. Then, the aqueous solution was adjusted to have a pH 14 by adding a KOH solution thereto and water was further added thereto to prepare the aqueous solution of 1 l. While being stirred, this aqueous solution was reacted at 100° C. for four hours. The resultant precipitate was rinsed by water by decantation, filtered, further rinsed by water and then dried at 100° C. for all day long.
The X-ray diffraction pattern of the fine particle powder obtained by the above treatment was substantially the same as that shown in FIG. 1 and it was confirmed that this fine powder was Ba 2/3 Sr 1/3 TiO 3 . Further, according to the transmission electron microscope, the fine powder of substantially the same shape as that in FIG. 3 was observed. The lattice constant a 0 of the fine powder was 3.981 Å.
EXAMPLE 3
50 g of TiCl 4 was dissolved into 50 ml of an iced water while being stirred so as to make a Ti aqueous solution. Then, water was added thereto to prepare the aqueous solution of 500 ml. Then, 34.44 g of Ba(NO 3 ) 2 and 27.89 g of Sr(NO 3 ) 2 were added and dissolved into this aqueous solution. Thereafter, the aqueous solution was adjusted to have a pH 14 by adding a KOH solution thereto and water was added thereto to prepare the aqueous solution of 1 l. While being stirred, this aqueous solution was reacted at 100° C. for four hours. The resultant precipitate was rinsed by water by decantation, filtered, further rinsed by water and then dried at 100° C. for all day long.
The X-ray diffraction pattern of the fine powder obtained by the above treatment was substantially the same as that of FIG. 1, and it was confirmed that this fine powder was Ba 0 .5 Sr 0 .5 TiO 3 of cubic perovskite structure. According to the transmission electron microscope, the fine powder of substantially the same shape as that of FIG. 3 was observed. In this case, the lattice constant a 0 thereof was 3.968 Å.
EXAMPLE 4
50 g of TiCl 4 was dissolved into 50 ml of an iced water while being stirred so as to make a Ti aqueous solution. Then, water was added thereto to prepare the aqueous solution of 500 ml. Next, 22.96 g of Ba(NO 3 ) 2 and 37.18 g of Sr(NO 3 ) 2 were added and dissolved into this aqueous solution. Thereafter, this aqueous solution was adjusted to have a pH 14 by adding a KOH solution thereto and water was further added thereto to prepare the aqueous solution of 1 l. While being stirred, this aqueous solution was reacted at 100° C. for four hours. The resultant precipitate was rinsed by water by decantation, filtered, further rinsed by water and then dried at 100° C. for all day long.
The X-ray diffraction pattern of the fine powder made by the above treatment was substantially the same as that of FIG. 1, and it was confirmed that this fine powder was Ba 1/3 Sr 2/3 TiO 3 of cubic perovskite structure. Further, according to the transmission electron miscroscope, the fine powder of substantially the same shape as that of FIG. 3 was observed. In this case, the lattice constant a 0 thereof was 3.948 Å.
EXAMPLE 5
50 g of TiCl 4 was dissolved into 50 ml of an iced water while being stirred so as to make a Ti aqueous solution. Then, water was added thereto to prepare the aqueous solution of 500 ml. Then, 13.78 g of Ba(NO 3 ) 2 and 44.63 g of Sr(NO 3 ) 2 were added and dissolved into this aqueous solution. Thereafter, this aqueous solution was adjusted to have a pH 14 by adding a KOH solution thereto and water was further added thereto to prepare the aqueous solution of 1 l. While being stired, this aqueous solution was reacted at 100° C. for four hours. The resultant precipitate was rinsed by water by decantation, filtered, further rinsed by water and then dried at 100° C. for all day long.
The X-ray diffraction pattern of the fine powder obtained by the above treatment was as shown in FIG. 2 and it was confirmed that this fine powder was Ba 0 .2 Sr 0 .8 TiO 3 of cubic perovskite structure. Comparing the X-ray diffraction patterns of the fine powders of five kinds in Examples 1 to 5, it was made clear that as the value x becomes large, namely, in accordance with the sequential order from Example 1 to Example 5, the diffraction peak was shifted in the order. Further, according to the transmission electron microscope, the fine powder of substantially the same shape as that of FIG. 3 was observed in this example. In this case, its lattice constant a 0 was 3.936 Å.
Regarding the Ba 1-x Sr x TiO 3 fine powders obtained in Examples 1 to 5, a characteristic graph showing a relation between the lattice constant a 0 and the value x is shown in FIG. 5. From this graph of FIG. 5, it was clear that a curve A substantially follows Vegard's law.
EXAMPLE 6
50 g of TiCl 4 was dissolved into 50 ml of an iced water while being stirred so as to make a Ti aqueous solution. Then, water was added thereto to prepare the aqueous solution of 500 ml. Next, this aqueous solution was adjusted to have pH 7 by adding an NaOH solution thereto. 66.52 g of Ba(OH) 2 . 8H 2 O and 14.01 g of Sr(OH) 2 .8H 2 O were added and dissolved into this aqueous solution. Thereafter, this aqueous solution was adjusted to have pH 13.5 by adding an NaOH solution thereto and water was added thereto to prepare the aqueous solution of 1 l. While being stirred, this aqueous solution was reacted at 100° C. for four hours. The resultant precipitate was filtered, rinsed by water and then dried at 70° C. for two days long.
The X-ray diffraction pattern of the fine powder obtained by the above treatment is completely the same as that of FIG. 1 except for that the diffraction intensity is very slightly lowered as compared with that of FIG. 1. And, it was confirmed that this fine powder was barium-strontium titanate of cubic perovskite structure. In this case, the lattice constant a 0 thereof was 4.002 Å. Further, according to the transmission electron misroscope, the fine powder of substantially the same shape as that of FIG. 3 was observed.
EXAMPLE 7
The respective fine powders synthesized in Examples 1 to 5 were used and subjected to heat treatment at 800° C. for 2 hours in the atmosphere. Thereafter, they are pressed at 1500 kg/cm 2 and molded so as to make disc-shape products. After the respective disc-shape products were fired at 1300° C. (the rising speed of temperature was 100° C./hour) for two hours in the atmosphere, the change of temperature of dielectric constant ε (the temperature change of electrostatic capacitance) thereof were measured at 1 kHz. By way of example, a characteristic graph showing the results in which the capacitance of the disc-shape products made of Ba 0 .8 Sr 0 .2 TiO 3 fine powder was measured was shown in FIG. 4. Since no additives to improve sintering property was used, the density did not reach the vicinity of 100% of the theoretical density so that the true dielectric constant can not be obtained. However, it may be considered that the temperature where the peak value was obtained is substantially equal to Curie temperature Tc.
FIG. 6 is a characteristic graph showing a relation between Curie temperature Tc and the value x of Ba 1-x Sr x TiO 3 . This characteristic graph of FIG. 6 makes it clear that according to this invention, it is possible to obtain the dielectric material in which the maximum value of the dielectric constant is set at a desired temperature (not higher than 135° C.).
The above description is given on the preferred embodiments of the invention, but it will be apparent that many modifications and variations could be effected by one skilled in the art without departing from the spirits or scope of the novel concepts of the invention, so that the scope of the invention should be determined by the appended claims only. | A method for manufacturing dielectric titanate fine powder having the formula Ba 1-x Sr x TiO 3 wherein 0<x<1 is disclosed, which includes the steps of preparing a hydrolysis product of an inorganic titanium compound TiO 2 .xH 2 O by dissolving the inorganic titanium compound in a neutral or alkaline aqueous solution, reacting the hydrolysis product with a water soluble salt of Ba and a water soluble salt of Sr in an aqueous alkaline solution having a pH no less than 13.0 to thereby obtain the dielectric fine powder having the formula Ba 1-x Sr x TiO 3 wherein 0<x<1, and filtering the fine powder from the remaining solution. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a U.S. National Stage Application, which claims the benefit under 35 U.S.C. § 371 of PCT International Patent Application No. PCT/JP2014/070196, filed Jul. 31, 2014, which claims the foreign priority benefit under 35 U.S.C. § 119 of Japanese Patent Application No. 2013-159117, filed Jul. 31, 2013, the contents of which are incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to a diagnosis device, and in particular to a diagnosis device for a cooler arranged in an intake and exhaust system of an engine.
BACKGROUND ART
As a cooler arranged in an intake system (intake air passage) of an engine, an intercooler to cool an intake air to be introduced into the engine, for example, is known. As a cooler arranged in an exhaust system (exhaust gas passage) of the engine, an EGR cooler disposed in an exhaust gas recirculation system (hereinafter referred to as “EGR system”) adapted to partially recirculate an exhaust gas into the intake system, for example, is known.
A significant reduction in cooling efficiency of these coolers may affect an engine performance. Accordingly, a technique of arranging a temperature sensor on a downstream side of the cooler, calculating the temperature of a fluid on an upstream side of the cooler based on, for example, a state quantity of the fluid, and then comparing a value obtained by the sensor to the calculated value to diagnose the cooling efficiency of the cooler has been proposed (see, for example, Patent Literature Documents 1 and 2).
LISTING OF REFERENCES
Patent Literature Document 1: Japanese Patent Application Laid-Open Publication No. 2013-108416
Patent Literature Document 2: Japanese Patent Application Laid-Open Publication No. 2013-108414.
If a diagnostic method calculates the temperature of a fluid on the upstream side of the cooler and compares the calculated fluid temperature to a value obtained by the sensor on the downstream side of the cooler, then the calculated value which does not involve a response delay of the sensor and an actual sensor value which involves a response delay are compared to each other. This may cause an inaccurate diagnosis. If temperature sensors are arranged on both the upstream and downstream sides of the cooler for easier comparison, this leads to an increased cost of the diagnosis device as a whole due to an increased number of sensors.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a diagnosis device which is capable of carrying out an effective diagnosis of a cooler without a temperature sensor being arranged on the upstream side of the cooler.
A diagnosis device disclosed herein is directed to a diagnosis device for a cooler. The cooler is adapted to cool a fluid flowing in an intake and exhaust system of an engine. The diagnosis device includes a downstream temperature sensor that detects a temperature of the fluid on a downstream side of the cooler, a fluid temperature calculation unit that calculates a temperature of the fluid on an upstream side of the cooler on the basis of at least a state quantity of the fluid, a sensor output value calculation unit that assumes an upstream temperature sensor configured to detect the temperature of the fluid on the upstream side of the cooler, and reflects a response delay of a sensor in the temperature of the fluid calculated by the fluid temperature calculation unit to calculate an estimated sensor output value of the upstream temperature sensor, and a cooler diagnosis unit that diagnoses a cooling efficiency of the cooler on the basis of an actual sensor input value entered from the downstream temperature sensor and the estimated sensor output value calculated by the sensor output value calculation unit.
A diagnosis device disclosed herein is capable of carrying out an effective diagnosis of a cooler without a temperature sensor being arranged on an upstream side of the cooler.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic overall configuration diagram of a diagnosis device according to a first embodiment of the present invention.
FIG. 2 is a flowchart illustrating control performed by the diagnosis device according to the first embodiment of the present invention.
FIG. 3 is a schematic overall configuration diagram of a diagnosis device according to a second embodiment of the present invention.
FIG. 4 is a flowchart illustrating control performed by the diagnosis device according to the second embodiment of the present invention.
DETAILED DESCRIPTION
Hereinafter, diagnosis devices according to embodiments of the present invention will be described with reference to the accompanying drawings. Same parts are designated by same reference numerals, and such same parts have same names and functions. Accordingly, redundant detailed descriptions of such parts will be omitted.
First Embodiment
Referring to FIG. 1 , a diesel engine (hereinafter simply referred to as “engine”) 10 is has an intake manifold 10 A and an exhaust manifold 10 B. An intake passage (intake pipe) 11 for introducing a fresh air is connected to the intake manifold 10 A, and an exhaust passage (exhaust pipe) 12 for discharging an exhaust gas to the atmosphere is connected to the exhaust manifold 10 B.
On the exhaust passage 12 , disposed are a turbine 14 B of a turbo charger 14 , an exhaust gas aftertreatment device (not shown), and other elements. The turbine 14 B is arranged upstream of the exhaust gas aftertreatment device. On the intake passage 11 , disposed are an air cleaner 15 , an intake air flow sensor 33 , an intake air temperature sensor 32 , a compressor 14 A of the turbo charger 14 , an intercooler 16 , a cooler outlet intake air temperature sensor 34 , a throttle valve 17 , an intake air oxygen concentration sensor 35 , and a boost pressure sensor 36 . The air cleaner 15 , the intake air flow sensor 33 , the intake air temperature sensor 32 , the compressor 14 A, the intercooler 16 , the cooler outlet intake air temperature sensor 34 , the throttle valve 17 , the intake air oxygen concentration sensor 35 , and the boost pressure sensor 36 are arranged in this order from the upstream side. Sensor values obtained (detected) by the respective sensors 32 to 36 are supplied to an electronic control unit (hereinafter referred to as “ECU”) 40 , which is electrically connected to the sensors 32 to 36 . It should be noted that the cooler outlet intake air temperature sensor 34 is an example of a downstream temperature sensor according to the present invention.
An engine rotation speed sensor 29 detects the rotation (revolution) speed of a crankshaft (not shown). An accelerator opening degree sensor 30 detects an accelerator opening degree, which corresponds to a depressed amount of an accelerator pedal (not shown). An atmospheric pressure sensor 31 is installed on a vehicle (not shown), and detects an atmospheric pressure. Sensor values obtained by these sensors 29 to 31 are supplied to the ECU 40 , which is electrically connected to the sensors 29 to 31 .
The ECU 40 performs various types of control, such as control over fuel injection for the engine 10 , and includes a CPU, a ROM, a RAM, input ports, output ports, and other elements which are known in the art. In addition, the ECU 40 includes an intake air temperature calculation unit 42 , a sensor output value calculation unit 44 , and an intercooler diagnosis unit 45 as functional components thereof. It is assumed in the following description that all of these functional components are included in the ECU 40 , which is a single piece of hardware, but one or more of these functional components may be included in a separate piece of hardware.
The intake air temperature calculation unit 42 is an example of a fluid temperature calculation unit according to the present invention, and calculates the temperature of the intake air on an upstream side of the intercooler 16 , i.e., between the compressor 14 A and the intercooler 16 , (hereinafter referred to as “cooler inlet intake air temperature”) T 2 on the basis of a state quantity of the intake air and other factors. More specifically, the ECU 40 stores the expression (1), where T 2 is the cooler inlet intake air temperature, T 1 is a compressor inlet intake air temperature, P 1 is a compressor inlet intake air pressure, P 2 is a compressor outlet intake air pressure, and k is the specific heat ratio of the intake air.
T
2
=
(
P
2
P
1
)
k
-
1
k
·
T
1
[
Math
.
1
]
The intake air temperature calculation unit 42 substitutes in the expression (1) the compressor inlet intake air temperature T 1 , which is detected by the intake air temperature sensor 32 , the compressor inlet intake air pressure P 1 , which is detected by the atmospheric pressure sensor 31 , and the compressor outlet intake air pressure P 2 , which is detected by the boost pressure sensor 36 , to calculate the cooler inlet intake air temperature T 2 in real time.
It should be noted that the cooler inlet intake air temperature T 2 may not necessarily be calculated using the expression (1), but may be calculated on the basis of, for example, the expression (2), where T 2 is the cooler inlet intake air temperature, T 1 is the compressor inlet intake air temperature, P 1 is the compressor inlet intake air pressure, P 2 is the compressor outlet intake air pressure, k is the specific heat ratio, and η com is a compressor efficiency.
T
2
=
T
1
+
T
1
·
(
P
2
/
P
1
)
k
-
1
k
η
com
[
Math
.
2
]
In the expression (2), the compressor inlet intake air temperature T 1 is detected by the intake air temperature sensor 32 , the compressor inlet intake air pressure P 1 is detected by the atmospheric pressure sensor 31 , and the compressor outlet intake air pressure P 2 is detected by the boost pressure sensor 36 . The compressor efficiency η com is obtained from a performance data map of the turbo charger 14 , which is stored in advance in the ECU 40 .
The sensor output value calculation unit 44 is an example of a sensor output value calculation unit according to the present invention, and assumes a virtual upstream intake air temperature sensor (hereinafter referred to as “virtual intake air temperature sensor”) between the compressor 14 A and the intercooler 16 . The sensor output value calculation unit 44 reflects a sensor response delay into the cooler inlet intake air temperature T 2 , which is calculated by the intake air temperature calculation unit 42 , using a second-order low pass filter (LPF) to calculate an estimated sensor output value T est of the virtual intake air temperature sensor. A detailed procedure of this calculation will be described below.
The time constant of a temperature sensor is not constant because it depends on the flow rate of a fluid and other factors. It is therefore necessary to derive a dependence relation between the time constant and physical quantities from physical formulas. Assuming that a thermal energy transferred from the fluid to an outer wall surface of the temperature sensor or to an inner wall surface of the intake pipe is equal to an energy required for a change in the temperature of the wall surface, a heat transfer equation is given by the expression (3), where ρ w is the density of a solid, c p is the specific heat of the solid, V w is the volume of the solid, T s is the wall surface temperature, h is a heat transfer coefficient, S is a heat transfer surface area, and T f is the temperature of the fluid.
ρ
w
c
p
V
w
d
T
s
d
t
=
-
h
S
(
T
s
-
T
f
)
[
Math
.
3
]
Subjecting the expression (3) to a Laplace transform gives the expression (4).
T
s
T
f
=
1
τ
·
S
+
1
where
τ
=
K
h
,
K
=
ρ
w
c
p
V
w
S
[
Math
.
4
]
It is apparent from the expression (4) that the time constant for temperature change is inversely proportional to the heat transfer coefficient h between the fluid and the wall surface.
In this embodiment, the relation between physical quantities and the heat transfer coefficient of the temperature sensor is firstly taken into consideration. For example, assuming that the fluid flows in a uniform manner and the sensor has a substantially columnar shape, the average heat transfer coefficient of the columnar sensor placed in the uniform flow is expressed by the expression (5), where Nu is the Nusselt number, Re is the Reynolds number, Pr is the Prandtl number, and C is a constant, on the basis of a known empirical formula for the heat transfer coefficient.
N
u
=
(
h
l
λ
)
=
C
·
R
e
n
1
·
P
r
n
2
[
Math
.
5
]
Solving the expression (5) with respect to the heat transfer coefficient h, making various assumptions and approximations, and extracting the fluid temperature T f and a mass flow rate m f gives the expression (6).
h
=
C
′
·
T
f
n
3
·
m
f
n
1
=
C
″
·
(
T
f
T
f
0
)
n
3
·
(
m
f
m
f
0
)
n
1
[
Math
.
6
]
Substituting the expression (6) into the expression (4) gives the expression (7). A temperature change time constant τ 1 of the temperature sensor is proportional to both the fluid temperature T f and the mass flow rate m f . It should be noted that in the expression (7) T f0 represents a reference value of the fluid temperature, and m f0 represents a reference value of the mass flow rate.
T
s
1
T
f
=
1
τ
·
S
+
1
where
τ
1
=
K
h
=
τ
0
·
(
T
f
T
f
0
)
-
n
3
·
(
m
f
′
m
f
0
′
)
-
n
1
[
Math
.
7
]
Next, in this embodiment, the relation between physical quantities and the heat transfer coefficient of the intake passage (intake pipe) 11 is taken into consideration. Assuming that the intake passage 11 is formed by a smooth cylindrical tube, the average heat transfer coefficient inside the circular tube is expressed by the expression (8) on the basis of a known empirical formula.
N
u
=
(
h
l
λ
)
=
C
·
R
e
n
4
·
P
r
n
5
[
Math
.
8
]
If the rearrangement similar to that of the expression (7) is applied to the expression (8), a proportional relation between a temperature change time constant τ 2 of the intake pipe and the physical quantities (fluid temperature T f and the mass flow rate m f ) is expressed by the expression (9).
T
s
2
T
f
=
1
τ
2
·
S
+
1
where
τ
2
=
K
h
=
τ
0
·
(
T
f
T
f
0
)
-
n
6
·
(
m
f
′
m
f
0
′
)
-
n
4
[
Math
.
9
]
In this embodiment, the relation between the estimated sensor output value T est of the temperature sensor and the temperature of the wall surface of the intake passage (intake pipe) 11 is also taken into consideration. Assuming that the estimated sensor output value T est be a value between a sensor wall surface temperature T s1 and an intake pipe temperature T s2 , the estimated sensor output value T est can be expressed by the expression (10), where α is a weighting coefficient.
T est =(1−α)· T s1 +α·T s2 [Math. 10]
where 0<α<1
Assuming that the sensor wall surface temperature T s1 and the intake pipe temperature T s2 have separate time constants and vary in accordance with the expression (7) or (9), a transfer function representing a variation in the estimated sensor output value T est is expressed by the expression (11) (a model formula) with a second-order LPF being used.
T
est
T
f
=
(
1
-
α
)
·
T
S
1
T
f
+
α
·
T
S
2
T
f
=
1
-
α
τ
1
·
S
+
1
+
α
τ
2
·
S
+
1
where
τ
1
=
τ
10
·
(
T
f
T
f
0
)
-
n
3
·
(
m
f
′
m
f
0
′
)
-
n
1
τ
2
=
τ
20
·
(
T
f
T
f
0
)
-
n
6
·
(
m
f
′
m
f
0
′
)
-
n
4
[
Math
.
11
]
The sensor output value calculation unit 44 substitutes the cooler inlet intake air temperature T 2 , which is calculated by the intake air temperature calculation unit 42 , for the fluid temperature T f in the expression (11) to calculate the estimated sensor output value T est of the virtual intake air temperature sensor. Thus, the estimated sensor output value T est , which reflects the sensor response delay, is calculated in real time on the basis of the cooler inlet intake air temperature T 2 , which varies in accordance with the running condition of the engine 10 .
The intercooler diagnosis unit 45 is an example of a cooler diagnosis unit according to the present invention, and diagnoses a cooling efficiency of the intercooler 16 on the basis of an actual sensor input value T act entered from the cooler outlet intake air temperature sensor 34 and the estimated sensor output value T est calculated by the sensor output value calculation unit 44 .
More specifically, the ECU 40 stores a lower limit threshold value η min of the cooling efficiency, which is prepared in advance on the basis of experiments or the like, to indicate a fault of the intercooler 16 . Here, the “fault” refers to, for example, a condition in which a significant degradation is observed in heat exchange between the intake air and a coolant due to a deterioration of a part of the intercooler, adhesion of a foreign substance contained in the intake air to the intercooler or the like. The intercooler diagnosis unit 45 determines that a fault has occurred in the intercooler 16 when the cooling efficiency η IC , which is calculated on the basis of the estimated sensor output value T est and the actual sensor input value T act , becomes lower than the lower limit threshold value η min . It should be noted that the cooling efficiency η IC may be calculated by the expression (12).
η
I
C
=
T
est
-
T
act
T
est
-
T
l
[
Math
.
12
]
Next, a control flow of a diagnosis device according to this embodiment will be described with reference to FIG. 2 .
Firstly, in Step S 100 , the sensor values of the various sensors 29 to 36 are supplied to the ECU 40 upon turning on of an ignition key.
In Step S 110 , the cooler inlet intake air temperature T 2 is calculated on the basis of the expression (1) or (2). In Step S 120 , the estimated sensor output value T est of the virtual intake air temperature sensor is calculated on the basis of the cooler inlet intake air temperature T 2 using the model formula of the expression (11), which reflects the response delay of the sensor.
In Step S 130 , the cooling efficiency η IC of the intercooler 16 is calculated on the basis of the actual sensor input value T act , which is entered from the cooler outlet intake air temperature sensor 34 , and the estimated sensor output value T est , which is calculated in Step S 120 .
In Step S 140 , the cooling efficiency η IC and the lower limit threshold value η min are compared to each other to diagnose the intercooler 16 . If the cooling efficiency η IC is lower than the lower limit threshold value η min (YES), it is determined in Step S 150 that a fault has occurred in the intercooler 16 . On the other hand, if the cooling efficiency η IC is equal to or greater than the lower limit threshold value η min (NO), the control returns to Step S 100 . Thereafter, Steps S 100 to S 150 are repeatedly performed until the ignition key is turned off.
Next, beneficial effects of the diagnosis device according to this embodiment will be described.
Conventionally, the temperature of the intake air on the downstream side of the intercooler is detected by an intake air temperature sensor, the temperature of the intake air on the upstream side of the intercooler is calculated on the basis of, for example, a state quantity of the intake air, and then the sensor value and the calculated value are compared to each other to diagnose the cooling efficiency of the intercooler. However, this is a comparison between the calculated value which does not involve a response delay of the sensor and the actual sensor value which involves a response delay, and may therefore provide an inaccurate diagnosis especially during a transient operation. If one intake air temperature sensor is arranged on the upstream side of the intercooler and another intake air temperature sensor is arranged on the downstream side of the intercooler for easier comparison, a cost of the entire device increases due to an increased number of sensors.
In contrast, the diagnosis device according to this embodiment calculates the estimated sensor output value T est of the virtual intake air temperature sensor in real time using the expression (11), which reflects the response delay of the sensor. The expression (11) is configured as a second-order LPF which includes the relation between the temperature change time constant τ 1 of the intake air temperature sensor and the physical quantities (exhaust gas flow rate m f and an exhaust gas temperature T f ) and the relation between the temperature change time constant τ 2 of the intake passage (intake pipe) 11 and the physical quantities (exhaust gas flow rate m f and the exhaust gas temperature T f ) to precisely reflect the response delay of the sensor. Such second-order LPF enables precise calculation of the estimated sensor output value T est of the virtual intake air temperature sensor, which reflects the response delay of the sensor, over the entire operating range, including the transient operation, of the engine 10 .
Accordingly, the diagnosis device according to this embodiment can dispense with the intake air temperature sensor on the upstream side of the intercooler 16 and effectively minimize an increase in the cost of the device as a whole. In addition, the diagnosis device of this embodiment is able to calculate the estimated sensor output value T est , which reflects the response delay of the sensor, in real time, and more precisely diagnose the cooling efficiency of the intercooler 16 over a wide operating range including the transient operation than a conventional technique that simply compares the calculated value and the sensor value to each other.
Second Embodiment
Hereinafter, a diagnosis device according to a second embodiment of the present invention will be described with reference to FIGS. 3 and 4 . The second embodiment of the present invention is applied to diagnosis of an EGR cooler 22 . Components that have the same functions as those of their equivalents in the first embodiment are designated by the same reference numerals as those of their equivalents in the first embodiment, and detailed descriptions of those components will be omitted.
An EGR system 20 includes an EGR passage 21 for recirculating a portion of the exhaust gas into an intake system, the EGR cooler 22 for cooling an EGR gas, and an EGR valve 23 for regulating the flow rate of the EGR gas. A cooler outlet exhaust gas temperature sensor 37 to detect the temperature of the EGR gas, which is cooled by the EGR cooler 22 , is arranged on the EGR passage 21 at a position on the downstream (outlet) side of the EGR cooler 22 . A sensor value obtained by the cooler outlet exhaust gas temperature sensor 37 is supplied to an ECU 50 , which is electrically connected to the sensor 37 .
The ECU 50 includes a fuel injection control unit 51 , an indicated thermal efficiency calculation unit 52 , an exhaust gas temperature calculation unit 53 , a sensor output value calculation unit 54 , and an EGR cooler diagnosis unit 55 as functional components thereof. It is assumed in the following description that all of these functional components are included in the ECU 50 , which is a single piece of hardware, but one or more of these functional components may be included in a separate piece of hardware.
The fuel injection control unit 51 controls fuel injection timing and an amount of fuel injection by a fuel injection device (not shown) of an engine 10 on the basis of an engine revolution speed N entered from an engine rotation speed sensor 29 and an accelerator opening degree Q entered from an accelerator opening degree sensor 30 .
The indicated thermal efficiency calculation unit 52 constitutes part of a fluid temperature calculation unit according to the present invention, and calculates an amount Δη i of change in the indicated thermal efficiency of the engine 10 on the basis of sensor values obtained from the sensors 29 to 37 , equations presented below, and so on. A procedure of this calculation will now be described in detail below.
Due to energy conservation in cylinders of the engine 10 , an exhaust gas energy H ex is expressed by the expression (13), where H in is an intake air energy, Q fuel is a combustion energy of the fuel, U hloss is a cooling loss energy, and η i is the indicated thermal efficiency of the engine 10 .
H ex =(1−η 1 ) Q fuel −U hloss +H in [Math. 13]
On the basis of the expression (13), assuming that the amount of fuel injection is constant and a change in the cooling loss energy U hloss is only minimal, the amount ΔH ex of change from a reference exhaust gas energy H ex,ref is approximated by the expression (14).
Δ H ex ≈ H in − H in,ref −Δη i · Q fuel [Math. 14]
The temperature of that portion of the exhaust gas which is discharged from the engine 10 and reaches an inlet of the EGR cooler 22 (hereinafter referred to as “cooler inlet exhaust gas temperature”) T 3 is expressed by the expression (15).
T
3
=
1
C
p
,
ex
·
m
ex
(
H
ex
,
ref
+
Δ
H
ex
)
where
H
ex
=
C
p
,
ex
T
3
m
ex
[
Math
.
15
]
With the expression (14) being substituted into the expression (15), the cooler inlet exhaust gas temperature T 3 is expressed by the expression (16), where C p,in is the specific heat of the intake air at constant pressure, m ex is an exhaust gas flow rate, H ex,ref is the reference exhaust gas energy, H in,ref is a reference intake air energy, H in is the exhaust gas energy, and Q fuel is the combustion energy.
T
3
=
1
c
p
,
ex
·
m
ex
(
H
ex
,
ref
+
H
in
-
H
in
,
ref
-
Δ
η
i
·
Q
fuel
)
[
Math
.
16
]
As factors that cause the change in the indicated thermal efficiency η i , a fuel injection start timing φ and an intake air oxygen concentration X O2 are taken into consideration. Assuming that the variation of the amount Δη i of change in the indicated thermal efficiency with respect to the intake air oxygen concentration X O2 is linear, the amount Δη i of change in the indicated thermal efficiency is, via Taylor expansion, approximated by the expression (17), where X O2 is the intake air oxygen concentration, φ is the fuel injection start timing, k 1,O2 is an intake air oxygen concentration correction coefficient, X O2,ref is a reference intake air oxygen concentration, k n(n=1,2),soi is a fuel injection start timing correction coefficient, and φ ref is a reference fuel injection start timing.
Δη
i
=
η
i
-
η
i
,
ref
≈
k
1
,
soi
·
(
ϕ
-
ϕ
ref
)
+
k
1
,
o
2
·
(
x
o
2
-
x
o
2
,
ref
)
+
k
2
,
soi
·
(
ϕ
-
ϕ
ref
)
2
+
k
2
,
soi
·
o
2
·
(
ϕ
-
ϕ
ref
)
·
(
x
o
2
-
x
o
2
,
ref
)
[
Math
.
17
]
Assuming that an influence of a change in the intake air oxygen concentration X O2 on the injection start timing φ is minimal in the expression (17), the amount Δη i of change in the indicated thermal efficiency is expressed by the expression (17).
Δη i =k 1,soi ·(φ−φ ref )+ k 1,o 2 ·( x o 2 −x o 2 ,ref )+ k 2,soi ·(φ−φ ref ) 2 [Math. 18]
The indicated thermal efficiency calculation unit 52 calculates the amount Δη i of change in the indicated thermal efficiency in real time on the basis of the expression (18). More specifically, the ECU 50 stores a correction value map (not shown) which defines the relation among the engine revolution speed N, the accelerator opening degree Q, and the intake air oxygen concentration correction coefficient k 1,O2 , and also stores a reference value map (not shown) which defines the relation among the engine revolution speed N, the accelerator opening degree Q, and the reference intake air oxygen concentration X O2,ref . These maps are prepared in advance on the basis of experiments or the like. The ECU 50 further stores a correction value map (not shown) which defines the relation among the engine revolution speed N, the accelerator opening degree Q, and the injection start timing correction coefficient k n(n=1,2),soi , and a reference value map (not shown) which defines the relation among the engine revolution speed N, the accelerator opening degree Q, and the reference injection start timing φ ref . These maps are prepared in advance on the basis of experiments or the like.
The indicated thermal efficiency calculation unit 52 reads appropriate values from these maps in accordance with the running condition of the engine 10 and substitutes the values into the expression (18), and also substitutes the intake air oxygen concentration X O2 , which is entered from an intake air oxygen concentration sensor 35 , and the injection start timing φ, which is determined by the fuel injection control unit 51 , into the expression (18). Thus, the amount Δη i of change in the indicated thermal efficiency, which reflects an amount of change from the reference intake air oxygen concentration X O2,ref and an amount of change from the reference injection start timing φ ref , is calculated in real time.
The exhaust gas temperature calculation unit 53 constitutes part of the fluid temperature calculation unit according to the present invention, and calculates the cooler inlet exhaust gas temperature T 3 in real time on the basis of the expression (16). More specifically, the ECU 50 stores a reference value map (not shown) which indicates the relation among the engine revolution speed N, the accelerator opening degree Q, and the reference intake air energy H in,ref , and also stores a reference value map (not shown) which indicates the relation among the engine revolution speed N, the accelerator opening degree Q, and the reference exhaust gas energy H ex,ref . These maps are prepared in advance on the basis of experiments or the like.
The exhaust gas temperature calculation unit 53 substitutes appropriate values, which are read from these maps in accordance with the running condition of the engine 10 , the intake air energy H in , which is calculated on the basis of, for example, a state quantity of the intake air, and the combustion energy Q fuel , which is calculated on the basis of a lower heating value of the fuel, the amount of fuel injection, and/or the like, into the expression (16) to calculate the cooler inlet exhaust gas temperature T 3 in real time.
The sensor output value calculation unit 54 is an example of the sensor output value calculation unit according to the present invention, and assumes a virtual upstream exhaust gas temperature sensor (hereinafter referred to as “virtual exhaust gas temperature sensor”) on the upstream side of the EGR cooler 22 . The sensor output value calculation unit 54 uses a second-order LPF to reflect a response delay of the sensor in the cooler inlet exhaust gas temperature T 3 , which is calculated by the exhaust gas temperature calculation unit 53 , to calculate an estimated sensor output value T est of the virtual exhaust gas temperature sensor.
More specifically, the ECU 50 stores the expression (11) used in the first embodiment. The sensor output value calculation unit 54 substitutes the cooler inlet exhaust gas temperature T 3 , which is calculated by the exhaust gas temperature calculation unit 53 , for the fluid temperature T f in the expression (11) to calculate the estimated sensor output value T est of the virtual exhaust gas temperature sensor. Thus, the estimated sensor output value T est , which reflects the response delay of the sensor, is calculated in real time on the basis of the cooler inlet exhaust gas temperature T 3 , which varies in accordance with the running condition of the engine 10 .
The EGR cooler diagnosis unit 55 is an example of the cooler diagnosis unit according to the present invention, and diagnoses a cooling efficiency of the EGR cooler 22 on the basis of an actual sensor input value T act entered from the cooler outlet exhaust gas temperature sensor 37 and the estimated sensor output value T est calculated by the sensor output value calculation unit 54 .
More specifically, the ECU 50 stores a lower limit threshold value T min of a temperature difference that indicates a fault of the EGR cooler 22 . The lower limit threshold value T min is obtained in advance on the basis of an experiment or the like. Here, the “fault” refers to, for example, a condition in which a significant degradation is observed in heat exchange between the exhaust gas and a coolant due to a deterioration of a part, an adhesion of, for example, soot contained in the exhaust gas to the EGR cooler, or the like. The EGR cooler diagnosis unit 55 calculates the temperature difference ΔT between the estimated sensor output value T est and the actual sensor input value T act , and determines that a fault has occurred in the EGR cooler 22 when the temperature difference ΔT becomes lower (smaller) than the lower limit threshold value T min .
Next, a control flow of the diagnosis device according to this embodiment will be described with reference to FIG. 4 .
Firstly, in Step S 200 , the sensor values of the sensors 29 to 37 are supplied to the ECU 50 upon turning on of the ignition key.
In Step S 210 , the amount Δη i of change in the indicated thermal efficiency is calculated on the basis of the expression (18). In Step S 220 , the cooler inlet exhaust gas temperature T 3 is calculated on the basis of the expression (16).
In Step S 230 , the estimated sensor output value T est of the virtual exhaust gas temperature sensor is calculated on the basis of the cooler inlet exhaust gas temperature T 3 using the model formula of the expression (11), which reflects the response delay of the sensor.
In Step S 240 , the temperature difference ΔT, which indicates the cooling efficiency of the EGR cooler 22 , is calculated on the basis of the actual sensor input value T act entered from the cooler outlet exhaust gas temperature sensor 37 and the estimated sensor output value T est calculated in Step S 230 .
In Step S 250 , the temperature difference ΔT and the lower limit threshold value T min are compared to each other to diagnose the EGR cooler 22 . If the temperature difference ΔT is lower (smaller) than the lower limit threshold value T min (YES), it is determined in Step S 260 that a fault has occurred in the EGR cooler 22 . On the other hand, if the temperature difference ΔT is equal to or greater than the lower limit threshold value T min (NO), the control returns to Step S 200 . Thereafter, Steps S 200 to S 260 are repeatedly performed until the ignition key is turned off.
Next, beneficial effects of the diagnosis device according to this embodiment will be described.
Conventionally, the temperature of the exhaust gas on the downstream side of the EGR cooler is detected by an exhaust gas temperature sensor, the temperature of the exhaust gas on the upstream side of the EGR cooler is calculated on the basis of, for example, a state quantity of the exhaust gas, and then the sensor value and the calculated value are compared to each other to diagnose the cooling efficiency of the EGR cooler. However, this is a comparison between the calculated value which does not involve a response delay of the sensor and the actual sensor value which involves a response delay, and may therefore provide an inaccurate diagnosis especially during a transient operation. If one exhaust gas temperature sensor is arranged on the upstream side of the EGR cooler and another exhaust gas temperature sensor is arranged on the downstream side of the EGR cooler for easier comparison, a problem arises, i.e., the cost of the entire device increases due to an increased number of sensors.
In contrast, the diagnosis device according to this embodiment calculates the estimated sensor output value T est of the virtual exhaust gas temperature sensor in real time using the expression (11), which reflects the response delay of the sensor. The expression (11) is configured as a second-order LPF which includes the relation between a temperature change time constant τ 1 of the exhaust gas temperature sensor and physical quantities (exhaust gas flow rate m f and an exhaust gas temperature T f ) and the relation between a temperature change time constant τ 2 of the exhaust passage (exhaust pipe) 12 and the physical quantities (exhaust gas flow rate m f and the exhaust gas temperature T f ) to precisely reflect the sensor response delay. Such second-order LPF enables precise calculation of the estimated sensor output value T est of the virtual exhaust gas temperature sensor, which reflects the sensor response delay, over the entire operating range, including the transient operation, of the engine 10 .
Accordingly, the diagnosis device according to this embodiment can dispense with the exhaust gas temperature sensor on the upstream side of the EGR cooler 22 and effectively minimize an increase in the cost of the device as a whole. In addition, the diagnosis device according to this embodiment is able to calculate the estimated sensor output value T est , which reflects the sensor response delay, in real time, and more precisely diagnose the cooling efficiency of the EGR cooler 22 over a wide operating range including the transient operation than a conventional technique that simply compares the calculated value to the sensor value.
It should be noted that the present invention is not limited to the above-described embodiments, and that changes and modifications may be made as appropriate without departing from the scope and spirit of the present invention.
For example, although the above-described embodiments are directed to the diagnosis of the cooling efficiency of the intercooler 16 and the EGR cooler 22 , other embodiments of the present invention may be applied to, for example, diagnosis of a cooler arranged between compressors of a multi-stage turbo-charging system. In addition, the engine 10 is not limited to the diesel engine, and embodiments of the present invention can be widely applied to other engines, such as gasoline engines. All such embodiments can achieve beneficial effects similar to those of the above-described embodiments. | A diagnosis device diagnoses a cooler adapted to cool a fluid flowing through intake and exhaust systems of an engine, and includes: a downstream temperature sensor for detecting a fluid temperature downstream of the cooler; a fluid temperature calculation unit for calculating a fluid temperature upstream of the cooler based on a fluid state quantity; a sensor output value calculation unit for assuming an upstream temperature sensor configured to detect a fluid temperature upstream of the cooler, reflecting a sensor response delay in the calculated fluid temperature, and calculating an estimated sensor output value of the upstream temperature sensor; and a cooler diagnosis unit for diagnosing the cooling efficiency of the cooler based on an actual sensor input value entered from the downstream temperature sensor and the calculated estimated sensor output value. | 5 |
FIELD OF INVENTION
The invention relates to a process and apparatus for utilizing hazardous inorganic wastes to produce a new, useful, and environmentally benign abrasive product for use in loose grain abrasive processes, as a coated or bonded abrasive, or as a polishing agent.
BACKGROUND OF THE INVENTION
There is substantial need throughout the world for technologies that are capable of producing safe and effective recycled products from various types of wastes, including "hazardous" wastes containing heavy metals. The most desirable method of recycling employs wastes a raw materials in the production of other safely usable products. The "hazardous" constituents of these products are often useful and valuable, yet, they are not fully exploited. Known recovery processes which attempt to recover certain elements from the waste stream, typically leave a substantial amount of residual slag or similar residual waste materials. These residuals typically contain "hazardous" components harmful to the environment.
The present invention is particularly well suited for recovering and reusing inorganic wastes such as emission control dusts or sludges. These wastes typically contain economically valuable levels of ingredients for making glass. They also typically contain organics, certain less valuable inorganic ingredients, and certain "hazardous" ingredients, such as lead, cadmium, chromium oxides or other heavy metals and/or compounds containing heavy metals.
An increasing measure of environmental concern throughout the world has grown from professional and public awareness of the increasing hazard of landfilling heavy metals and other inorganic wastes. Inorganic wastes are often hazardous due to their ability to react with acids and release soluble heavy metal compounds into the environment. This has focused attention on reducing landfilling and on regulations that prevent leachable toxic materials from being disposed of in landfills. The extent of groundwater pollution from leaching of heavy metals and other inorganic toxins is only now being understood.
As a result of groundwater pollution, federal law mandates that inorganic hazardous wastes now be "stabilized" prior to being landfilled. Stabilizing of inorganic wastes which renders the wastes inert or unreactive is a costly process and not always available. This has or will increased the cost of landfilling and, accordingly, the operating costs of the generators of the waste.
The cost of stabilization and landfilling essentially purchases a volume of space in a landfill. While the landfill will eventually become full and be "closed," the waste, stabilized or otherwise, remains in the ground exposed to other reactive elements. Inherent in any landfill, operating or closed, is the potential liability imposed in the United States by the Comprehensive Environmental Resources Compensation and Liability Act and in other countries, by similar laws.
Under these laws and the implementing regulations, corporations which generate waste remain liable for any damage which that waste may do to the environment. Further, the Resource Conservation and Recovery Act extends liability to waste generators which place wastes in landfills that subsequently leach or become contaminated, for the clean-up of those landfills. The waste generators' exposure is potentially huge, and does not end after a specific period of time. The potential liability extends in perpetuity and follows the waste generator and any subsequent entity related to the waste generator. This endless liability is another cost to corporations and, in certain cases, actually threatens a waste generator's continued existence.
The typical inorganic waste streams that contain these heavy metals are sludges from various processes or from waste water treatment; emission control dusts from high temperature industrial processes; fly ash from incineration of industrial and residential wastes; and certain other process-specific effluents. Examples of these are the aluminum industry's spent pot liner; refractory wastes from smelting, melting or refining furnaces; various types of slags and precipitants related to metal recovery operations from waste streams and certain glass wastes from producing television and cathode ray tubes.
The existing technology for dealing with these wastes is to use reduction or precipitation processes to recover metals from emission control dusts and sludges mostly from the steel industry and the plating industry. Emission control dusts are subjected to a reducing process in kilns to reduce chromium, zinc, and nickel from their oxides. In such cases, a fee is charged for processing and the recovered metals are sold back to the generator for reuse. Certain of the furnace slags, particularly in the aluminum industry, are processed to recover alumina, aluminum, and certain fluxing salts in a waste minimization program.
Methods of waste stabilization include: incorporating the hazardous wastes into cement; various types of chemical treatments; and vitrification, i.e., incorporating the hazardous waste into a glassy material. The principal danger from inorganic wastes is from heavy metal oxides and certain other oxides which may be considered "hazardous". Heavy metal oxides readily react when exposed to strong acids or alkalines to produce soluble compounds. Vitrifying the metal oxide in a glass substantially reduces the oxides' solubility in acid. The incorporation of these materials in glass is one known long-term method of "stabilization".
This method, however, has proven to be extremely expensive for several reasons. First, substantial amounts of energy are typically required to melt the materials. Care must also be taken in batching the raw material to ensure that an amorphous glass is formed at the most insoluble phase of the glass material. Both factors significantly increase the cost of vitrification relative to rival technologies. Although vitrification is a highly desirable method of waste treatment, it is rarely used commercially because of its high cost. It has, however, frequently been utilized in laboratory research. Except in isolated circumstances, the process has never been put into commercial practice. Patents have been issued disclosing vitrification processes, however those processes each have limitations that are addressed by the instant invention.
One such patent is U.S. Pat. No. 5,009,511 to Sarko, et al for "INORGANIC RECYCLING PROCESS", issued Apr. 23, 1991. The Sarko, et al reference teaches a mobile system for fixing hazardous wastes in a silicate matrix for subsequent disposal. Although this reference teaches a vitrification process for disposal of hazardous wastes, it is directed to stabilizing those wastes in a silicate matrix. Further, while this type of material is acceptable for use in stabilizing wastes, it is inappropriate for fabrication of a high hardness, abrasive material. Moreover, Sarko, et al does not disclose a material having the desirable characteristic of an alumina content in the range of 15 to 30%. contemplated by this reference.
Another example is U.S. Pat. No. 5,002,897 to Balcar, et al. for "METHOD FOR HAZARDOUS WASTE REMOVAL AND NEUTRALIZATION," which discloses a method for disposing of hazardous waste from secondary aluminum smelting in a neutralized amorphous glass product. The waste gas stream from the aluminum smelting process is directed towards a baghouse dust collector which comprises a series of fibrous filters to remove residues from the waste stream. The residue forms a coating on the filters, which is periodically removed and discarded as hazardous waste. The hazardous wastes which include metal oxides, are combined with glass dust and sodium silicate are melted to the molten state. These additives neutralize the wastes by dissolving the metal oxides in the molten glass to form a neutralized amorphous glass. The glass in turn helps prevent leaching of the metal oxides.
However, Balcar, et al does not describe a process which provides for the extraction of soluble salts via a hot water extraction process. Moreover, Balcar, et al is directed to collection, via bag-house filtration, and re-processing of hazardous waste products resulting from the aluminum smelting process. Additionally, Balcar, et al requires that powdered soda-lime glass be seeded into the flow of air-borne hazardous waste. The seeded soda-lime glass and hazardous waste is directed into a baghouse as part of the pre-coat material, which also includes lime, generally hydrated agricultural lime or calcium hydroxide. As the pre-coat of the baghouse, the soda-lime glass powder and the lime is intimately mixed with the effluents from the furnace or other heating device. This had the undesirable effect of increasing raw materials costs. Moreover, addition of soda-lime glass powder and lime renders the fabrication of high hardness, alumina containing materials relatively expensive, while reducing yield of usable end product.
Thus, a need exists for an environmentally acceptable, efficient, and cost-effective process for removing and neutralizing hazardous wastes, such as heavy metal oxides, from the waste stream and for reusing or recycling the wastes as raw materials in the production of safe and useful products. One problem that has threatened some attempts to resolve these concerns is the lack of appropriate reasonable uses for recycled products incorporating heavy metal oxides. By virtue of its hardness and toughness, amorphous glass is useful as an abrasive. In glass, lead oxide in small quantities can serve as a toughening agent.
There are essentially four market segments for abrasives. First, bonded abrasives are manufactured from abrasive particles which are normally joined by some form of organic binding agent. For example, bonded abrasive may form grinding and cutting wheels. Another form of bonded abrasives are tumbling abrasives, which are typically used in fine metal finishing.
The second general market for abrasives is for so-called "coated abrasives." In these, the abrasive is bonded to a substrate. For example, the abrasive may be bonded to paper, to form sandpaper.
The third general market segment for abrasives is for "loose grain" abrasives, in which the abrasive particles are thrown at a surface at high speed, in a stream of compressed air or pressurized water. The abrasives attack the surfaces of the metal, removing coatings or scale and leaving a clean surface. While sand is often used as a loose grain abrasive, its use is now restricted in several countries. This is due to the potential of silica-based fine abrasive particles to cause lung damage. Other fine loose grain abrasives include glass beads and fused aluminum oxide. These latter two abrasives are typically used for removing scale, coatings, and for finishing aircraft engine parts or materials which must meet specifications for a smooth surface finish. They are called "fine" because they are fine or small particle. Standards exist for the cleaning of aircraft surfaces with such treatments.
Loose grain media are also used for shot peening, for transforming the stresses in the surfaces of metals from tensile to compressive. This is done mainly to increase the useful life of the metal or to increase its resistance to fatigue cracking. Fine loose grain abrasive cleaning and finishing and shot peening are extremely efficient, as compared to other alternate methods of smoothing surfaces.
The fourth general form of abrasive is polishing agents. These are typically hard materials of extremely fine particles ranging in size from 1 or 2 microns up to 25 to 30 microns. These are often used in connection with cleaning, typically in burnishing and polishing machinery for finishing metals, ceramics, and glass articles.
A common material used for all of these types of abrasives is fused aluminum oxide. Fused aluminum oxide is manufactured by heating alumina to extremely high temperatures, i.e., approximately 2200°-2400° C. typically in an electric arc furnace, to produce a mass of crystalline alumina. Crystalline alumina is denser than natural alumina and possesses greater strength. Fused aluminum oxide has a hardness between 8 and 9 on the MOH scale, or a Vickers hardness of approximately 2000. In contrast, crystalline quartz or sand has a hardness of only about 7 on the MOH scale. Common soda lime glass has a Vickers hardness of approximately 420 and quartz has a hardness of 590. Soda lime glass in beaded form is well known as a cleaning and finishing media, and it is also used for shot peening.
While crushed soda lime glass is inexpensive and may also be used as an abrasive, it has a severe disadvantage. Hydrolysis will occur between the particles if they become wet. This binds the particles together, causing clumping and, eventually hardening. Hydrolysis typically occurs between the sodium ions on the surface of the glass. Sodium oxide makes up approximately between 12-14% of a typical soda lime formulation. This is also true of glass beads. Glass beads, however, are easier to keep dry with desiccation due to their reduced surface area. However, glass beads are not suitable for the applications to which angular abrasives are normally put. This is because glass beads are spherical and thus clean by peening a surface underneath a coating, cracking the coating off. If a coating is bonded adhesively to a surface, glass beads do not work as well since they do not break the adhesive bond. Rather angular abrasive materials, such as fused aluminum oxide, which has cutting surfaces, cut into contaminants and coatings to remove them faster than glass beads.
Quartz suffers from another deficiency, which is generally considered more serious than hydroscopicity. When shattered, quartz fractures along the silicon-to-oxygen bonds, leaving unbonded silicon. This is known in the trade as "free silica". This unbonded silicon (SiO) reacts slowly at ambient temperatures with molecular oxygen (O 2 ). Free silica, when it reacts with oxygen, forms silica (SiO 2 ). Fine, breathable particles of free silica can combine quickly with nascent oxygen in the lungs of humans or animals and bind to the lung tissue. This hardens the lung tissue and reduces its oxygenation potential. Over time, this process results in an irreversible deterioration in lung function. This disease process has come to be known as "silicosis." As a result of the health risks of silica, the use of fine silica particles is outlawed or restricted by regulation in many countries.
Thus, a need exists for an abrasive particle in the hardness range between glass and fused aluminum oxide. This material should have a hardness of approximately 7 MOH. It should not be hydroscopic, allowing it to be separated by water sedimentation methods. It should also be environmentally acceptable.
The invention described herein addresses these needs by employing emission control dusts from the secondary aluminum industry, as well as other segments of the metals industry, as well as fly ash from industrial incinerators, to produce a glass abrasive product containing a high percentage of alumina, with a Vickers hardness of between approximately 620 and 680. None of the known approaches, prior to the present invention, are able to resolve all of these concerns in as cost-effective and reliable a manner as is the present invention.
OBJECTS OF THE INVENTION
It is therefore an object of the present invention to provide a method and apparatus for using inorganic wastes as a feed stock to produce an environmentally acceptable and effective abrasive.
Another object of the present invention is to provide a product manufactured from emission control dusts and sludges from the aluminum industry and other industries, which is capable of forming tough and useful abrasives.
Another object of the present invention is to provide an abrasive product manufactured from emission control dusts and sludges of the aluminum industry and other industries which may also contain small amounts of lead and cadmium oxides as toughening agents.
An additional object of the present invention is to provide an abrasive product in the form of particles which can be sized either by screen sifting, by air flow classification methods or by water sedimentation separating methods.
A further object of the present invention is to provide a product with characteristics suitable for use as a coated abrasive.
Another object of the present invention is to provide an abrasive product containing specified percentages of alumina, to be used as a loose grain fine abrasive or as a polishing grain.
Yet another object of the present invention is to provide an abrasive product which may be manufactured from virgin materials.
Yet another object of the present invention is to provide an abrasive product which may be manufactured from a variety of feed stock materials.
Another object of the present invention is to provide an abrasive product with a MOH hardness of 7 to 8.
An additional object of the present invention is to provide a process for manufacturing abrasive material using a glass melter that will oxidize organics, and a scrubber that will recapture vaporized heavy metal oxides and particles of glass-making ingredients.
Another object of the present invention is to provide a process using an oxygen injection system, to ensure thorough burning of organics in the melt.
Yet another object of the present invention is to provide a process which produces a cost-effective abrasive comprising silica, alumina, and lime.
A further object of the present invention is to provide a process in which certain sodium compounds can be added to the melt to reduce the melting temperature.
These and other objects and advantages of the invention will become apparent from a perusal of the description of the invention, the drawings and the claims which follow.
SUMMARY OF THE INVENTION
The invention relates to a method of utilizing "hazardous" inorganic wastes to produce an effective and environmentally acceptable abrasive product for use in loose grain processes as an abrasive or a polishing grain. To achieve the objects of the invention, and in accordance with the purpose of the invention, as embodied and broadly described herein, the invention is a process for manufacturing an abrasive, which comprises a pre-treatment process for removing soluble salts from the hazardous waste stream; using a computer matrix to assay and group a volume of material having aluminum oxide component into different lots based on their chemical composition for batching and mixing with glass-making materials to form a batch mixture; depositing said batch mixture within a melter means having an outlet means; heating said batch mixture within said melter to a working temperature sufficient to oxidize the organic compounds contained in said batch mixture; melting the remaining batch mixture to form a glasseous substance; and passing said glasseous substance through said outlet means to a fritting means; wherein said glasseous substance is fritted to form the size and shape of said abrasive.
The instant invention also relates to a process for manufacturing a high hardness abrasive material comprising between 15% and 35% alumina. This high hardness material is fabricated by providing a volume of hazardous waste materials comprising at least aluminium oxide, heavy metal elements and organic compounds. Thereafter a volume of glass-forming materials is added to the hazardous waste, the volume and composition of the glass-forming materials being dependent upon the composition of the hazardous waste. Typical glass-forming materials include silica, sand, soda ash and combinations thereof. In the event that the hazardous waste materials further include soluble salts, the process may include the further step of removing said soluble salts by hot water extraction.
The mixture of hazardous waste and glass-forming materials is heated in an oxidizing environment, to a temperature sufficient to oxidize any organic compounds present in said hazardous waste, and vaporize said heavy metal oxides except for the oxides of chromium. The hazardous wastes and said glass-forming materials are heated to the molten state in an oven means comprising a vapor exhaust means and an outlet means. Oxidized/vaporized heavy metal oxides are recovered by a process comprising the steps of: passing said vaporized heavy metal oxides through the vapor exhaust means to a scrubber means; precipitating the heavy metal oxides by quenching the vaporized heavy metal oxides in said scrubber means; and collecting said precipitated heavy metals oxides in a filter means. The remaining mixture is then melted to form a molten glasseous substance, which is quenched to form the high hardness abrasive material.
To achieve the objects of the invention, and in accordance with the purpose of the invention, as embodied and broadly described herein, the invention is also an abrasive compound, comprising an alumina bearing material which is fracture resistant and well shaped as in blocky, spheroidal and pyramidal particles which can be used in loose grain abrasive blasting; as a coated abrasive particle and as a polishing and finishing agent. The collected heavy metal oxides mat be added to the molten glasseous substance to increase the hardness of the abrasive material.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the invention as claimed.
The accompanying drawings, which are incorporated by reference and constitute a part of this specification, illustrate a preferred embodiment of the invention, and, together with the description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be discussed in more detail, with particular reference to the drawings.
FIG. 1 is a flow chart illustrating the steps involved in processing hazardous wastes into an environmentally benign abrasive product;
FIG. 2 is a vertical sectional view of the melter apparatus of the present inventive process, as illustrated in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made to a preferred embodiment of the present invention, an example of which is illustrated in the accompanying drawings. A preferred embodiment of the invention is illustrated in FIG. 1.
In one preferred embodiment, the present invention is a process for making an effective and environmentally acceptable abrasive product from the effluent of industrial incinerators and emission control dusts of, for example, the aluminum industry. These industrial wastes typically contain significant percentages of alumina. Included with the alumina may be siliceous materials, calcium compounds, magnesium compounds, iron compounds and heavy metal compounds. FIG. 1 illustrates the process in accordance with one preferred embodiment of the present invention. As shown in FIG. 1, the process preferably comprises the general steps of: pre-processing the waste stream; using a computer-based matrix system to group the waste stream into different batches; mixing the feed stream with other glass-making materials to form a batch mixture; melting the batch mixture to form a glass; and fritting the glass to form an abrasive. The process also oxidizes the organics and vaporizes the heavy metal oxides contained in the mixed batch mixture during the melting phase. Heavy metal oxides, which may be discharged with the exhaust gases, may later be recovered. Of course, the first step in the process of producing an environmentally acceptable abrasive product from a stream of hazardous wastes is to provide hazardous wastes. This step is illustrated as Box 10 of FIG. 1. The hazardous waste stream employed in this process typically includes a relatively high aluminum content, heavy metals elements and compounds, and other organic and inorganic wastes and toxins.
PRE-PROCESSING
As embodied herein, the pre-processing step of the present invention includes the extraction of soluble salts from the waste stream. This pre-processing step is illustrated in FIG. 1 as Box 12, and more particularly includes a hot water extraction process for removing soluble salts from the waste stream. The hot water extraction process is done as waste materials arrive for processing. The incoming waste is washed and stirred in a water bath equal to twenty (20) times the weight of the raw waste being washed. The water bath is a hot water bath in which the bath temperature is maintained at about 50 to about 80 degrees C. The materials will remain in the water bath for a period of time equal to about 2 hours.
The resulting solution is passed through a filter press, where the insoluble components of the waste stream are caught and retained as a filter cake. The filter cake is then partially dried and repackaged. A number of different filter cakes can be merged for easier control of assaying. The material is also weighed before the extraction process and again the filter cake resulting from the hot water extraction. The weight loss is recorded in a computer batching matrix, which organizes the extracted material for batching and melting.
After completing the hot water process, the extracted filter cakes of the hazardous wastes (such as emission control dusts) are segregated and merged into lots. The lots are then sampled by known assaying methods for organic content, alumina content, and the content of other relevant materials. The step of assaying and analyzing the content of the filter cakes is illustrated as Box 14 of FIG. 1. While any number of known assaying techniques may be employed, it is most important to accurately measure the percentage of alumina and the percentage of inorganic materials. Accordingly, the amount of organic material may be easily ascertained by conducting an energy content test, or a loss-on-ignition test. A thermogravimetric analysis may also be employed to identify the amount of organic material present in the lot, as well as the percentage of hydrates. The presence of heavy metals can be easily determined through the use of an atomic absorption spectrophotometer or other similar techniques. A combination of each of these tests, plus historical data relating to specific type of waste generated by specific waste generator can be used to establish the characteristics of the materials.
As embodied herein, the data collected from the analysis of each lot is entered into a computer batching matrix for analysis and recording and for development of melting batches incorporating the addition of glass formers and modifiers such as silica and soda ash respectively. The computer batching process is discussed in greater detail hereinbelow.
The soluble salts collected from the hot water extraction process are the residual after concentration, crystallization and evaporation. This step in the inventive reclamation process is illustrated in Box 16 of FIG. 1. The collected soluble salts are tested for heavy metals to determine their potential as by-products. For example, the collected soluble salts may be usable for roadway ice melting purposes, for weed control or reused in metal processing. However, in order to be usable for these purposes, the salts must be substantially free from heavy metals.
BATCHING AND MIXING
The invention preferably further includes a computer batching system which tracks the characteristics of particular waste streams from particular waste generators, across time affording an understanding of the historical trends in constituent percentages of the total weight. It also creates batch matrices into which the lots of particular waste streams with the other ingredients, mainly glass formers such as sand and modifiers such as soda ash, are fitted to produce particular abrasive specifications. The contents of each batch will, in turn, meet the required product specifications. The step of batching by computer matrix is illustrated in FIG. 1 as box 18, and includes the further step of inputting the results of the chemical assaying discussed hereinabove with respect to the pre-processing of the wastes stream.
Many of the particles included in the batch mix are fine particles, measuring between 2 and 20 microns across their broadest dimension. These particles are dusty and, by virtue of their extremely small size, cannot be handled directly in the batch mix. For this reason, they may be coated to coagulate them onto larger particles of the batch mix. In a preferred embodiment of the present invention, to a mixture of water and glycerin, or other suitable materials that will readily evaporate or oxidize and will not impede the heating of the particles and particularity the organics, is used. The fine particles inside the melter will be further managed by baffles within the melter which will keep them from continuing to travel in the gas stream and direct them to settle out in the molten glass. Certain types of heating routines may be used in this connection where the feed is periodically reduced or increased as may be sensed to be needed in the exit from the melter atmosphere. The heating routines are a function of the batching matrix, and will depend upon the composition of the starting materials, including, but not limited to, the amount of iron and organic matters present in them.
MELTING AND OXIDATION
In a preferred embodiment of the present invention, the batched mixture is next delivered to an apparatus adapted to melt the batch mixture into a glass-like material in an oxidizing environment. The melting apparatus is further adapted to oxidize organic materials and vaporize heavy metal oxides in the gas stream. The step of melting the waste stream is illustrated in FIG. 1 as Box 20. The collection of the vaporized organic materials is illustrated as Box 22, and the step of collecting vaporized heavy metal oxides is illustrated in Box 24 of FIG. 1.
Melting in an oxidizing environment is required in order to assure that organic materials are oxidized as completely as possible from the batched mixture. An oxidizing environment also serves the function of oxidizing at least some fine elemental or alloyed metal particles in the batched mixture. Moreover, failure to melt the batched mixture in an oxidizing environment could lead to reduction of the heavy metals or other metal oxides, particularly if carbon is present in the batched mixture. Carbon would reduce metal oxides to the metal and carbon dioxide, thus making it more difficult to reclaim the metal component of the batched mixture. Metal components or molten glass are also damage refractories and cause premature failures.
An appropriate apparatus for melting the batch mixture is a glass melter as illustrated in FIG. 2 and indicated generally as 30. As embodied herein, glass melter 30 is also adapted to oxidize organic materials in the batch mixture. Thorough oxidation of organic materials is ensured by providing an oxygen injection system 32 which assures an oxidation atmosphere in the melter. As embodied herein, glass melter 30 also vaporizes any heavy metal oxides, such as for example, lead and cadmium oxides, and excepting chromium oxides, in the batch mixture. The vaporized heavy metal oxides are directed from the melter 30 to a scrubber 40 attached to the melter via an exhaust duct 35.
The scrubber 40 is a wet/dry scrubber which condenses the metal oxides from the stream of vaporized materials. Vaporized heavy metals are preferably maintained in the vapor state in the melter 30 and in the exhaust path 35 from the melter 30 to the first quench zone 45 of the scrubber 40. Temperatures along the exhaust path should be maintained above about 1100° C. to avoid the precipitation of the heavy metals prior to the quench zone 45. Premature precipitation will cause such the heavy metals to accumulate in the exhaust pathway 45.
In a preferred embodiment of the invention, scrubber 40 is a wet/dry scrubber, such as the Waterloo Scrubber known is the art, modified to recapture the vaporized heavy metal oxides and particles of the glass-making materials from the melter exhaust gases. In a preferred embodiment of the present invention the exhaust gasses are quenched in the quench zone 45 by exposure to a spray of water and by exposure to the water irrigated surfaces of the quench zone 45. The quench water is recovered and filtered through a filter press to remove the precipitated lead oxide and cadmium oxide. In general, this water will be maintained in a slightly alkaline condition with the use of calcium hydroxide. Specifically, the scrubber liquid is maintained at a pH of about 9 and is regularly monitored to assure that it remains in an acceptable range.
The air stream is passed through a wet particle scrubbing zone or a "contact" zone where water vapor contacts the particles in the gas stream and removes them by a wetting process. The moisture is then removed from the air with the particles in the zone of an axial fan and in the moisture entrapment zone. The water containing the particles is treated in a treatment process to remove the particles in a filter. The filter cake of particles contains glass making ingredients such as silica, alumina, magnesia, calcia, soda, potash and zinc oxide which can be used in batching materials after being assayed and analyzed. After the collection materials are complete, they are assayed and the resulting data is entered into the computer batching matrix. They are reused in this or other glass processes.
After passing through the contact zone, through the axial fan and through the entrapment zone the air is then heated to approximately 150° C. The air stream is then passed through a dry baghouse 50 which substantially collects any remaining metal oxides allowing any remaining water to pass through and be collected for reuse or disposal.
The precipitated heavy metals are collected in collection chamber 46. The metal oxides are then dried and collected. The lead oxide and cadmium oxides can be later used as a raw material for other glass manufacturing processes.
The temperature of the glass melter 30 is adjusted to heat to the proper melting temperature for a batch mixture of a given composition. For example, furnace temperatures may need to be increased depending on the amount of high melting point material, such as iron, that is present in the batch. Additionally, the melting point of the batch mixture may be changed by the addition of various materials. For example, certain sodium compounds such as Na 2 CO 3 , or NaSiO 3 may be added to reduce the melting point of the batch mixture. In addition, thermal analysis, i.e., the weight and energy gain or loss and gas emission as a sample material is heated to, for example, 1000° C. in 10° C. increments and viscosity measurements are also input into the process base data in order to determine the optimum melter temperature. Melting will occur in an oxygenizing atmosphere, though the time/temperature regiment will depend upon the starting materials of the batch mixture and the specific composition of the material. For example, materials with a high content of metal oxides with high melting temperatures will take longer to melt at a given temperature.
In a preferred embodiment of the present invention, the process oxidizes substantially all organics which are present, as well as all metals present as fine particles. The minimum temperature required to perform this oxidation is 1250° C. for producing the abrasive particles. During the processing of emission control dusts or sludge as a feed stock, organic constituents of the melt will be exposed to a temperature of 1250° C. in an oxygen rich atmosphere for a period of greater than three seconds. This will also satisfy requirements for the destruction of PCB's and other possible toxic organics present in the batch mixture. The required vaporizing temperature is 1100° C. for lead and cadmium oxides, though the upper vaporizing temperature is approximately 1750° C. in order to assure vaporization of fluoride containing compounds in the batch mixture. As embodied herein, the melter 30 should provide for a long dwell time. The melter 30 should also provide for oxygen injection to insure complete oxidation of the organic compounds. In a preferred embodiment of the present invention, the melter 30 will oxidize up to 500 ppm toxic organics, allowed in the waste stream under current EPA regulations.
The final product is discharged (as described below) directly into a water bath or may be first "frizzled."
FRITTING AND FRIZZLING
In a preferred embodiment of the present invention the resulting glass is fritted to the correct shape. This step is illustrated in Box 26 of FIG. 1. Sizing of the materials is accomplished by discharging the material at high temperature (1200° C.) from the melter 30 to a quenching water bath. This produces blocky or block-like, round or spheroidal and pyramidal shaped particles with high fracture resistance. The resulting integral particles are between 75 and 125 microns in maximum dimension. The temperature at fritting is critical to produce this result. This temperature of the outflow of glass must be adjusted to impart to the glass a low viscosity just prior to fritting.
Alternatively, it is possible to spray the glass as it emerges from the furnace with a fine mist of cooling liquid, such as water. This process is called frizzling in which the flow of melted liquor is sprayed with a fixed amount of water to begin the cooling process. Frizzling results in larger particles than in fritting. These particles are then dropped onto a refractory belt composed of ceramic materials with high melting temperatures where the individual particles still have enough residual heat to heal cracks in them. This particular process may be employed in the manufacture of coarse abrasives.
The resulting materials, weather fritted or frizzled, is then collected as illustrated in Box 28 of FIG. 1. Under certain circumstances, it may be desirable to add collected heavy metal oxides to the collected abrasive product.
EXAMPLES
EXAMPLE 1
In one variation of the process, emission control dusts from the aluminum industry are formulated directly to the specifications of the abrasive material. This material is known as "Alumaglass." An initial volume of emission control dust, weighing 200 gm, was submerged and stirred in a hot water bath having a weight of approximately 20 times that of the emission control dust, i.e., approximately two liters of water. The hot water bath was maintained at a temperature of approximately 80° C.
The emission control dust was allowed to remain in the hot water bath for 2 hours, after which time the entire mass was passed through a filter. The filtered materials were weighed in order to determine the loss in weight. The filtered materials weighed 112 gm. The filtrate was evaporated to crystallize and collect the soluble salts washed out in the water bath. The filtrate consisted mainly of Calcium chloride dihydrate and some complex calcium hydrate salts. No evidence of heavy metals was found. There salts will be dehydrated prior to use by calcining.
The materials collected on the filter weighed 112 gm and consisted of the following materials in the following percentages in the column below to the left:
______________________________________Material Percent of Total______________________________________SiO.sub.2 3.59Al.sub.2 O.sub.3 28.72MgO 7.23CaO 3.74Na.sub.2 O 0.44Fe.sub.2 O.sub.3 1.48TiO.sub.2 1.48MnO 0.56P.sub.2 O.sub.5 0.46ZnO 0.28Li.sub.2 O 0.03CoO 0.01Loss on Ignition (organics) 48.70______________________________________
The 112 gm sample of material was placed in a crucible fabricated of zirconia. The batching/mixing matrix indicated that 41.3 gm of sand and 19.8 gm of soda ash should also disposed into the crucible. The crucible and materials were placed in a melting oven. The oven was heated to a temperature of between 1450° C. and 1500° C.
An oxidizing atmosphere was maintained inside the melting oven. The temperature of the oxidizing atmosphere was maintained at approximately 1480°-1500° C. The melt temperature was maintained for a period of approximately 4 hours. Thereafter, the molten material was discharged directly into a water bath maintained at a temperature of between 90° and 95° C. The resulting fritted material had a size distribution of between 250-75 microns.
The resulting high hardness, abrasive material included the following components in the following percentages:
______________________________________Material Percent of Total______________________________________SiO.sub.2 49.20Al.sub.2 O.sub.3 25.80MgO 6.40CaO 3.40Na.sub.2 O 8.40Fe.sub.2 O.sub.3 1.30Balance (various) all ≦0.25______________________________________
EXAMPLE 2
In another variation of the process an emission control dust from the aluminum industry is mixed with a waste water treatment sludge ("WTS") containing mainly lime, alumina, magnesia and silica and which may be hazardous by characteristic for lead according to the Toxic Constituent Leaching Procedure ("TCLP") test 1311.
After completing the hot water extraction process on the emission control dust as described in Example 1, the wastes comprised the following materials in the following percentages:
______________________________________Material Percent ECD Total Percent WTS Total______________________________________SiO.sub.2 0.00 2.60Al.sub.2 O.sub.3 74.30 4.20MgO 6.30 1.33CaO 0.00 47.60Na.sub.2 O 0.00 0.28Fe.sub.2 O.sub.3 1.50 1.20TiO.sub.2 0.40 0.76P.sub.2 O.sub.3 0.00 0.13ZnO 0.00 1.90CaF 11.30 0.00So.sub.3 0.00 4.38PbO 0.00 0.87SrO 0.00 0.22K.sub.2 O 0.00 0.13Zn.sub.2 O.sub.2 0.00 0.01F.sub.2 /Cl.sub.2 1.30 15.00Loss on Ignition 0.90 14.33(organics)C 0.00 5.06Insolubles 4.30 0.00______________________________________
The batching matrix determined that 144 gm of WTS should be mixed with 40 gm of ECD. The batching matrix also indicated that 40 gm of silica sand and 16 gm of soda ash should be added to the mixture. The silica sand and anhydrous sodium silicate was added to the mixture. The mixture was subjected to the same heating regimen described above in Example 1. The resulting high hardness, abrasive material comprised the following components in the following percentages:
______________________________________Material Percent of Total______________________________________SiO.sub.2 52.02Al.sub.2 O.sub.3 27.50MgO 2.00Fe.sub.2 O.sub.3 1.40CaO 9.40Na.sub.2 O 7.50TiO.sub.2 0.22ZnO 0.05So.sub.3 0.01PbO 0.09K.sub.2 O 0.11______________________________________
With respect to the high hardness, abrasive product fabricated according to the above examples, the specifications of this material are as follows:
______________________________________Physical Properties:______________________________________Color: Black-opaque (Gray in fine sizes)Stucture: AmorphousHardess: 575-625 Knoop - 100 gm.Density: 2.7-2.8 gm/ccSoftening Point: 1100-1125° C.Working Point: 1150° C.______________________________________
Exemplary high hardness, abrasive materials will comprise at least the following materials in the following amounts:
______________________________________Chemical Constituents:______________________________________SiO.sub.2 48-54%Al.sub.2 O.sub.3 22-28%Na.sub.2 O 8-10%Ca.sub.2 O 8-12%MgOFe.sub.2 O.sub.3 1-3%PbO 0.1-1%Others Max. 0.25%______________________________________
This material has superior characteristics as a loose grain abrasive. This indicates that it will also be a superior material for the manufacture of coated abrasives for wood and metal working and conceivably also, on a limited basis, bonded abrasives. Because it can be separated into size profiles by water sedimentation, it can also be used as a polishing material.
Part of the formulation requires a small amount of lead to be included in the glass of extraordinary toughness as well as adequate hardness for abrasive applications. The glass contains small amounts of iron oxide which renders it a black color which is desirable for materials used as loose grain or coated abrasives. Dark colors are necessary to show the residual material after clean-up or blow-off and thus assist in quality assurance by identifying that the abrasive has not been cleaned away adequately.
It will be apparent to those skilled in the art various modifications and variations can be made to the present invention and in particular to the specification or the claims without departing from the scope or spirit of the invention. Thus, it is intended that the present invention cover the modifications and variations of the invention provided they come within the scope of the claims and their equivalents. | A method and apparatus of reclaiming hazardous inorganic wastes to produce an environmentally benign abrasive for use in loose grain processes, as a coated or bonded abrasive, or as a polishing grain. A tough and useful abrasive, with a MOH hardness of 7 to 8, is manufactured from emission control dusts of the aluminum industry or sludges from other industries, and may include small amounts of lead and cadmium oxides as toughening agents. The abrasive particles are sized by air sifting or by water sedimentation separating methods. The process for the manufacture of abrasive material comprises the steps of removing soluble salts from a waste stream by hot water extraction; using a computer matrix to group the waste stream into different batches for mixing with other glass-making materials to form a batch mixture; oxidizing the organic compounds and heavy metal elements contained in the batched mixture; melting the batch mixture to form a glasseous substance; and fritting the glasseous substance to form the abrasive. The process preferably uses a glass melter that will oxidize organics; a scrubber to recapture vaporized heavy metal oxides and particles of the glass-making materials; and an oxygen injection system ensure thorough burning of organics. Certain sodium compounds may be added to reduce the melting point of the batch mixture. | 2 |
This invention was made with government support under CA28896, CA38352 and Cancer Center Support Grant CA30199 awarded by the National Cancer Institute. The government has certain rights in the invention.
This application is a continuation of Ser. No. 07/857,097, filed Mar. 20, 1992, which is a continuation of Ser. No. 07/302,047, filed Jan. 25, 1989, which is a continuation of Ser. No. 06/740,240, filed May 31, 1985, all now abandoned.
FIELD OF THE INVENTION
This invention relates generally to the field of biochemistry and more particularly to a cell surface glycoprotein having the apparent molecular weight of 140,000 daltons with the properties expected of a fibronectin receptor, and the use of the receptor to prepare liposomes with predetermined adhesion properties.
BACKGROUND OF THE INVENTION
Cell-substrate adhesion is generally considered to be a multistep process involving recognition of extracellular matrix components by cell surface receptors, followed by cytoskeletal rearrangements that lead to cell spreading (Grinnell, 1978; Hynes, 1981). Several extracellular matrix glycoproteins, such as fibronectin (Ruoslahti, et al., 1981b), laminin (Timpl, et al., 1979), vitronectin (Hayman, et al., 1983), and collagens have been shown to promote attachment of various cell types to tissue culture substrates (Kleinman, et al., 1981). The cell membrane receptors that recognize these matrix proteins, however, remain essentially unknown, although putative receptors for laminin (Lesot, et al., 1983; Malinoff and Wicha, 1983) and collagens (Chiang and Kang, 1982; Mollenhauer and yon der Mark, 1983) are currently being investigated.
A number of candidates for the role of a fibronectin receptor have been proposed. By photoaffinity labeling, it was shown that a 49 kd glycoprotein comes into close contact with substrate-bound fibronectin (Aplin, et al., 1981). Further support for the notion that the receptor is a protein comes from studies showing that treatment of cells with certain proteases abolishes the ability of cells to attach to fibronectin (Tarone, et al., 1982). Treatment with trypsin, however, at least in the presence of Ca ++ , leaves the receptor activity intact (Oppenheimer-Marks and Grinnell, 1984). Based upon the calcium-dependent stability to trypsin, Oppenheimer-Marks and Grinnell (1984) have proposed a 48 kd wheat germ agglutinin-binding glycoprotein as a potential fibronectin receptor.
It has also been suggested that heparan sulfate proteoglycans might be involved in cell attachment to fibronectin (Culp, et al., 1979; Laterra, et al., 1983). Indeed, photocross-linking experiments performed by Perkins, et al. (1979) showed that proteoglycans are associated with fibronectin at the cell surface.
A different type of cell surface component has been implicated in fibronectin-cell interactions by studies showing an inhibitory effect of di- and trisialogangliosides on the attachment of cells to fibronectin (Kleinman, et al., 1979). The inhibitory activity was found to reside in the carbohydrate moiety of the glycolipid. Antibodies that interfere with cell attachment have been described by a number of investigators, and the corresponding antigens have been found to be proteins with molecular weights ranging from 60 to 160 kd (Hsieh and Sueoka, 1980; Knudsen, et al., 1981; Neff, et al., 1982; Greve and Gottlieb, 1982; Oesch and Birchmeier, 1982), or specific gangliosides (Dippold, et al., 1984).
A large number of binding affinities are known to be present in the fibronectin molecule, such as for collagen (Engvall and Ruoslahti, 1977), fibrinogen and fibrin (Ruoslahti and Vaheri, 1975), proteoglycans (Stathakis and Mosesson, 1977), cell surfaces (Klebe, 1974; Pearlstein, 1976), and actin (Keski-Oja, et al., 1980), and there have been some studies of the interaction of cell surfaces with the cell attachment site. (Pierschbacher, et al., 1981). A large fibronectin fragment, that promotes cell attachment but lacks the other binding activities is also known, (Pierschbacher, et al., 1982, 1983; Pierschbacher and Ruoslahti, 1984a).
It has now been discovered that a 140 kd protein from detergent extracts of cells, when incorporated into liposomes, promotes their binding specifically to fibronectin-coated substrates via the Arg-Gly-Asp sequence in the fibronectin molecule.
REFERENCES
The content of the following references is incorporated into the foregoing specification, as fully as though set forth therein as a background for those skilled in the art.
Aplin, J. D., Hughes, R. C., Jaffe, C. L., and Sharon, N. (1981) Reversible cross-linking of cellular components of adherent fibroblasts to fibronectin and lectin-coated substrata. Exp. Cell Res. 134, 488-494.
Billiau, A., Edy, V. G., Heremans, H., Van Damme, J., Desmyter, J., Georgiades, J. A., and DeSomer, P. (1977). Human interferon: mass production in a newly established cell line, MG-63. Antimicrob. Agents Chemother. 12, 11-15.
Cheresh, D. A., Harper, J. R., Schulz, G., and Reisfeld, R. A. (1984). Localization of the gangliosides GD 2 and GD 3 in adhesion plaques and on the surface of human melanoma cells. Proc. Nat. Acad. Sci. USA 81, in press.
Chiang, T. M., and Kang, A. H. (1982). Isolation and purification of collagen αl(I) receptor from human platelet membrane. J.Biol.Chem. 257, 7581-7586.
Culp. L. A., Murray, B. A., and Rollins, B. J. (1979). Fibronectin and proteoglycans as determinants of cell-substratum adhesion. J.Supramol. Struct. 11, 401-427.
Dippold, W. G., Knuth, A., and Meyer zum Buschenfelde, K. (1984). Inhibition of human melanoma cell growth in vitro by monoclonal anti-GD3-ganglioside antibody. Cancer Res. 44, 806-810.
Engvall, E., and Ruoslahti, E. (1977). Binding of soluble form of fibroblast surface protein, fibronectin, to collagen. Int. J. Cancer 20, 1-5.
Engvall, E., Krusius, T., Wewer, U., and Ruoslahti, E. (1983). Laminin from rat yolk sac tumor: isolation, partial characterization, and comparison with mouse laminin. Arch. Biochem. Biophys. 222, 649-656.
Greve, J. M., and Gottieb, D. I. (1982). Monoclonal antibodies which alter the morphology of cultured chick myogenic cells. J. Cell. Biochem. 18, 221-229.
Grinnell, F. (1978). Cellular adhesiveness and extracellular substrata. Int. Rev. Cyto. 53, 65-144.
Hayman, E. G., Engvall, E., and Ruoslahti, E. (1981). Concomitant loss of cell surface fibronectin and laminin from transformed rat kidney cells. J. Cell Biol. 88, 352-357.
Hayman, E. G., Pierschbacher, M. D., Ohgren, Y., and Ruoslahti, E. (1983). Serum spreading factor (vitronectin) is present at the cell surface and in tissues. Proc. Nat. Acad. Sci. USA 80, 4003-4007.
Hoffman, S., Sorkin, B. C., White, P. C., Brackenbury, R., Mailhammer, R., Rutishauser, U., Cunningham, B. A., and Edelman, G. M. (1982). Chemical characterization of a neural cell adhesion molecule purified from embryonic brain membranes. J. Biol. Chem. 257, 7720-7729.
Hsieh, P., and Sueoka, N. (1980). Antisera inhibiting mammalian cell spreading and possible cell surface antigens involved. J. Cell Biol. 86, 866-873.
Hynes, R. O. (1981). Relationships between fibronectin and the cytoskeleton. In Cell Surface Reviews, Vol. 7, G. Poste and G. L. Nicolson, eds (Amsterdam: Elsevier/North Holland), pp. 97-136.
Keski-Oja, J., Sen. A., and Todaro, G. S. (1980). Direct association of fibronectin and actin molecules in vitro. J.Cell Biol. 85, 527.
Klebe, R. J. (1974). Isolation of a collagen-dependent cell attachment factor. Nature 250, 248-251.
Kleinman, H. K., Martin., G. R., and Fishman, P. H. (1979). Ganglioside inhibition of fibronectin mediated cell adhesion to collagen. Proc. Nat. Acad. Sci. USA 76, 3367-3371.
Kleinman, H. K., Klebe, R. J., and Martin, G. R. (1981). Role of collagenous matrices in the adhesion and growth of cells. J. Cell Biol. 88, 473-485.
Knudsen, K. A., Rao, P. E., Damsky, C. H., and Buck, C. A. (1981). Membrane glycoproteins involved in cell-substratum adhesion. Proc. Nat. Acad. Sci. USA 78, 6071-6075.
Laemmli, U. K. (1970). Cleavage of structural proteins during the assembly of the head of bacteriophage T4. Nature 227, 680-685.
Laterra, J., Siebert, J. E., and Culp, L. A. (1983). Cell surface heparan sulfate mediates some adhesive responses to glycosaminoglycan-binding matrices, including fibronectin. J. Cell Biol. 96, 112-123.
Lebien, T. W., Bouet, D. R., Bradley, J. G., and Kersey, J. H. (1982). Antibody affinity may influence antigenic modulation of the common acute lymphoblastic leukemia antigen in vitro. J. Immunol. 129, 2287-2292.
Lesot, H., Kuhl, U., and von der Mark, K. (1983) Isolation of a laminin-binding protein from muscle cell membranes. EMBO J. 2, 861-865.
Malinoff, H. L., and Wicha, M. S. (1983). Isolation of a cell surface receptor protein for laminin from murine fibrosarcoma cells. J.Cell Biol. 96, 1475-1479.
McAbee, D. D., and Grinnell, F. (1983). Fibronectin-mediated binding and phagocytosis of polystyrene latex beads by baby hamster kidney cells. J. Cell Biol. 97, 1515-1523.
McKeown-Longo, P. J., and Mosher, D. F. (1983). Binding of plasma fibronectin to cell layers of human skin fibroblasts. J.Cell Biol. 97, 466-472.
Mimms, L. T., Zampighi, G., Nozaki, Y., Tanford, C., and Reynolds, J. A. (1981). Phospholipid vesicle formation and transmembrane protein incorporation using octyl glucoside. Biochemistry 20, 833-840.
Mollenhauer, J., and von der Mark, K. (1983). Isolation and characterization of a collagen-binding glycoprotein from chondrocyte membranes. EMBO J. 2, 45-50.
Neff, N. T., Lowrey, C., Decker, C., Tovar, A., Damsky, C., Buck, C., and Horwitz, A. F. (1982). A monoclonal antibody detaches embryonic skeletal muscle from extracellular matrices. J.Cell Biol. 95, 654-666.
Oesch, B., and Birchmeier, W. (1982). New surface component of fibroblast's focal contacts identified by a monoclonal antibody. Cell 31, 671-679.
Oppenheimer-Marks, N., and Grinnell, F. (1982). Inhibition of fibronectin receptor function by antibodies against baby hamster kidney cell wheat germ agglutinin receptors. J.Cell Biol. 95, 876-884.
Oppenheimer-Marks, N., and Grinnell, F. (1984). Calcium ions protect cell-substratum adhesion receptors against proteolysis. Exp. Cell Res. 152, 467-475.
Pearlstein, E. (1976). Plasma membrane glycoprotein which mediates adhesion of fibroblasts to collagen. Nature 262, 497-500.
Perkins, M. E., Ji, T. H., and Hynes, R. O. (1979). Cross-linking of fibronectin to sulfated proteoglycans at the cell surface. Cell 16, 941-952.
Pierschbacher, M. D., and Ruoslahti, E. (1984a). Cell attachment activity of fibronectin can be duplicated by small synthetic fragments of the molecule. Nature 309, 30-33.
Pierschbacher, M. D., and Ruoslahti, E. (1984b). Variants of the cell recognition site of fibronectin that retain attachment-promoting activity. Proc. Nat. Acad. Sci. USA 81, 5985-5988.
Pierschbacher, M. D., Hayman, E. G. and Ruoslahti, E. (1981). Location of the cell attachment site in fibronectin with monoclonal antibodies and proteolytic fragments of the molecule. Cell 26, 259-267.
Pierschbacher, M. D., Ruoslahti, E., Sundelin, J., Lind, P., and Peterson, P. A. (1982). The cell attachment domain of fibronectin. Determination of the primary structure. J. Biol. Chem. 267, 9593-9597.
Pierschbacher, M. D., Hayman, E. G., and Ruoslahti, E. (1983) Synthetic peptide with cell attachment activity of fibronectin. Proc. Nat. Acad. Sci. USA 80, 1224-1227.
Rauvala, H., Carter, W. G., and Hakomori, S.-I.(1981). Studies on cell adhesion and recogition I. Extent and specificity of cell adhesion triggered by carbohydrate-reactive proteins (glycosidases and lectins) and by fibronectin. J. Cell Biol. 88, 127-137.
Ruoslahti, E., and Vaheri, A. (1975). Interaction of soluble fibroblast surface antigen with fibrinogen and fibrin. J. Exp. Med. 141, 497-501.
Ruoslahti, E., Hayman, E. G., Engvall, E., Cothran, W. C., and Butler, W. T. (1981a). Alignment of biologically active domains in the fibronectin molecule. J. Biol. Chem. 256, 7277-7281.
Ruoslahti, E., Engvall, E., and Hayman, E. G. (1981b). Fibronectin: current concepts of its structure and function. Coll. Rel. Res. 1, 95-128.
Stathakis, N. E., and Mosesson, M. W. (1977). Interactions among heparin, cold-insoluble globulin, and fibronectin in formation of the heparin-precipitable fraction of plasma. J. Clin. Invest. 60, 855-865.
Tarone, G., Galetto, G., Prat, M., and Comoglio, P. M. (1982). Cell surface molecules and fibronectin-mediated cell adhesion: effect of proteolytic digestion of membrane proteins. J. Cell Biol. 94, 179-186.
Timpl, R., Rohde, H., Robey, P. G., Rennard, S. I., Foidart, J. M., and Martin, G. R. (1979). Laminin-a glycoprotein from basement membranes. J. Biol. Chem. 254, 9933-9937.
Yoshida, C., and Takeichi, M. (1982). Teratocarcinoma cell adhesion: identification of a cell-surface protein involved in calcium-dependent cell aggregation. Cell 28, 217-224.
SUMMARY OF THE INVENTION
The present invention relates to the discovery, identification, separation and isolation, and the use of a cell surface glycoprotein characterized in that it has a molecular weight of about 140,000 daltons, specifically binds with the cell attachment site in fibronectin and is substantially separated from interfering and diluting cell surface glycoproteins.
As a composition of matter, the invention may be described as consisting essentially of cell surface glycoprotein characterized in that it has a molecular weight of about 140,000 daltons, specifically binds with the cell attachment site in fibronectin, is eluted from such cell attachment site by a peptide consisting essentially of the amino acid sequence Arginine, Glycine, Aspartic Acid (ARG-GLY-ASP), and is substantially separated from interfering cell surface glycoproteins.
The composition may also be described as consisting essentially of cell surface glycoprotein characterized in that it has a molecular weight of about 140,000 daltons, specifically binds with the cell attachment site in fibronectin, can be labelled by a procedure which is specific for cell surface proteins, and is substantially separated from interfering cell surface glycoproteins.
The invention, in one facet, may be described as a cell surface glycoprotein characterized in that it has a molecular weight of about 140,000 daltons, specifically binds with the cell attachment site in fibronectin, incorporates into lipid vesicles, and is substantially separated from interfering cell surface glycoproteins.
The invention also contemplates a method utilizing a composition for targeting liposomes to fibronectin-containing tissues consisting essentially of a cell surface glycoprotein having a molecular weight of about 140,000 daltons which specifically binds with the cell attachment site in fibronectin and is eluted from such cell attachment site by a peptide consisting essentially of the sequence ARG-GLY-ASP.
The composition for targeting liposomes to fibronectin containing tissues may, in a preferred form, consist essentially of cell surface glycoprotein having a molecular weight of about 140,000 daltons which specifically binds with the cell attachment site in fibronectin, is eluted from such cell attachment site by a peptide consisting essentially of the sequence ARG-GLY-ASP.
The invention, in another feature, is a method of targeting liposomes to fibronectin containing tissues comprising exposing such tissues to liposomes containing cell surface glycoprotein characterized in that it has a molecular weight of about 140,000 daltons, specifically binds with the cell attachment site in fibronectin and is substantially separated from interfering and diluting cell surface glycoproteins.
The preferred method of targeting liposomes to fibronectin containing tissues comprises exposing such tissues to liposomes containing a cell surface glycoprotein characterized in that it has a molecular weight of about 140,000 daltons, specifically binds with the cell attachment site in fibronectin, is eluted from such cell attachment site by a peptide consisting essentially of the sequence ARG-GLY-ASP, and is substantially separated from interfering cell surface glycoproteins.
The method of targeting liposomes to fibronectin containing tissues may comprise exposing such tissues to liposomes containing a cell surface glycoprotein having a molecular weight of about 140,000 daltons which specifically binds with the cell attachment site in fibronectin, is eluted from such cell attachment site by a peptide consisting essentially of the sequence ARG-GLY-ASP, labelled by a procedure which is specific for cell surface proteins.
As a new composition of matter suitable for assay and detection purposes, the invention is at least one liposome containing a cell surface glycoprotein characterized in that it has a molecular weight of about 140,000 daltons, specifically binds with the cell attachment site in fibronectin, is eluted from such cell attachment site by a peptide consisting essentially of the sequence ARG-GLY-ASP, and is substantially separated from interfering cell surface glycoproteins.
The liposome composition preferably contains labelled cell surface glycoprotein having a molecular weight of about 140,000 daltons which specifically binds with the cell attachment site in fibronectin and is eluted from such cell attachment site by a peptide consisting essentially of the sequence ARG-GLY-ASP.
As assay reagent, the invention may be described as consisting essentially of a carrier and cell surface glycoprotein characterized in that it has a molecular weight of about 140,000 daltons, specifically binds with the cell attachment site in fibronectin, incorporates into lipid vesicles, and is substantially separated from interfering cell surface glycoproteins.
The assay reagent preferably consists essentially of a carrier and a labelled cell surface glycoprotein having a molecular weight of about 140,000 daltons which specifically binds with the cell attachment site in fibronectin, is eluted from such cell attachment site by a peptide consisting essentially of the sequence ARG-GLY-ASP.
The assay reagent may also consist essentially of a carrier and at least one liposome containing cell surface glycoprotein characterized in that it has a molecular weight of about 140,000 daltons, specifically binds with the cell attachment site in fibronectin, incorporates into lipid vesicles, and is substantially separated from interfering cell surface glycoproteins. The assay reagent preferably includes cell surface glycoprotein having a molecular weight of about 140,000 daltons which specifically binds with the cell attachment site in fibronectin and is eluted from such cell attachment site by a peptide consisting essentially of the sequence ARG-GLY-ASP. The cell--cell surface glycoprotein can be labelled by a procedure which is specific for cell surface proteins.
The compositions and methods of this invention are not limited to the specific examples given herein; rather, these compositions and methods are fundamental tools and will find broad applicability in scientific research, clinical assays and therapy.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B are representations of sodium dodecyl sulfate-polyacrylamide gel electrophoresis (SDS-PAGE) analysis of fractions eluted from the fibronectin cell-binding fragment affinity matrix. MG-63 human osteosarcoma cells (10 8 cells) were surface-labeled and extracted as described in Example I. The extract (2 ml) was chromatographed on a column of Sepharose 4B (bed volume 2 ml) containing a covalently bound, cell-attachment-promoting fragment of fibronectin. Fractions of 1 ml were collected, and aliquots (50 μl) of each fraction were analyzed by SDS-PAGE (7.5% acrylamide) under reducing conditions, using autoradiography (A) or silver staining (B) for visualization of protein bands. Where indicated by arrows, 1 mg/ml of the synthetic peptide glycyl-L-arginyl-glycyl-L-glutamyl-L-seryl-L-proline (GRGESP) or glycyl-L-arginyl-glycyl-L-aspartyl-L-seryl-L-proline (GRGDSP) was added to the elution buffer. Lane 1, flow-through; lanes 2-12, column fractions obtained by washing the starting buffer alone or supplemented with peptides; lane 13, material eluted with 8M urea. Arrowheads denote the position of the 140 kd protein. Molecular weight markers in this and subsequent figures were: myosin, 200 kd; β-galactosidase, 116 kd; phosphorylase B, 94 kd; bovine serum albumin, 67 kd; ovalbumin, 43 kd.
FIG. 2 is a representation of the analysis of the 140 kd protein by SDS-PAGE under nonreducing conditions. A preparation of radiolabeled 140 kd protein, as shown in FIG. 1, lane 10, and molecular weight markers were subjected to SDS-PAGE under nonreducing and reducing conditions. The nonreduced and reduced samples were run on separate gels. Lane 1, molecular weight markers visualized using silver staining; lane 2, 140 kd protein visualized using autoradiography.
FIG. 3 is a graph depicting incorporation of the 140 kd protein into liposomes. A 140 kd protein fraction (0.5 ml) obtained by affinity chromatography as shown in FIG. 1 was supplemented with 200 μg of phosphatidylcholine and 2.5×10 6 cpm of 3 H-phosphatidylcholine and dialyzed against phosphate-buffered saline (PBS) containing 1 mM phenylmethyl sulfonyl fluoride (PMSF) for 24 hr at 4° C. The resulting liposomes were fractionated by sucrose gradient centrifugation under conditions described herein. Two hundred microliter fractions of the gradient and the pellet (P) were analyzed for 3 H-labeled lipid by liquid scintillation counting and for the 125 I-labeled 140 kd protein by gamma counting. Note that interference by 125 I in liquid scintillation counting was negligible, since the 3 H radioactivity was present in a large excess relative to 125 I.
FIG. 4 is a representation of SDS-PAGE of fractions obtained after sucrose gradient fractionation of 140 kd protein-containing liposomes. Top and bottom fractions and the pellet of the sucrose gradient fractionation shown in FIG. 3 were analyzed by SDS-PAGE under nonreducing conditions, using silver staining for the visualization of the bands. Lane 1, 140 kd protein-containing fraction before incorporation into liposomes; lane 2, top fraction (liposomes); lane 3, bottom fraction (nonincorporated proteins); lane 4, pellet. Equal volumes (100 μl) of sample were applied to each lane. Molecular weight standards were run in the lanes marked S. Arrowheads indicate the position of the bands corresponding to the nonreduced form of the 140 kd protein.
FIG. 5 is a graph depicting binding of the liposomes containing the 140 kd protein to fibronectin-coated substrate. 3 H-labeled liposomes (5×10 4 cpm/μg phosphatidylcholine) were prepared as described in the legend to FIG. 3. Fifty micrograms of phosphatidylcholine (PC) and 140 kd protein from 2×10 8 cells (estimated to be approximately 10 μg based on staining in SDS-PAGE) were used. One hundred microliters of the liposome suspension (containing 3 μg phosphatidylcholine) were added to microtiter wells coated with various concentrations of fibronectin (FN) or laminin (LM), and the binding assay was carried out as described in Example I.
FIG. 6 is a graph depicting specificity of binding of the 140 kd protein-liposomes to fibronectin. The liposome-attachment assay was performed as in FIG. 5. The protein concentration used in the coating was 20 μg/ml. Where indicated, synthetic peptides (1 mg/ml) were added to the wells with the liposome suspension. The active cell-attachment peptide (GRGDSP) inhibits liposome binding by approximately 50%, while inactive variants have no effect. The mean and range are given for each condition.
FIG. 7 is a graph depicting lectin affinity chromatography of 140 kd protein. 125 I-labeled 140 kd protein obtained by fibronectin fragment chromatography was chromatographed on columns (bed volume, 1 ml) containing Wheat Germ-Agglutinin (WGA)-Sepharose or Concanavalin (Con) A-Sepharose. The columns were eluted with PBS containing 0.5 Nonidet-P40 and 1 mM PMSF, and supplemented with the appropriate sugar where indicated by arrows. Arrow 1 denotes the addition of α-methylmannoside (αMM) to the WGA-column and N-acetyl glucosamine (NAGA) to the ConA-column, arrow 2 shows the addition of NAGA to the WGA and αMM to the ConA column.
FIGS. 8A and 8B are representations of SDS-PAGE of the 140 kd protein eluted from WGA-Sepharose. The fractions obtained as shown in FIG. 7 were analyzed under nonreducing conditions using autoradiography (A) or silver staining (B) for the visualization of the protein bands. Lane 1, sample before application to the column; lane 2, material eluting in the flow-through; and lane 3, material eluted specifically by N-acetyl-glucosamine.
DETAILED DESCRIPTION OF THE INVENTION
Extracts of surface-labeled cells were fractionated on an immobilized fibronectin fragment that is capable of promoting cell attachment. Human osteosarcoma MG-63 cells that had first been surface-iodinated with lactoperoxidase were dissolved in octylglucoside. MG-63 cells attach to and spread on fibronectin, and deposit fibronectin-containing extracellular matrix fibers in a manner similar to that of normal fibroblast cell lines.
An affinity matrix was prepared by coupling to Cyanogen-Bromide (CNBr)-activated Sepharose a 120 kd chymotryptic fragment of fibronectin that binds to neither gelatin nor heparin but retains cell-attachment-promoting activity (Ruoslahti, et al., 1981a; Pierschbacher, et al., 1981). Specific elution was effected by treating the column with the synthetic peptide:
glycyl-L-arginyl-glycyl-L-aspartyl-L-seryl-L-proline
(GRGDSP), which contains the cell-attachment recognition site of fibronectin (Pierschbacher and Ruoslahti, 1984a, 1984b). The eluted fractions were analyzed by SDS-PAGE followed by silver staining and autoradiography for detection of total protein and radioactively labeled surface proteins, respectively.
As shown in FIG. 1A, a radioactive protein with an apparent molecular weight of 140 kd specifically eluted from the affinity matrix with the GRGDSP peptide (lanes 9-12). The affinity of the 140 kd protein for the matrix was essentially unaffected by a related peptide (lanes 4-7) in which the aspartic acid residue is replaced by glutamic acid (GRGESP). Since this peptide does not promote cell attachment (Pierschbacher and Ruoslahti, 1984b), but does have structural and charge propertites closely similar to those of the active peptide, the resistance of the 140 kd protein toward elution with this peptide establishes the specificity of the elution with the active peptide. No specific protein bands could be obtained by the same elution procedure when albumin-Sepharose was used instead of the fibronectin fragment-Sepharose.
Silver-stained SDS-PAGE (FIG. 1B) showed that the 140 kd protein was a major component among the proteins eluted from the fibronectin fragment column. It appeared as a darkly stained, diffuse band. The silver staining also revealed the presence of a number of other protein bands in the eluted material. The elution of these additional bands, however, was not dependent upon the GRGDSP peptide, and they were not labeled by lactoperoxidase-catalyzed iodination of intact cells. Thus, it appears that these bands represent intracellular, possibly cytoskeletal, proteins that bind nonspecifically to the column and slowly leach off during the elution.
Elution of the affinity column with urea subsequent to the elution with the GRGDSP peptide resulted in the release of a large number of proteins (FIG. 1, lanes 13). This underlines the high specificity provided by the elution with the synthetic cell-attachment peptide. The urea eluate did not contain detectable amounts of the 140 kd protein, suggesting that it had been quantitatively removed from the column by elution with the GRGDSP peptide.
When the 125 I-labeled, affinity-purified 140 kd protein was subjected to SDS-PAGE under nonreducing conditions, a major band appeared at 120 kd (FIG. 2). In addition, a double band was seen at the position that is occupied by the single band under reducing conditions. No radioactivity was found in larger aggregates, indicating that the 140 kd protein is not cross-linked by disulfide bonds into oligomers. The increased mobility of the nonreduced protein in SDS-PAGE (120 kd vs. 140 kd) suggests that the molecule has a compact conformation stabilized by disulfide bonds. The conformation of the 140 kd protein is apparently influenced by intrachain disulfide bonds.
A preparation containing 125 I-labeled 140 kd protein dissolved in octylglucoside (as shown in FIG. 1, lane 10) was mixed with phosphatidylcholine (containing a tracer of 3 H-phosphatidylcholine), and the mixture was freed of detergent by dialysis against phosphate-buffered saline (PBS). After centrifugation through a sucrose gradient with the sample loaded at the bottom of the tube, the distributions of the resulting liposomes and of the 125 I-labeled protein were determined. As shown in FIG. 3, approximately 90% of the 125 I-labeled protein codistributed with the tritium-labeled lipid vesicles. SDS-PAGE analysis of the top and bottom fractions and the pellet obtained by the centrifugation (FIG. 4) showed that most of the contaminating proteins present in the sample remained at the bottom of the tube or were pelleted, while the 140 kd protein migrated to the top of the gradient, appearing highly enriched in the liposome fraction. When the sucrose gradient centrifugation was carried out with a sample prepared without added phospholipid, most of the 140 kd protein radioactivity was recovered in the pellet fraction and none of it floated to the top of the gradient. Even when the detergent was not removed by dialysis, all of the reactivity remained in the lower fractions of the gradient, but did not precipitate. This indicates that floating of the 140 kd protein occurs only in the presence of phospholipid vesicles and is not due to the presence of residual detergent bound to the protein. These results indicate that the 140 kd protein can become inserted into a lipid bilayer.
As depicted in FIG. 5, liposomes containing the 140 kd protein bound to fibronectin-coated microtiter wells in a dose-dependent manner, similar to the attachment of cells to fibronectin. In contrast, no significant binding to another adhesive glycoprotein, laminin (Engvall, et al., 1983), was observed. In further control experiments, it was found that neither liposomes without incorporated protein nor liposomes prepared from a crude octylglucoside extract of cells adhered to fibronectin-coated wells. In addition, the binding was specifically inhibited by the cell-attachment peptide, GRGDSP (FIG. 6). This peptide, at a concentration of 1 mg/ml, inhibited the binding of liposomes by approximately 50%, while inactive variants, GRGESP and GRADSP (alanine replacing glycine in the latter peptide), were without any effect at the same concentration. Increasing the concentration of the peptides to 4 mg/ml resulted in a higher degree of inhibition, but at this concentration some apparent nonspecific inhibition was observed.
Chromatography on WGA-Sepharose or ConA-Sepharose of a fraction containing affinity-purified, radiolabeled 140 kd protein showed that most of the radioactivity binds to WGA and elutes specifically with N-acetylglucosamine, whereas it does not bind to Con A (FIG. 7). Analysis of the fractions by SDS-PAGE under nonreducing conditions confirmed the presence of the radiolabeled 140 kd protein in the fraction eluted with N-acetylglucosamine (FIG. 8A). Silver staining of SDS-PAGE showed that the WGA-bound material was further enriched for the 120 kd and 140 kd components characteristic of the nonreduced 140 kd protein (FIG. 8B, lane 3) relative to the preparation obtained from fibronectin fragment-Sepharose (FIG. 8B, lane 1).
EXAMPLE I
Synthetic peptides were prepared by Peninsula Laboratories (San Carlos, Calif.) according to our specifications (Pierschbacher, et al., 1983; Pierschbacher and Ruoslahti, 1984a, 1984b). Fibronectin was prepared from human plasma according to Engvall and Ruoslahti (1977). Laminin was prepared from rat yolk sac tumor according to Engvall, et al. (1983). Egg yolk phosphatidylcholine was purchased from Sigma (St. Louis, Mo.), octylglucoside from Behring Diagnostics (La Jolla, Calif.). 125 I-sodium iodide was from Amersham (Arlington Heights, Ill.) and 3 H-phosphatidylcholine from New England Nuclear (Boston, Mass.). Chemicals used for SDS-PAGE were from BioRad (Richmond, Calif.).
MG-63 human osteosarcoma cells (Billiau, et al., 1977) were grown on 175 cm 2 tissue culture dishes in Dulbecco's Minimum Essential Medium (DMEM) supplemented with 5% fetal calf serum, glutamine, and penicillin/streptomycin. For subculturing or harvesting, confluent layers of cells were incubated in 1 mM Ethylenediamine Tetraacetic Acid (EDTA) for 15 minutes.
Cells grown to confluence in 175 cm 2 dishes were detached with 1 mM EDTA for 15 minutes, collected by centrifugation and resuspended in phosphate-buffered saline (PBS, 150 mM NaCl, 10 mM sodium phosphate, 1 mM CaCl 2 , 1 mM MgCl 2 , pH 7.3) containing 0.2 mM phenylmethyl sulfonylfluoride (PMSF; added from a 100×stock solution in ethanol). The suspended cells were radioiodinated according to Lebien, et al. (1982) using 2 mCi of 125 I-sodium iodide and 0.2 mg/ml of lactoperoxidase per 10 8 cells. All subsequent operations were performed at 4° C. Cells were lysed by adding 1 ml of PBS containing 200 mM octylglucoside and 3 mM PMSF to 10 8 packed cells and incubating for 10 min. Insoluble material was removed by centrifugation at 12,500×g for 15 minutes.
The 120 kd chymotryptic cell binding fragment of fibronectin was prepared and coupled to cyanogen-bromide-activated Sepharose (Sigma) as described (Ruoslahti, et al., 1981a; Pierschbacher, et al., 1981). This matrix contained 3 mg/ml of the chymotryptic fragment of fibronectin.
The octylglucoside extract of cells was then applied to 2 ml of this affinity matrix, which had been equilibrated in column buffer (PBS containing 50 mM octylglucoside and 1 mM PMSF). Elution with the synthetic cell-attachment peptide was carried out by slowly washing the column with 1 volumn column buffer supplemented with 1 mg/ml of GRGDSP over a period of 1 hour.
Samples of SDS-PAGE were boiled for 3 min in the presence of 3% SDS, with or without 5% 2-mercaptoethanol, and electrophoresed on 7.5% acrylamide gels according to Laemmli (1970). Molecular weight markers were myosin (200 kd), β-galactosidase (116 kd), phosphorylase B (94 kd), bovine serum albumin (67 kd), and ovalbumin (43 kd). Gels were silver-stained using a commercially available reagent kit (Bio-Rad), following the manufacturer's instructions. Autoradiography was performed by placing Kodak XAR X-ray film between the dried gel and a Cronex Lightning Plus intensifying screen (DuPont, Newtown, Conn.) at -70° C. for 1-3 days.
Liposomes were prepared essentially as described by Mimms, et al. (1981). Egg yolk phosphatidylcholine was dried onto a glass tube under a stream of N 2 and dissolved in PBS containing 50 mM octylglucoside or protein fractions in this buffer. Detergent was removed by dialysis against PBS for 24 hours at 4° C., resulting in the formation of liposomes with an average diameter of approximately 200 nm, as judged by electron microscopy. To purify the liposomes, the suspension was made 45% in sucrose, overlaid with 2 ml of 30% sucrose and 1 ml of 10% sucrose, and centrifuged at 4° C. for 18 hours at 45,000 rpm in a Beckman SW60 rotor. The liposomes were recovered as a white band at the top of the 10% sucrose layer.
Wells of a polystyrene microtiter plate (Linbro/Titertek, Inglewood, Calif.) were coated with protein solutions in PBS by incubating overnight at room temperature. Unoccupied binding sites on the polystyrene surface were then saturated by incubation with 2 mg/ml bovine serum albumin (BSA) in PBS for 2 hours at 37° C. 3 H-labeled liposomes suspended in PBS containing 2 mg/ml BSA were added to the wells and incubated for 5 hours at 4° C. The supernatants were then removed and wells were washed twice with PBS. Bound liposomes were dissolved in 1% SDS (100 μl/well) and quantitiated by scintillation counting.
INDUSTRIAL APPLICATION
This invention finds direct and immediate application in the assay of fibronectin receptor in cells and tissues. The isolation method described above can be used to assay cultured cells or tissue samples for their content of the fibronectin receptor. Such analysis will be important in determining the adhesion capacity of cells such as those in tumors. Alternatively, the isolated receptor can be used to prepare antibodies for such assays.
A reagent consisting essentially of the cell surface glycoprotein described in the foregoing examples may be used in therapy to carry reagents to selected tissues.
The cell surface glycoprotein is also useful in assaying for receptor antibodies and, together with such antibodies, will permit establishment of graft tissue assays for the receptor such as a radioimmunoassay or enzyme linked assay. | Method for the isolation and characterization of a 140,000 dalton cell surface glycoprotein with the properties expected of a fibronectin receptor is described. | 2 |
TECHNICAL FIELD OF THE INVENTION
The present invention relates to the field of pet toys. More specifically, the present invention relates to the field of pet toys affixed to a wand.
BACKGROUND OF THE INVENTION
Among interactive pet toys, especially those pet toys intended to allow humans to interactively play with their pets, there exists a specific type of pet toy known as a “teaser.” In its simplest form, a teaser consists of a wand upon an end of which is affixed a play object. A teaser is intended as an interactive toy for cats and other animals that instinctively hunt and pounce upon small prey, such as mice and birds.
When using a teaser, the human would shake the wand. This would cause the play object to bounce and bob enticingly before the pet. This triggers the pet's instincts, and the pet pounces upon and/or otherwise attacks the play object.
Ideally, the motion of the play object should emulate the motion of the animal's natural prey. Since the natural prey of cats and other similar-sized predators are mice, birds, lizards, and the like, it is desirable that the motion of the teaser emulates the movements of such small prey animals. Such emulation would maximally trigger instinctive responses and produce optimal interactive play for both the human and the pet.
The natural movement of small prey consists of relatively rapid short smooth motions and very rapid jerky motions. These motions are produced as the prey changes location and moves in place, respectively. In order to emulate these motions, the human would have to move the teaser wand so that the play object moves relatively rapidly over a broad area while very quickly jerking about.
The play object is typically firmly affixed to the end of the wand. In this case, the emulation of both the broader and the quicker motions is dependent solely upon the movement imparted to the wand by the human. To provide maximum stimulation, excessive and complex wrist action is required. This wrist action is both tiring and potentially injurious.
In some cases, the play object is loosely attached to the end of the wand. In this case, it is intended that the wand imparts the desired broader movements, while the movement of the play object on the end of the wand imparts the quicker movements. Unfortunately, a loosely attached play object tends to flop. This flopping is a poor emulation of the quicker movements at best, and tends to emulate injured or diseased prey at worst. A flopping prey may therefore arouse suspicion in the pet that the prey is sick. Many hunting animals instinctively avoid sick prey. A loosely attached, floppy teaser, therefore, produces a less than optimal effect.
The desired dual-action motion may be achieved through the use of a spring teaser, i.e., a teaser where the play object is attached to a spring or wire. With a spring teaser, the human may impart the broader motions, while the spring allows the play object to bob about and therefore imparts the quicker motions. The problem with spring teaser is one of control. Since the prey object bobs about on the end of the spring, it is virtually impossible for the human to determine where the play object will be at any given instant. This lack of control may result in the play object striking the pet unexpectedly. Such a strike may easily be interpreted by the pet as an attack. This in turn may cause the pet to become wary, and lessen the enjoyment for both the pet and the human.
What is desirable, therefore, is a teaser where the human imparts the broader movements through the wand while the play object is simultaneously free to make controlled quick movements about the end of the wand. Such a teaser would provide a maximal emulation of the movements of small prey without requiring undue care or effort on the part of the human, and without posing a risk of injury or displeasure to the pet.
SUMMARY OF THE INVENTION
Accordingly, it is an advantage of the present invention that a pet toy having controlled movement is provided.
It is another advantage of the present invention that a pet toy is provided that incorporates a play object coupled to the end of a wand.
It is another advantage of the present invention that a pet toy is provided that a play object is coupled to a wand in a manner allowing only controlled movement.
The above and other advantages of the present invention are carried out in one form by a pet toy formed of a play object having an object axis, a wand having a wand axis at an intersection of a first plane and a second plane, and a flexible coupling affixed to the play object, affixed to the wand, and configured so that the object axis may freely pivot no more than ±45° relative to the wand axis in the first plane.
The above and other advantages of the present invention are carried out in one form by a method of producing a pet toy that includes coupling a play object to a wand, limiting movement of the play object to no more than ±45° relative to the wand in a first plane, and limiting movement of the play object to no more than ±30° relative to the wand in a second plane substantially perpendicular to the first plane.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the Figures, wherein like reference numbers refer to similar items throughout the Figures, and:
FIG. 1 shows a plan view of a pet toy having a play object, a flexible coupling, and a wand in accordance with a preferred embodiment of the present invention;
FIG. 2 shows a side view of a pet toy demonstrating a one-piece flexible coupling in accordance with a preferred embodiment of the present invention;
FIG. 3 shows a side view of a pet toy demonstrating a two-piece flexible coupling in accordance with a preferred embodiment of the present invention;
FIG. 4 shows a side view of a pet toy demonstrating attachment and detachment of the two-piece flexible coupling of FIG. 3 in accordance with a preferred embodiment of the present invention;
FIG. 5 shows a plan view of a wand for a pet toy in accordance with a preferred embodiment of the present invention;
FIG. 6 shows a side view of a wand for a pet toy in accordance with a preferred embodiment of the present invention;
FIG. 7 shows a cross sectional plan view of a pet toy taken at line 7 — 7 of FIG. 2 and demonstrating a wand head encompassed with a coupling pocket in accordance with a preferred embodiment of the present invention;
FIG. 8 shows a cross sectional side view of a pet toy taken at line 8 — 8 of FIG. 1 and demonstrating a wand head encompassed with a coupling pocket in accordance with a preferred embodiment of the present invention;
FIG. 9 shows a schematic view demonstrating controlled movement in a first plane of a coupling pocket relative to a wand head in accordance with a preferred embodiment of the present invention; and
FIG. 10 shows a schematic view demonstrating controlled movement in a second plane of a coupling pocket relative to a wand head in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 , 2 , 3 , and 4 show a plan view ( FIG. 1 ) and side views ( FIGS. 2 , 3 , and 4 ) of a pet toy 20 having a play object 22 , a one-piece ( FIG. 2 ) or two-piece ( FIGS. 3 and 4 ) flexible coupling 24 , and a wand 26 in accordance with a preferred embodiment of the present invention. The following discussion refers to FIGS. 1 , 2 , 3 , and 4 .
Pet toy 20 is a “teaser,” i.e., pet toy 20 consists of wand 26 to which play object 22 is attached. In the present invention, play object 22 is attached to wand 26 by flexible coupling 24 . Flexible coupling 24 is configured to impart a controlled movement to play object 22 relative to wand 26 as discussed hereinafter.
In the Figures, play object 22 is depicted as undefined. This is because play object 22 may be any of a large class of objects. Exemplary play objects 22 include, but are not limited to, a ball, a stuffed object, a catnip container, a feather, or a cluster of feathers, synthetic tinsel, yarn, or string. Those skilled in the art will appreciate that the form of play object 22 is not a part of the present invention. The use of any specific object or objects for play object 22 does not depart from the spirit of the present invention.
In the preferred embodiment, pet toy 20 is produced by coupling play object 22 to wand 26 via flexible coupling 24 . Flexible coupling 24 has a flexible coupling body 28 . Coupling body 28 is desirably affixed to play object 22 by an object collar 30 and affixed to wand 26 by a wand collar 32 .
Flexible coupling 24 needs to be flexible. In the preferred embodiment, therefore, coupling body 28 is desirably formed of a fabric (not shown) to allow flexible coupling 24 to flex freely during use. The use of fabric also has the desirable effect of maintaining a low assembly cost. It will be understood, however, that this is not a requirement of the present invention. Other materials may be used to form the coupling body without departing from the spirit of the present invention.
Object and wand collars 30 and 32 serve only to attach flexible coupling 24 to play object 22 and wand 26 , respectively. It is therefore not necessary that object and wand collars 30 and 32 be themselves flexible. For example, in the preferred embodiment, wand collar 32 is desirably affixed to wand 26 by an adhesive (not shown). This adhesive may saturate wand collar 32 and render wand collar 32 inflexible. Similarly, object and wand collars 30 and 32 , while components of flexible coupling 24 , need not be integral to coupling body 28 . For example, in an alternative embodiment (not shown), wand collar 32 may be a ring clip or other clamping device configured to securely affix coupling body 28 to wand 26 . Those skilled in the art will appreciate that the forms taken by object collar 30 and wand collar 32 are not a part of the present invention. The use of any particular forms for object collars 30 and 32 does not depart from the spirit of the present invention.
Flexible coupling 24 may be a one-piece flexible coupling 24 ′ ( FIG. 2 ), or a two-piece flexible coupling 24 ″ ( FIGS. 3 and 4 ). When flexible coupling 24 is one-piece flexible coupling 24 ′, then coupling body 28 consists of an object-wand connector 34 between object collar 30 and wand collar 32 . Object-wand connector 34 effectively forms a substantially permanent flexible connection between play object 22 and wand 26 .
Alternatively, when flexible coupling 24 is two-piece flexible coupling 24 ″, then coupling body consists of an object connector 36 substantially permanently affixed to play object 22 and a wand connector 38 substantially permanently affixed to wand 26 . Object connector 36 is configured to detachably couple to wand connector 38 . In the preferred embodiment of FIGS. 3 and 4 , this is accomplished by incorporating into object connector a first portion 40 of a hook-and-loop connector 42 , and by incorporating into wand connector 38 a second portion 44 of hook-and-loop connector 44 . First and second portions 40 and 44 of hook-and-loop connector 42 are configured to engage each other, as demonstrated in FIG. 4 , to detachably couple play object 22 to wand 26 .
Those skilled in the art will appreciate that connectors other than hook-and-loop connector 42 may be used to form two-piece flexible coupling 24 ″. The use of any other form of attachment to couple object connector 36 to wand connector 38 does not depart from the spirit of the present invention.
It will also be appreciated that the use of two-piece flexible coupling 24 ″ is preferable over one-piece flexible coupling 24 ′ in that two-piece flexible coupling 24 ″ allows the use of multiple play objects 22 with a single wand 26 . For the sake of simplicity and clarity, however, one-piece flexible coupling 24 ′, referred to simply as flexible coupling 24 , will be assumed for the remainder of this discussion except where specifically indicated otherwise.
In the Figures, FIGS. 1 , 5 , 7 , and 9 depict plan or “top” views, while FIGS. 2 , 3 , 4 , 6 , 8 , and 10 depict side views. That is, FIGS. 1 , 5 , 7 , and 9 depict pet toy 20 and/or wand 26 in a plan plane 46 , while FIGS. 2 , 3 , 4 , 6 , 8 , and 10 depict pet toy 20 and/or wand 26 in a side plane 48 substantially perpendicular to plan plane.
FIGS. 5 and 6 show a plan view ( FIG. 5 ) and a side view ( FIG. 6 ) of wand 26 for pet toy 20 in accordance with a preferred embodiment of the present invention. The following discussion refers to FIGS. 1 , 2 , 5 , and 6 .
Wand 26 is formed of a wand shaft 50 onto one end of which is rigidly affixed wand head 52 . Wand shaft 50 is desirably cylindrical, though this is not a requirement of the present invention, and has a predetermined shaft diameter 54 . Wand 26 has a wand axis 56 extending longitudinally through a center of wand shaft 50 at an intersection of plan and side planes 46 and 48 .
In the preferred embodiment, wand head 52 is desirably asymmetrical relative to wand axis 56 . In plan plane 46 ( FIG. 5 ), wand head 52 desirably has a base width 58 substantially wider than shaft diameter 54 , though this is not a requirement of the present invention. Wand head 52 is also desirably formed in plan plane 46 with a shape incorporating a first plan-plane head side 60 and a second plan-plane head side 62 . Head sides 60 and 62 are desirably straight, though this is not a requirement of the present invention.
In the preferred embodiment, plan-plane head sides 60 and 62 are two sides of a modified triangle. In this embodiment, wand head 52 also has a plan-plane base 64 whose width is base width 58 . Desirably, base 64 is a tangential arcuate base flowing smoothly into head sides 60 and 62 . This gives wand head 52 a “spade” shape in horizontal plane 46 , which has certain advantages discussed hereinafter.
Those skilled in the art will appreciate that wand head 52 may have a shape in plan plane 46 other than that of a modified triangle without departing from the spirit of the present invention.
In side plane 48 ( FIG. 6 ), wand head 52 desirably has a base thickness 66 substantially equal to shaft diameter 54 , though this is not a requirement of the present invention. Similarly, wand head 52 is also desirably formed in side plane 48 with a shape incorporating a first side-plane head side 68 and a second side-plane head side 70 . Head sides 68 and 70 are desirably straight, though this is not a requirement of the present invention.
In the preferred embodiment, side-plane head sides 68 and 70 are two sides of a modified triangle. In this embodiment, wand head 52 also has a side-plane base 72 whose thickness is head base thickness 58 , i.e., is shaft diameter 54 . This gives wand head 52 a wedge shape in side plane 48 , which has certain advantages discussed hereinafter.
Those skilled in the art will appreciate that wand head 52 may have a shape in side plane 68 other than that of a modified triangle without departing from the spirit of the present invention.
FIGS. 7 and 8 show cross sectional plan and side views of pet toy 20 taken at lines 7 — 7 and 8 — 8 of FIGS. 2 and 1 , respectively, and demonstrating wand head 52 encompassed with a coupling pocket 74 in accordance with a preferred embodiment of the present invention. FIGS. 9 and 10 show schematic views of FIGS. 7 and 8 , respectively, and demonstrating controlled movement of coupling pocket 74 relative to wand head 52 . The following discussion refers to FIGS. 1 , 2 , 5 , 6 , 7 , 8 , 9 , and 10 .
Flexible coupling 24 is affixed to play object 22 and wand 26 via object and wand collars 30 and 32 . Play object 22 may be aligned so that an object axis 76 extending through a nominal center (not shown) of play object 22 aligns with wand axis 56 . In this discussion, such an alignment is an arbitrary “rest condition,” and is the condition depicted in FIGS. 1 , 2 , 7 , and 8 . When in this arbitrary rest condition, object axis 76 and wand axis 56 are both at the intersection of plan and side planes 46 and 48 .
Coupling body 28 is hollow. Coupling pocket 74 is an internal pocket within coupling body 28 , i.e., within flexible coupling 24 . Those skilled in the art will appreciate that the materials and formation of coupling pocket 74 are discussed herein as being part and parcel with the materials and formation of flexible coupling 24 . While it is desirable that coupling pocket 74 be formed of the same materials as, and coincidentally with the remainder of, coupling body 28 , this is not a requirement of the present invention. For example, in some embodiments, it may be desirable that coupling pocket 74 be separately formed as an insert to be placed within flexible coupling 24 during production. The use of specific materials and/or formation techniques well known to those of ordinary skill in the art does not depart from the spirit of the present invention.
When flexible coupling 24 is formed, coupling pocket 74 is formed and/or placed within coupling body 28 (i.e., within flexible coupling 24 ). When flexible coupling 24 is affixed to wand 26 , wand head 52 is encompassed within coupling pocket 74 and wand collar 32 is affixed to wand shaft 50 proximate wand head 52 .
In the preferred embodiment, coupling pocket 74 is desirably asymmetrical relative to object axis 76 . In plan plane 46 ( FIG. 7 ), coupling pocket 74 desirably has a pocket width 76 greater than base width 58 . Coupling pocket 74 is also desirably formed in plan plane 46 with a shape incorporating a first plan-plane pocket side 78 and a second plan-plane pocket side 80 . Pocket sides 78 and 80 are desirably straight, though this is not a requirement of the present invention.
Coupling pocket 74 is formed so that, when wand head 52 is encompassed within coupling pocket 74 and flexible coupling 24 is deflected in plan plane 46 ( FIG. 9 ) so that one of pocket sides 78 and 80 is substantially parallel with one of head sides 60 and 62 , the other of pocket sides 78 and 80 is aparallel (i.e., not parallel) with the other of head sides 60 and 62 . This is accomplished in the preferred embodiment by forming coupling pocket 74 so that plan-plane sides 78 and 80 are two opposing sides of a modified rectangle.
Those skilled in the art will appreciate that coupling pocket 74 may have a shape in plan plane 46 other than that of a modified rectangle. For example, if wand head 52 were to have the shape of a modified rectangle, then coupling pocket 74 may have the shape of a modified trapezoid to achieve the same ends. Any given set of functional shapes for wand head 52 and coupling pocket 74 may be used without departing from the spirit of the present invention.
By forming coupling pocket 74 so that when pocket side 78 is substantially parallel with head side 60 , pocket side 80 is aparallel with head side 62 , play object 22 is able to pivot relative to wand 26 in plan plane 46 . Because of this, object axis 76 may freely pivot a predetermined plan-plane pivot angle 82 in plan plane 46 relative to wand axis 56 ( FIG. 9 ). In the preferred embodiment, coupling pocket 74 is configured relative to wand head 52 so that object axis 76 may pivot at least ±10° and not greater than ±45° relative to wand axis 56 . Movement of play object 22 relative to wand 26 is therefore at least ±10° but limited to ±45° in plan plane 46 .
By forming wand head 52 in a “spade” shape, i.e., as a modified isosceles triangle having a tangential arcuate base, wand collar 32 may be affixed to wand shaft 50 closely proximate wand head 52 . This allows a greater freedom of movement of coupling pocket 74 with a reduction of material and cost for flexible coupling 24 . Those skilled in the art will appreciate while a spade-shaped wand head 52 is desirable, it is not a requirement of the present invention. Other shapes may be used for wand head 52 without departing from the spirit of the present invention.
In side plane 48 ( FIG. 8 ), coupling pocket 74 desirably has a pocket thickness 84 greater than base thickness 66 . Coupling pocket 74 is also desirably formed in side plane 48 with a shape incorporating a first side-plane pocket side 86 and a second side-plane pocket side 88 . Pocket sides 86 and 88 are desirably straight, though this is not a requirement of the present invention.
Coupling pocket 74 is formed so that, when wand head 52 is encompassed within coupling pocket 74 and flexible coupling 24 is deflected in side plane 48 ( FIG. 10 ) so that one of pocket sides 86 and 88 is substantially parallel with one of head sides 68 and 70 , the other of pocket sides 86 and 88 is aparallel with the other of head sides 68 and 70 . This is accomplished in the preferred embodiment by forming coupling pocket 74 so that side-plane sides 86 and 88 are two opposing sides of a modified rectangle.
Those skilled in the art will appreciate that coupling pocket 74 may have a shape in side plane 48 other than that of a modified rectangle. Any given set of functional shapes for wand head 52 and coupling pocket 74 may be used without departing from the spirit of the present invention.
By forming coupling pocket 74 so that when pocket side 86 is substantially parallel with head side 68 , pocket side 88 is aparallel with head side 70 , play object 22 is able to pivot relative to wand 26 in side plane 48 . Because of this, object axis 76 may freely pivot a predetermined side plane pivot angle 90 in side plane 48 relative to wand axis 56 ( FIG. 10 ). In the preferred embodiment, coupling pocket 74 is configured relative to wand head 52 so that object axis 76 may pivot at least ±5° and not greater than ±30° relative to wand axis 56 . Movement of play object 22 relative to wand 26 is therefore at least ±5° but limited to ±30° in side plane 48 .
By forming wand head 52 in a “spade” shape (i.e., as a modified isosceles triangle having a tangential arcuate base) in plan plane 48 and as a wedge (i.e., as a modified triangle) in side plane 48 , wand collar 32 may be affixed to wand shaft 50 closely proximate wand head 52 . This allows a greater freedom of movement of coupling pocket 74 with a reduction of material and cost for flexible coupling 24 . Those skilled in the art will appreciate while a spade-shaped wedge wand head 52 is desirable, it is not a requirement of the present invention. Other shapes may be used for wand head 52 without departing from the spirit of the present invention.
By allowing play object a movement relative to wand 26 of at least ±10° in plan plane 46 and ±5° in side plane 48 , but limiting that movement to not more than ±45° in plan plane 46 and not more than ±30° in side plane 48 , play toy 20 provides a human the ability to easily and effectively emulate broad prey motions through the gross movements of wand 26 while simultaneously emulating short, quick prey movements through the restricted independent movements of play object 22 on the end of wand 22 . This composite motion directly stimulates the instincts of a cat or other small carnivore and significantly increases the pleasure of play for both human and pet.
The following discussion refers to FIGS. 1 , 3 , 4 , 7 , and 8 .
When pet toy 20 is produced with two-part flexible coupling 24 ″, it is desirable that coupling pocket 74 be integral to wand connector 38 , rather than object connector 36 . This construct provides a maximum of flexibility in that multiple play objects 22 may be utilized with a single wand 22 and associated coupling pocket. Easily changed multiple play objects 22 alloy pet toy to be customized according to the preferences and/or moods of both the human and the pet.
Also, because the pet attacks (i.e., bites or claws) play object 22 but not wand 26 , it is likely that play object 22 will wear out first. The two-piece construct of pet toy 20 permits the replacement of a worn-out play object 22 with a new play object 22 . This allows extension of the life of pet toy 20 into the indefinite future.
In summary, the present invention teaches a pet toy 20 having controlled movement. Pet toy 20 incorporates a play object 22 coupled to the end of a wand 26 in a manner allowing predetermined controlled movement.
Although the preferred embodiments of the invention have been illustrated and 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. | A pet toy ( 20 ) made up of a wand ( 26 ) and a play object ( 22 ) flexibly coupled to an end of the wand ( 26 ) is taught. The wand ( 26 ) has a wand shaft ( 50 ) and a wand head ( 52 ) rigidly affixed to the end of the wand shaft ( 50 ). The wand shaft ( 50 ) has a predetermined shaft diameter ( 54 ). The wand head ( 52 ) has a base width ( 58 ) greater than the shaft diameter ( 54 ). A flexible coupling ( 24 ) flexibly couples the play object ( 22 ) to the wand ( 26 ). The flexible coupling ( 24 ) has a coupling pocket ( 74 ) encompassing the wand head ( 52 ). The coupling pocket ( 74 ) is configured so that the wand head ( 52 ) has limited free movement therein. Motion of the wand ( 26 ) by a human therefore imparts a complex motion to the play object ( 22 ). This complex motion emulates the motion of prey and stimulates the instinct of the pet. | 0 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to solenoid operated valves of the type having a supply or inlet port and a pressure control outlet port and an exhaust port through which fluid is discharged to a sump or pressure source return. Such valves are employed to provide electrical control of a fluid pressure signal by controlling the flow of fluid from the inlet port to a valving chamber communicating with the pressure control port and also controlling the amount of fluid bleed to the exhaust for maintaining the desired pressure at the pressure signal outlet port.
[0002] Solenoid valves of the aforesaid type have found widespread usage in controlling the flow of hydraulic fluid in automatic transmissions for motor vehicles. In such transmissions the shifting of the transmission speed ratios is controlled by an electronic controller providing an electrical signal to the solenoid operated valve which provides a fluid pressure signal to a pressure responsive actuator for effecting the transmission speed ratio change.
[0003] Known valves employed in automatic transmission shift control have utilized a ball valve member disposed in the valving chamber with the ball moved with respect to a valve seat by an operating rod connected to the solenoid armature for controlling flow from the supply port to the valving chamber. However, valves of this type have encountered instability and flutter of the ball valve member upon exposure to hydraulic transients in the system and vibration encountered by the transmission. Efforts to counteract such instability and valve flutter in solenoid operation transmission shift control valves have utilized stiffer bias springs acting against the ball valve. This results in greater force and increased power requirements for the solenoid. For applications requiring a plurality of shift control valves a prohibitively high power consumption for the valves is the result.
[0004] The aforesaid solenoid valves employing a ball valve member have been found particularly susceptible to flutter when the ball valve member is in a position to substantially restrict the flow or near the closed position where the flow velocity is increased over the valve seat. It therefore has long been desired to provide a simple and relatively low cost way or means of reducing or eliminating the flutter in a solenoid operated pressure control valve and particularly valves of the type employing solenoid operating off of low voltage power supply widely employed in motor vehicle applications.
BRIEF SUMMARY OF THE INVENTION
[0005] The present invention provides a solenoid operated pressure control valve having a supply inlet port valved by a raised surface on a pressure responsive member such as a diaphragm, which raised surface forms an obturator moveable with respect to a valve seat. The obturator is contacted by an operating member extending through an exhaust port valve seat in the valving chamber and the operating member is operatively moved by the solenoid armature. The pressure responsive member preferably in the form of an elastomeric diaphragm has the obturator preferably formed by a rigid insert in the central region of the diaphragm. A bleed orifice provides limited flow across the pressure responsive member to provide viscous dampening of the movement of the obturator. Viscous dampening of the movement of the pressure responsive member and obturator render the valve substantially insensitive to instability and flutter when the valve supply port is subject to transients the valve body is subjected to vibration or the valve is in the nearly closed condition.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1 is a cross-section of the valve assembly of the present invention;
[0007] [0007]FIG. 2 is an enlarged view of the lower portion of the body of the assembly of FIG. 1;
[0008] [0008]FIG. 3 is an axonometric view of the pressure responsive member of the assembly of FIG. 1;
[0009] [0009]FIG. 4 is a view similar to FIG. 3 with a portion broken away showing the bleed orifice;
[0010] [0010]FIG. 5 is a view similar to FIG. 1 of an alternate embodiment of the invention with the inlet valve normally open in the de-energized condition; and,
[0011] [0011]FIG. 6 is a view of the valve of FIG. 5 in the energized closed condition.
DETAILED DESCRIPTION OF THE INVENTION
[0012] Referring to FIGS. 1 and 2, the valve assembly of the present invention is indicated generally at 10 and includes a valve body 12 having a supply or inlet preferably comprising a plurality of circumferentially spaced ports 14 which communicate with a valving chamber 16 formed in the lower end of the body and which is closed by a closure member 18 attached to the body by any suitable expedient, as for example, press fit staking or weldment.
[0013] The valving chamber 16 communicates with a valving passage 20 , the lower end of which defines a valve seat 22 and the upper end of passage 20 communicates with an enlarged diameter bore 24 which has pressure control outlet ports 26 communicating therewith.
[0014] The upper end of enlarged bore 24 communicates with an exhaust chamber 28 which has exhaust ports 30 formed therein for discharge to a sump or the source or supply return. The pressure control outlet ports 26 are isolated from the exhaust ports 30 and the inlet supply ports 14 by a pair of resilient seal rings 32 , 34 disposed in spaced relationship on opposite sides of the pressure control ports 26 in annular grooves 36 , 38 formed in the outer surface of the body 12 .
[0015] A pressure responsive member preferably in the form of an elastomeric diaphragm 40 is disposed in the valving chamber 16 and sealed and retained therein by closure member 18 contacting the undersurface of the periphery of the diaphragm 40 .
[0016] Referring to FIGS. 2 through 4, the diaphragm 40 has a raised surface 42 on the upper side thereof and preferably centrally located, which surface 42 forms a moveable obturator for contacting inlet valve seat 22 . In the presently preferred practice of the invention, as shown in FIGS. 3 and 4, the obturator 42 is formed on a rigid insert 44 disposed in the central region of the diaphragm 40 and which has a small aperture or bleed orifice 46 formed therein. In the presently preferred practice of the invention, the insert 44 may be formed of plastic or metal as required for withstanding the pressure forces to be encountered in its intended application.
[0017] A bias spring 48 is disposed in valving chamber 16 with the lower end thereof registered against the inside surface of closure 18 and the upper end thereof registered against the undersurface of the insert 44 for biasing the obturator 42 in a direction so as to contact and close against inlet valve seat 22 thereby forming a normally closed valve assembly.
[0018] Referring to FIG. 1, a solenoid operator indicated generally at 50 has a coil bobbin 52 with coil 54 wound thereon received over a flux ring or collector 56 attached to the upper end of body 12 , with the lower end of bobbin 52 received thereover and registered thereagainst. An upper flux collector or ring 58 is partially received within the upper end of bobbin 52 ; and, the flux rings 56 , 58 and bobbin 52 are retained on body 12 as an assembly by an outer casing 60 having radially inwardly extending end flanges 61 , 63 .
[0019] A moveable armature 62 is slidably disposed within the upper flux collector 58 and has the lower end thereof defining a working air gap with the upper end of the lower flux collector 56 .
[0020] An operating member or rod 64 is received through armature 62 and secured thereto for movement therewith, with the upper end of rod 64 slidably received in a bearing 66 ; and, the rod 64 extends downwardly through sliding bearing 68 disposed in lower flux collector 56 . Rod 64 extends downwardly into exhaust chamber 28 and into enlarged bore 24 . The lower end of rod 64 has a reduced diameter pin portion 70 formed thereon which extends downwardly through valving passage 20 with the end thereof disposed for contacting obturator 42 .
[0021] The portion of operating member or rod 64 extending into the exhaust chamber 28 has formed thereon an annular flange 72 which has the undersurface 73 thereof configured to act as a poppet for seating against an annular exhaust valving surface 74 formed at the upper end of the enlarged bore 24 .
[0022] In operation, the normally closed valve 10 has the obturator 44 seated against valve seat 22 with the solenoid operator 50 de-energized; and, the pin 70 is in contact with the obturator 42 such that surface 73 of poppet 72 is raised from valve seat 74 permitting the pressure control outlet ports 26 to be open to the exhaust ports 30 and thus no pressure signal provided at ports 26 . Upon energization of the solenoid operator 50 , the arrangement of flux ring 58 and 56 is such that lower flux ring 56 acts as a pole piece attracting the armature 62 ; and, armature 62 is moved downwardly by overcoming the bias force of spring 48 tending to close the air gap between the lower surface of armature 62 and the upper end of lower flux ring 56 such that pin 70 progressively moves obturator 42 away from seat 22 and moves poppet 72 closer to valve seat 74 reducing flow to the exhaust and thereby increasing the pressure to the pressure control outlet ports 26 . When the undersurface 73 of poppet 72 contacts valving seating surface 74 and closes the exhaust ports 30 from the pressure control ports 26 , obturator 42 is held away from seat 22 permitting full supply pressure to be applied to the signal control outlet port 26 .
[0023] The bleed orifice 46 permits a small amount of flow therethrough from opposite sides of the diaphragm 40 as the diaphragm is moved. This viscous flow enables the diaphragm to absorb transients thereagainst as may enter the supply ports 14 and provides dampening of the movement of the obturator 42 .
[0024] Referring to FIGS. 5 and 6, an alternate embodiment of the valve assembly of the present invention is indicated generally at 80 and is shown in FIG. 5 in the de-energized normally open condition; and, the assembly 80 is shown in FIG. 6 in the energized condition with the inlet closed.
[0025] The assembly 80 is similar to the assembly 10 of FIGS. 1 through 4 with the exception that the annular armature 82 with operating rod 84 received therethrough and secured for movement therewith has the upper end of a spring 86 registered against the upper bearing 88 with the lower end of the spring 86 registered against the upper end of armature 82 and biasing the armature and operating rod 84 in a downward direction.
[0026] As in the case of the embodiment 10 of FIGS. 1 through 4, the embodiment 80 of FIGS. 5 and 6 has the operating rod 84 provided with an annular valving surface 90 for closing against the exhaust valve seat 92 for controlling flow to the exhaust port 94 . The lower end of rod 84 has a pin 98 provided thereon for extending downwardly through passage 100 which has a valve seat 102 formed on the undersurface thereof against which is moved an obturator 104 for closing against valve seat 102 . The obturator is attached to a pressure responsive diaphragm 106 which is similar to the diaphragm 40 of FIGS. 3 and 4. The obturator 104 thus controls flow between the supply pressure inlet ports 108 and the passage 100 which communicates with the control pressure signal outlet ports 94 .
[0027] A relatively light or low rate spring 110 biases the obturator and diaphragm upwardly in a direction to maintain contact with the end of pin 98 .
[0028] As shown in FIG. 5, with the coil 112 de-energized spring 86 provides sufficient preload to overcome the force of spring 110 and causes the pin 98 to move obturator 104 away from the valve seat 102 .
[0029] Referring to FIG. 6, the valve is shown with coil 112 energized wherein upper flux ring 114 acts as a pole piece attracting armature 82 ; and, armature 82 is moved upward overcoming the preload force of spring 86 and raises the valving surface 90 from valve seat 92 and allows flow from the pressure control ports 94 to the exhaust ports 93 and moves obturator 104 toward valve seat 102 to restrict flow from the inlet ports 108 through passage 100 . When the coil 112 is fully energized pin 98 is lifted sufficiently to allow obturator 104 to be biased against the valve seat 102 by spring 110 thereby closing flow from inlet 108 through passage 100 . With the inlet valve seat 102 closed, pressure in pressure control ports 94 is bled through the exhaust ports 93 until there is no control signal outlet pressure.
[0030] It will be understood that a bleed orifice 107 is provided in diaphragm 106 , similar to orifice 46 in diaphragm 40 of FIGS. 3 and 4; and, orifice 107 functions to provide viscous dampening of the movement of the obturator thereby minimizing inlet valve flutter.
[0031] The present invention thus provides a simple and low cost valve construction employing a pressure responsive diaphragm with a bleed orifice therethrough having the inlet valve obturator moveable therewith and thus the bleed orifice is operative to dampen movement of the obturator.
[0032] Although the invention has hereinabove been described with respect to the illustrated embodiments, it will be understood that the invention is capable of modification and variation and is limited only by the following claims. | A solenoid operated three port pressure control valve assembly of the exhaust pressure bleed type. The valve for the inlet pressure supply port includes a pressure responsive diaphragm with the supply port obturator attached. A bleed orifice in the diaphragm provides viscous dampening of the movement of the obturator and minimizes inlet valve flutter. The valve assembly is disclosed in both normally open and normally closed configurations. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to database management systems performed by computers. In particular, it concerns a technique for enforcing temporal uniqueness in an object or relational database management system environment.
2. Description of Related Art
Databases are computerized information storage and retrieval systems. An Object Relational Database Management System (ORDBMS) is a database management system (DBMS) which uses relational techniques for storing and retrieving objects. These databases are organized into tables which consist of rows and columns of objects, or data. A database will typically have many tables and each table will typically have multiple rows and columns.
ORDBMS software using a Structured Query Language (SQL) interface is well known in the art. The SQL interface has evolved into a standard language for RDBMS software. SQL has been adopted as such by both the American National Standards Organization (ANSI) and the International Standards Organization (ISO).
All data in ORDBMS software is externally structured into tables. The SQL interface allows users to formulate relational operations on tables. This can be done either interactively, in batch files, or embedded in host language, such as C, COBOL, .etc. Operators are provided in SQL that allow the user to manipulate the data. The power of SQL lies in its ability to link information from multiple tables or views together to perform complex sets of procedures with a single statement.
Temporal data is often used to track the period of time at which certain business conditions are valid. Several common forms of data analysis involve evaluating time-related data. Examples are examining customer buying behavior, assessing the effectiveness of marketing campaigns, and determining the impact of organizational changes on sales during a selected time period.
It is often desirable when working with temporal data to ensure integrity for time periods in which conditions will be valid. Unfortunately, conventional techniques used to support uniqueness of non-temporal data fail to work when temporal data is involved. This is because they do not include software needed for verifying and enforcing the temporal uniqueness constraint. For example, a firm may wish to have its DBMS enforce the temporal uniqueness constraint so that “employees cannot earn multiple salaries during the same period of time” or “departments can only report to one division during any given period of time.”
In non-temporal DBMS environments, data uniqueness is often guaranteed by defining one or more columns to serve as the primary key and/or defining a unique index on the appropriate columns. However, because commercial object or relational DBMS do not understand the underlying semantics of temporal data, these techniques cannot enforce temporal uniqueness. Thus, data that is considered invalid from a business point of view can be readily stored in a DBMS environment without error. This would violate the integrity rules that a firm may wish to enforce and render subsequent analysis of its data misleading or useless.
While there have been various techniques developed for enforcing temporal uniqueness in a DBMS environment, there is a need in the art for an approach which is cost-effective for vendors to implement and that integrates easily into existing object or relational DBMS environments of customers.
SUMMARY OF THE INVENTION
The foregoing and other objects, features, and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments, which makes reference to several figures.
The present invention enforces temporal integrity for valid time data. The technique consists of implementing user-defined functions with templates for triggers and setting constraints to dictate the conditions for the temporal data. Together, these support many forms of temporal analysis and help enforce the fundamental aspects of temporal integrity. Among these aspects are temporal uniqueness, which refers to data that is time period exclusive.
The present invention ensures the integrity of temporal data in object or relational database management systems. Temporal and non-temporal data are organized into data objects in databases, each data object comprised of at least one row and at least one column. A data object may also be a table containing data. When a user attempts to insert new data into a data object in which temporal uniqueness is a consideration, or when a user attempts to update existing data in a data object in which temporal uniqueness is a consideration, the present invention operates to provide a barrier against inserts or updates that would violate the temporal integrity of the existing data.
All functions include error-checking logic to verify that the start and end points of a time period constitute a valid time period. For example, if the database uses dates to track temporal data and employs a “closed, open” temporal representation, start dates should be less than end dates. Such error-checking logic is built into the functions. However, to avoid populating temporal tables with invalid time periods, it is recommended that CHECK constraints be defined on relevant time-related columns (such as columns that contain date information).
The present invention helps users enforce temporal uniqueness by providing trigger templates and CHECK constraints.. One preferred embodiment includes a combination of CHECK constraints and triggers. Since determining the correct logic to implement and successfully code this logic can be a rather challenging and error-prone experience for many users, the present invention simplifies the process by providing templates in a sample database. By substituting appropriate table and column names for those provided with the sample database, users can easily instruct the DBMS to enforce temporal uniqueness for those tables in which they deem such a constraint to be important.
The present invention may also be packaged as a DBMS system extender. The extender may be provided to users of ORDBMS systems desiring to enforce temporal integrity of data within their system environments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a block diagram overview of the system for enforcing integrity of temporal data usable in the present invention;
FIG. 2 is a table of common operators that may be used in conjunction with one aspect of the present invention;
FIG. 3 is a table of user-defined functions that may be used in conjunction with one aspect of the present invention. FIGS. 3 (A) through 3 (F) are scalar user-defined functions, while FIGS. 3 (G) and 3 (H) are table user-defined functions;
FIG. 4, consisting of FIGS. 4 (A), 4 (B), 4 (C) and 4 (D), show update trigger scenarios illustrating conditions by which the present invention operates within the database management system environment; and
FIG. 5, consisting of FIGS. 5 (A), 5 (B) and 5 (C), are a continuation of the triggers of FIG. 4, showing additional update trigger scenarios which may occur within the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description of the preferred embodiments reference is made to the accompanying drawings which form the part thereof, and in which are shown by way of illustration specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural and functional changes may be made without departing from the scope of the present invention.
The present invention discloses a system, method and extender for enforcing temporal data integrity in object or relational database management system environments. The preferred embodiments of the present invention relate in general to database management systems performed by computers, and in particular to a technique for enforcing temporal uniqueness in an object or relational DBMS environment. The present invention provides a trigger-based solution which is a relatively inexpensive development alternative. It affords the user complete control over deployment, and allows users to customize any action taken automatically by the DBMS. It is based on a combination of trigger-based logic, user-defined functions, and a routine to implement CHECK constraints.
This approach provides users with maximum flexibility by enabling them to determine which tables, if any, should be the subject of temporal uniqueness constraints. Users may also customize DBMS actions to be taken if a violation is detected, and inspect SQLSTATE errors to determine the exact nature of the condition that would cause a temporal integrity violation to occur, so that subsequent modifications can be made to avoid the problem in the future.
It should be noted that although many descriptions of this invention contained herein refer to temporal data in terms of dates or points in time, other units of measure, or other levels of temporal granularity, can be supported. These include but are not limited to more precise units of measure, such as timestamps, as well as less precise units of measure, such as data based on quarterly or annual information. However, since date-level granularity is arguably easier to understand and is the preferred form of temporal granularity for many business applications, it is a preferred embodiment of this invention and is frequently used to explain subsequent details about this invention.
FIG. 1 shows a block diagram representation of one preferred embodiment of the present invention. Referring to FIG. 1, a user of the system provides a condition that the time period start dates must be less than the time period end dates. This is shown in Block 102 . The user also provides a set of routines to verify that additions or changes to the data object will not violate temporal uniqueness. This is shown in Block 104 . Block 102 may be accomplished using a user-defined CHECK constraint providing the initial condition that temporal integrity is to be preserved. Block 104 may be accomplished by using the trigger templates provided as part of the invention. The trigger templates verify the subsequent conditions necessary to ensure that temporal integrity is preserved. Next, the user enters new data or updates existing data in a database management system as shown in Block 106 . The method of entry may be performed by computerized means, for example at a personal computer or over a workstation platform. When an insert of new data or an update of existing data is attempted, a time period comparison may be initiated between the attempted data entry or update and the existing temporal data as shown in Block 108 . The initiation of a comparison may be in the form of triggers within the database system that execute automatically when an attempt is made. Once an initiation is commenced, user-defined functions operate, to perform the actual comparisons of time period start dates and end dates. This is shown in Block 110 . After the time period comparisons are performed, the system disallows an attempted insert or update if temporal integrity is to be violated. This is shown in Block 112 .
The triggers utilize user-defined functions to test for whether a time period shares a time component with another time period. The user-defined functions utilize several operators. Among these operators are those listed in FIG. 2 . These operators, known collectively as Allen's operators, determine the appropriate logic function to be performed in the time period comparison by the user-defined function. For example, they perform comparisons between the start dates to determine if time periods meet, overlap, or equal each other. These operators, and others described herein, operate with the user-defined functions when triggered by an attempted insert of new data or update of existing data.
One of the user-defined functions, the SHARES function, is used by each of the triggers to determine whether a time period shares a time component with another time period. The SHARES function is described separately in a co-pending patent application by the same inventor herewith filed Jan. 28, 2000 and entitled Technique For Detecting A Shared Temporal Relationship Of Valid Time Data In A Relational Database Management System. The serial number of this co-pending patent application is, 09/494,325; Its description is incorporated herein by reference.
Other operators which may be used by the user-defined functions include WITHIN, SHARES, MERGES, INTERSECT and UNION. The WITHIN operator returns a true output if time period X is wholly or partly contained within time period Y. It combines the EQUAL, DURING, STARTS, and FINISHES operators into one operator. The SHARES operator returns a true output if time period X shares a time component with time period Y. Like WITHIN, it combines the EQUAL, DURING, STARTS, and FINISHES operators into one, and further adds X OVERLAPS Y and Y OVERLAPS X. The MERGES operator returns true if time period X MEETS or SHARES a time component with time period Y. The INTERSECT operator returns the maximum (latest) start date and minimum (earliest) end date of two time periods if time period X SHARES a time component with time period Y. The UNION operator returns the minimum (earliest) start date and the maximum (latest) end date of two time periods if these time period MEET or SHARE a time component.
In one preferred embodiment, each trigger is coded to raise a different SQLSTATE error and disallow attempted changes that would violate temporal uniqueness. However, users can modify this behavior of the trigger-based logic, if desired. This may be accomplished by altering the method in which the database management system operates when an attempt is disallowed. For example, the DBMS could be programmed to override the system if a user was not concerned with temporal integrity by disabling the trigger templates. A user may also wish to bypass the entire system of the present invention to disable the behavior of the triggers when entering new data or updating existing data in a data object. Another method involves formulating relational operations either interactively, in batch files, or embedded in a host language. The SQL interface therefore provides operators that allow users to manipulate data and modify the performance of the system.
The trigger-based logic is coded into several routines. One routine supports INSERT row instructions while other routines support UPDATE row instructions. The INSERT trigger routine tests for a match between the primary key of the new row and primary key values of the existing rows. Furthermore, it uses the SHARES function to check if the time period on the new row shares any time in common with time periods already in existing rows that have the same primary key value. If one or more rows exist in the data object that would cause both these tests to evaluate as true, a SQLSTATE error (e.g., SQLSTATE 70100) is raised.
In a DBMS that supports temporal data, the primary key signifies data values that should be unique in a data object over time. If a user attempts to insert new data into the data object, the INSERT trigger begins by comparing the new primary key value with existing primary key values. If a match is found, the trigger initiates additional routines for testing the period start and end dates associated with the new primary key value to ensure that there is no time shared with the start and end dates of any existing data in the data object that contains the same primary key value. If this condition were to occur, it would violate temporal uniqueness and the INSERT trigger would raise an error condition to prevent the INSERT operation from proceeding.
The UPDATE trigger routines test for a unique type of temporal change that might be expressed in the updated row, and could lead to a temporal integrity violation. A preferred embodiment of the present invention may include several UPDATE triggers testing for different conditions. These are listed in FIGS. 4 and 5. Another preferred embodiment includes a single UPDATE trigger consolidating all testing conditions. Consolidation adds complexity to developing, debugging, and maintaining such a trigger.
FIGS. 4 and 5, consisting of FIGS. 4 (A), 4 (B), 4 (C) and 4 (D), as well as 5 (A), 5 (B), and 5 (C), list the several types of temporal updates which might be expressed in the updated row that could result in integrity violations. Each sub-figure illustrates a different type of update that would trigger a comparison of data. Each such BEFORE UPDATE trigger provided in the software of the preferred embodiment of the present invention is described in FIGS. 4 and 5. For each description, “n” is a variable referring to the new version of the updated row and “o” is a variable referring to the old version of the row being updated. In addition, “'s” refers to the column name containing the start date of the period and “e” refers to the column name containing the end of the period.
Another kind of update attempt that involves the primary key can potentially cause temporal uniqueness to be violated. This involves non-temporal data in the primary key column. Additional trigger logic is provided for updates of non-temporal primary key data such that if an updated row shares a time component with the existing rows in the data object that have the same primary key values, SQLSTATE 70008 is raised.
Other user-defined functions may also be combined with triggers to determine whether various temporal conditions are valid, such as whether one time period shares a time component with another time period. Examples of these user-defined functions are listed in the table in FIG. 3 . Referring to FIG. 3 (A), the WITHIN function is satisfied if period 1 is DURING, STARTS, FINISHES, or EQUAL period 2 . The specific logical implementation of this function is: if date 1 >=date 3 AND date 2 <=date 4 , return 1; else return 0. In FIG. 3 (B), the SHARES function is satisfied if period 1 EQUAL, OVERLAP, STARTS, FINISHES, or DURING period 2 , or period 2 OVERLAP, STARTS, FINISHES, or DURING period 1 . The specific logical implementation of this function is: if (date 1 <date 4 AND date 3 <date 2 ) or (date 1 =date 3 AND date 2 =date 4 ) return 1; else return 0.
In FIG. 3 (C), the INTERSECT_START function is satisfied if the periods SHARE a time component. If they do, the function returns the start date of the intersection of these periods (maximum of date 1 , date 3 ). Otherwise, it returns null. The INTERSECT_END function in FIG. 3 (D) is also satisfied if the periods SHARE a time component. If they do, the function returns the end date of the intersection of these periods (minimum of date 2 , date 4 ). Otherwise, it returns null.
The UNION_START function as described in FIG. 3 (E) is satisfied if the periods SHARE a time component or if the periods MEET. The function returns the start date of the union of these periods (minimum of date 1 , date 3 ) if the condition is satisfied. Otherwise, it returns null. In FIG. 3 (F), the UNION_END function is satisfied if the periods SHARE a component or if the periods MEET. The function returns the end date of the union of these periods (maximum of date 2 , date 4 ) if the condition is satisfied. Otherwise, it returns null.
The INTERSECT function in FIG. 3 (G) is satisfied if the periods SHARE a time component, and returns the start and end dates of the intersection of these periods (maximum of date 1 , date 3 and minimum of date 2 , date 4 ). Otherwise, it returns null. In FIG. 3 (H), the UNION function is satisfied if the periods SHARE a time component or if the periods MEET. In this case the function returns the start and end dates of the union of these periods (minimum of date 1 , date 3 and maximum of date 2 , date 4 ). Otherwise, it returns null.
The CHECK constraint software routine is useful for both temporal uniqueness as well as general data integrity. It tests whether the starting or beginning point or date of a period is less than the ending point or date of a period. In addition, the columns considered to constitute the temporal primary key must be defined as NOT NULL. If defined otherwise, temporal uniqueness cannot be guaranteed. Primary key data is data used to signify the beginning of a time period. The CHECK constraint and the trigger functions use the primary key for determining where to begin a comparison of time period data starting and ending points.
In another preferred embodiment of the present invention, the system can be packaged into a DBMS extender for users to plug into existing DBMS environments. The extender includes the system and method of enforcing temporal data. Users desiring to enforce temporal data in their respective system environments can therefore utilize the system or method manually or choose to utilize the packaged system extender for accomplishing temporal integrity.
The foregoing description of the preferred embodiments of the invention have been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto. | A system, method and program extender for enforcing the uniqueness of temporal data in an object/relational database management system is provided. There is a combination of user-defined functions, triggers and specified conditions to determine if attempts to insert new data or update existing data in a data object in which temporal integrity is a consideration are valid. Barriers exist to protect against inserts or updates that would violate the temporal integrity of the existing data. Also included are ways for a user to modify the behavior of the system or method to override triggers for cases in which temporal integrity is not desired. | 8 |
FIELD OF THE INVENTION
The present invention relates to a method for insertion of a transponder into a living being using a guide near the base of the ear.
BACKGROUND OF THE INVENTION
Transponders are inserted into living beings for the purpose of being able to identify them. A transponder is a transmitter-receiver unit with a memory accommodated in a housing. When the antenna belonging to it is radiated from outside, the stored data are sent out by the transmitter unit, so that remote identification of the animals in question can take place. The stored data are unique for each animal through the coding used. Guns provided with a needle-shaped guide are generally used for the insertion of transponders. An opening is made in the skin in one way or another with said needle-shaped guide, following which the guide is inserted further into the body of the animal in question. The transponder is then ejected by the guide, either by means of a bar or by means of fluid pressure.
One method of injection discloses in particular an insertion point for living beings, such as pigs, behind the ear. Although this method of insertion was found to be satisfactory for many animals, it was found that it was unsuitable for animals with moving ears, such as cattle. Unlike pigs, cattle move their ears to a considerable extent, and such animals also have the habit of rubbing their heads along bars of feeder units and the like. These movements cause damage to the transponder and/or force it out of the body. There is also the disadvantage of the transponder being relatively easily accessible.
SUMMARY OF THE INVENTION
The object of the present application is to avoid these disadvantages and to provide an insertion point for transponders for cattle.
This object is achieved in the case of a method described above in that the insertion point of the guide into the skin is situated between the base of the earflap and the part of the triangular piece of cartilage lying closest to the skin (the cartilago scutiformis). This triangular piece of cartilage or scutiform cartilage is a typical phenomenon in cattle. It is a loose part and is situated on the top side of the base of the ear. It is surrounded by the muscles of the earflap and the masticatory muscles. The triangular piece of cartilage can be felt easily from the outside and lies with the base against the skull and with the tip against the earflap. The triangular piece of cartilage is easy to find by feeling the animal in the area around the earflap, so that the insertion point is established unequivocally.
It has been found that, when the transponder is inserted in place, movements of the ear and rubbing of the head along bars and other rough objects does not have any effect on movement away of the transponder.
Terms such as in front of and behind etc. in the description and claims must be understood as based on the position of the animal.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to an advantageous embodiment, the insertion direction of the guide is essentially parallel to the triangular piece of cartilage.
The position of the transponder under the triangular piece of cartilage can be any imaginable one. In order to achieve this, the direction of the guide can vary from perpendicular to the lengthwise direction of the living being to essentially parallel to the lengthwise direction of the living being. Fitting the transponder perpendicular to the living being has the advantage that reading thereof is easier if one is near the animal. On the other hand, there is the risk, in particular in the case of young animals, of the skull being hit. In order to avoid this, it is preferable to insert the guide parallel to the lengthwise direction of the animal. In all cases the insertion path of the guide extends under the triangular piece of cartilage. The insertion point of the transponder preferably lies past the triangular piece of cartilage in line with the insertion path of the guide. In this position it has been found that the transponder will not start to "stray", even a long time after placing. This means that after slaughter of the animal it is extremely simple to find the transponder, and it is ensured that the latter is not in different a place. In this way the transponder is also fitted in a place which cannot be felt, and which is extremely difficult to reach if the animal is still alive. This prevents fraud with transponders. The insertion point of the guide into the skin is preferably situated on or in front of the central axis of the earflap.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained below in greater detail with reference to an example of an embodiment shown in the drawing, in which:
FIG. 1 shows the head of an animal in side view;
FIG. 2 shows the head from FIG. 1 in top view; and
FIG. 3 shows a cross-section along the line III--III in FIG. 2, the insertion of a transponder also being shown schematically.
In FIG. 1 the head of an animal is indicated in its entirety by 1. The ear is indicated by 2, and the insertion point for a transponder is indicated by 3. This is illustrated again in FIG. 2, which is a top view of FIG. 1. The triangular piece of cartilage is indicated schematically therein by 4. This is also known by the names of "scutilum" and "scutiform cartilage". This triangular piece of cartilage 4 extends approximately parallel to the skin between the base of the earflap and the skull. The cartilage of the earflap is indicated by 8. This is also illustrated in FIG. 3. This figure shows an injector 5 provided with an insertion needle 6 for transponders 7. The injector 5 is inserted into the skin in front of the central axis of the earflap. The transponder is shown in the brought-out position, i.e. in the final position. It can be seen that it is provided extremely well protected, a little past the triangular piece of cartilage 4. It has been found that when the transponder is fitted in this way it does not become lost if the animal moves, for example between bars of a feeder unit, and when it flaps over its ears on moving back. Owing to the relatively protected place, it is also difficult to remove the transponder from the living being for fraudulent purposes. Fitting it in the head part means that automatic recognition is possible at automatic feeder stations. In this way, when the animal approaches the feed supply point it is possible to set the feed supply in operation by means of electronic recognition. On the other hand, after slaughtering it is simple to find the transponder again. It has been found that the transponder does not shift during the life of the animal. The transponder can be removed here when the ear of the animal is cut off. The tissue in which the transponder is fitted and the tissue directly surrounding it is not used directly for human consumption, but only after further processing. Consequently the value of the carcass is not adversely affected, and the chance of the transponder inadvertently going into the human consumption circuit on slaughter is minimal. The insertion position is shown essentially at right angles to the longitudinal axis of the animal here, but it must be understood that it is important only that the transponder should be under the triangular piece of cartilage. The needle 6 can therefore also be inserted in other positions, up to parallel to the lengthwise direction of the animal.
Although the insertion point described above is preferred, it must be understood that numerous modifications which lie within the scope of the appended claims can be made. | Method for inserting of a transponder into a living being using a guide. Introduction of the transponder is effected near the base of the ear. The guide (needle) is inserted in a position into the skin being situated between the base of the ear flap and the part of the triangular piece of cartilage (the cartilago scutiformis) lying closest to the skin. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a National stage application filed under 35 U.S.C. 371 and claims the benefit of priority to Patent Cooperation Treaty Application Number PCT/JP2005/006402 filed Mar. 31, 2005, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a quick freezing apparatus and a quick freezing method making it possible to suppress as much as possible deformation and deterioration of an object-to-be-frozen (for example, a food product, a food ingredient, medical product, a medicine, a living tissue, or a living cell) required to be preserved for a long term.
2. Description of the Related Art
Conventionally, various freezing methods and freezing apparatuses have been developed in order to realize storing of a food product or a food ingredient while keeping its freshness and quality at a high standard. As a technology enabling even a living cell to be frozen-preserved/stored, International Publication No. WO01/024647 discloses a quick freezing method and an apparatus therefor, which have been proposed by the inventor of the present application.
This quick freezing apparatus includes a freezing store capable of lowering a temperature inside the store to a temperature of −30 degrees C. to −100 degrees C., a fluctuating magnetic field generator for applying a unidirectional magnetic field whose strength fluctuates within a predetermined range in both of the positive and negative directions relative to any fixed value set as a reference value, a fan for circulating cold air in the freezing store at a wind velocity of 1 to 5 m/sec, a sound wave generator for superimposing a sound wave within the audio frequency range onto the cold wind circulated by the fan, and an electric field generating device for applying an electric field to the inside of the freezing store.
This freezing apparatus has achieved a significant result in preserving a food ingredient or a food product while keeping its freshness.
Patent Document 1: International Publication No. WO01/024647.
SUMMARY OF THE INVENTION
Problems to be Solved by the Invention
Meanwhile, in recent years, objects to be frozen-preserved are not limited to food products and food ingredients, and the range thereof has greatly extended to include medical products, medicines, living tissues, living cells and so on. Therefore, there has grown a strong demand for the development of a freeze-preserving method and a freezing apparatus capable of preventing deformation and deterioration more effectively.
For example, as regards living tissues, a treatment in which the preservation term of a living tissue is set to a long period of several years to several decades and the living tissue is then used in regeneration therapy is about to become feasible. Specifically, in the dentistry field, tooth regeneration, i.e., extracting a person's tooth such as a wisdom tooth when the person is still young, freeze-preserving it for more than several decades, and then using it for the regeneration therapy, is extremely close to practical use.
However, even the above-mentioned heretofore quick freezing technology is still not effective enough in terms of suppressing deformation and deterioration when the purpose is freeze-preserving a living tissue/cell or the like for such a long term as that described above in order to carry out the transplantation or regeneration therapy, and this technology leaves room for improvement. That is, subsequent research and development has revealed that if the purpose is regeneration therapy, it is necessary to suppress even deformation and deterioration caused by a subtle reaction that proceeds during freezing and preserving processes between an object-to-be-frozen and a gas in a preservation atmosphere surrounding the object, such as water evaporation or oxidization, or caused by a harmful substance or the like emitted from the object itself.
The present invention has been contrived in consideration of the above-mentioned circumstance, and one object thereof is to provide a quick freezing apparatus and a quick freezing method making it possible to suppress even a subtle reaction between an object-to-be-frozen and a gas in a preservation atmosphere surrounding the object to prevent, as much as possible, deformation and deterioration of the object-to-be-frozen and freeze-preserve the object maintaining its freshness and quality at a high standard for a long term, and thereby applicable to long-term preservation of a living tissue.
Means for Solving the Problems
To achieve the foregoing objects, a quick freezing apparatus and a quick freezing method according to the present invention include one or more of the following features:
A quick freezing apparatus according to the present invention includes a freezing store main body with a door for bringing in or taking out an object-to-be-frozen, a freezer capable of lowering a temperature inside the freezing store to a temperature equal to or less than approximately −30 degrees C., a pressure regulator capable of adjusting a gas pressure inside the freezing store, and a ventilator for sending cold air at a wind velocity of 1 to 5 m/sec to the object-to-be-frozen placed in the freezing store.
In some embodiments, the pressure regulator may be a pressurizer for increasing the inside gas pressure to a pressure equal to or more than atmospheric pressure by supplying a pressurized gas into the freezing store.
In other embodiments, the pressure regulator may be a depressurizer for decreasing the inside gas pressure to a pressure equal to or less than atmospheric pressure by drawing the inside gas.
In still other embodiments, the pressure regulator may include both of a pressurizer for increasing the inside gas pressure to a pressure equal to or more than atmospheric pressure by supplying a pressurized gas into the freezing store, and a depressurizer for decreasing the inside gas pressure to a pressure equal to or less than the atmospheric pressure by drawing the inside gas.
Preferably, the pressure regulator may include an actuation controller for detecting the temperature inside the freezing store; if the inside temperature is equal to or more than a predetermined temperature, then actuating the depressurizer to decrease the inside gas pressure to a pressure equal to or less than the atmospheric pressure; and when the inside temperature drops below a predetermined value, stopping the depressurizer and actuating the pressurizer to increase the inside gas pressure to a pressure equal to or more than the atmospheric pressure.
In some embodiments, the pressurizer may include a pressurizing pump, and a gas introduction path of the pressurizing pump may be connected to a circulating path through which the gas inside the freezing store is circulated.
In some embodiments, the depressurizer may include a suction pump, and a discharge side of the suction pump may be connected to a circulating path through which a sucked gas is circulated to the inside of the freezing store.
In other embodiments, the pressurizer may include a pressurizing pump and the depressurizer may include a suction pump, and a discharge side of the suction pump may be connected to a circulating path through which a sucked gas is circulated to a gas introduction path of the pressurizing pump.
Further, a sterilizer may be provided on the gas circulating path of the pressurizer.
Similarly, a sterilizer may be provided on the gas circulating path of the depressurizer.
Further, an oxygen absorber may be provided on the gas circulating path of the pressurizer.
Similarly, an oxygen absorber may be provided on the gas circulating path of the depressurizer.
Further, a gas supply source for selecting and supplying any gas suitable for the object-to-be-frozen such as a nitrogen gas may be provided to the gas circulating path of the pressurizer.
The quick freezing apparatus may further include a gas introducer for, when the door of the freezing store is being opened, supplying into the freezing store any gas suitable for the object-to-be-frozen such as a nitrogen gas to increase the inside gas pressure back to an atmospheric pressure level.
The quick freezing apparatus may further include a gas curtain unit provided near a door opening of the freezing store for producing a layered gas flow from the upper side toward the lower side, wherein the layered gas flow prevents the outside gas from mixing with the inside gas when the door is opened.
Further, an oxygen absorber may be disposed in the freezing store.
Further, a sterilizer may be disposed in the freezing store.
Preferably, the freezing store may include a static magnetic field generator for applying a static magnetic field with a strength of any fixed value to the object-to-be-frozen inside the freezing store, a fluctuating magnetic field generator for applying to the object-to-be-frozen inside the freezing store a fluctuating magnetic field fluctuating within a predetermined range in the positive and negative directions relative to any fixed value set as a reference value, an electric field generator for applying an electric field to the object-to-be-frozen inside the freezing store, and a sound wave generator for superimposing a sound wave within the audio frequency range onto the cold air.
A quick freezing method according to the present invention includes maintaining a temperature of approximately −30 degrees C. or less as a temperature inside a freezing store which includes a door for bringing in and taking out an object-to-be-frozen, increasing a gas pressure inside the freezing store to a pressure more than atmospheric pressure, and freezing the object-to-be-frozen while sending cold air at a wind velocity of 1 to 5 m/sec to the object-to-be-frozen placed in the freezing store.
Another quick freezing method according to the present invention includes maintaining a temperature of approximately −30 degrees C. or less as a temperature inside a freezing store which includes a door for bringing in and taking out an object-to-be-frozen, decreasing a gas pressure inside the freezing store to a pressure less than atmospheric pressure, and freezing the object-to-be-frozen while sending cold air at a wind velocity of 1 to 5 m/sec to the object-to-be-frozen placed in the freezing store.
It is preferable to maintain a temperature of approximately −30 degrees C. or less as a temperature inside a freezing store which includes a door for bringing in and taking out an object-to-be-frozen; decrease a gas pressure inside the freezing store to a pressure less than atmospheric pressure until a gas temperature inside the freezing store drops to a predetermined temperature; once the inside temperature drops to the predetermined temperature, increase the inside gas pressure to a pressure equal to or more than the atmospheric pressure; and freeze the object-to-be-frozen while sending cold air at a wind velocity of 1 to 5 m/sec to the object-to-be-frozen placed in the freezing store.
In increasing the inside gas pressure, it is preferable to compress any gas suitable for the object-to-be-frozen such as a nitrogen gas and supply it into the freezing store.
It is preferable, in decreasing the inside gas pressure, to suck the gas inside the freezing store with a suction pump to decrease the pressure; and in opening the door, to supply any gas suitable for the object-to-be-frozen such as a nitrogen gas into the freezing store to increase the inside gas pressure back to an atmospheric pressure level prior to opening the door.
In opening the door, it is preferable to produce a layered gas flow from the upper side toward the lower side with a gas curtain unit provided near an opening for the door, wherein the layered gas flow prevents the outside gas from mixing with the inside gas.
Effect of the Invention
According to a quick freezing apparatus and a freezing method of the present invention configured as described above, it is possible to freeze-preserve an object-to-be-frozen for a long term with its deterioration suppressed as much as possible.
More specifically, by adjusting a gas pressure inside a freezing store to decrease the inside pressure to a pressure equal to or less than atmospheric pressure using a pressure regulator, it becomes possible to reduce an amount of harmful gas in the freezing store atmosphere, such as oxygen, and to discharge and eliminate harmful gas emitted from the object-to-be-frozen itself, so that it becomes possible to freeze the object-to-be-frozen while suppressing oxidization of the object and deterioration thereof caused by the harmful gas as much as possible.
Further, by decreasing the gas pressure, a temperature drop can be facilitated, so that it becomes possible to accelerate cooling to a predetermined temperature and therefore improve the operation efficiency as much as possible.
On the other hand, by increasing the inside gas pressure to a pressure equal to or more than atmospheric pressure, it becomes possible to suppress evaporation of water in the cells of an object-to-be-froze and prevent drying of the object. Therefore, the deterioration can be prevented as much as possible.
In the above pressurization, for example, a gas with a low oxygen level or without oxygen at all, such as a pressurized nitrogen gas, is supplied to increase the inside gas pressure. This contributes to reducing the concentration of harmful gases in the freezing store atmosphere or the oxygen level, so that it becomes possible to freeze the object while suppressing as much as possible deterioration caused by the harmful gas or the oxygen. Here, a pressurizing pump may be used as a pressurizer, or a harmless gas may be directly supplied from a high pressure tank, for example, by using a high pressure nitrogen tank.
By providing a circulating path for the gas inside the freezing store, it becomes possible to recycle an already cooled air inside the freezing store, thereby promoting the efficiency of freezing operation and presenting an energy saving freezing system. In addition, by providing an oxygen absorber and a sterilizer on the circulating path, purification of a return gas can be facilitated, and it becomes possible to further enhance the effect of maintaining a high quality for a long preservation term.
Meanwhile, care should be taken at the time of bringing in or taking out an object-to-be-frozen so that harmful gases, germs, dusts and the like contained in the outside air do not flow into the freezing store while opening the door. By keeping the inside of the freezing store in a pressurized state, this can be achieved without any special caution.
Further, such an undesired inflow can be more securely prevented by disposing inside the freezing store near its door a gas curtain unit which uses a gas having a condition similar to the inside atmosphere. The gas curtain unit may be used in freezing an object while executing only depressurization.
Furthermore, it may be useful to combine depressurization and pressurization, that is, upon starting the freezing operation, to carry out freezing while decreasing the inside gas pressure to a pressure less than atmospheric pressure until a temperature inside the freezing store drops to a predetermined temperature (for example, −30 degrees C.), and after that, increase the inside gas pressure to a pressure more than the atmospheric pressure. Effects brought about by depressurization and pressurization are combined to produce a synergy effect, which contributes to a more effective suppression of deterioration of an object to be preserved. In addition, it is possible to efficiently and easily replace oxygen inside the freezing store with a harmless gas such as nitrogen.
According to the present invention, a unidirectional magnetic field is applied to an object-to-be-frozen during quick-freezing the object in the freezing store. Thus, this magnetic field makes it possible to direct magnetic moments, which are generated by the electron spins and nuclear spins of the molecules constituting the object-to-be-frozen and of the free water molecules contained therein, in one direction. Thus cold can be transmitted to the inner portion of the object-to-be-frozen quickly. That is, the difference between inside and surface temperatures in the object-to-be-frozen which occurs during cooling, i.e., the nonuniformity in cooling can be considerably diminished to realize quick cooling.
Since cooling is carried out while a magnetic field is applied to an object-to-be-frozen, the free water within the object-to-be-frozen can be brought into a supercooled state. (Meanwhile, at this time, the application of the magnetic field causes the clusters of the free water to become small, and thereby facilitates hydration of the clusters with the substrates of the food product to form hydration structures. As a result, the amount of the free water in the object-to-be-frozen is reduced, and thereby supercooling is further facilitated.) A further cooling will initiate freezing of the free water in a supercooled state to take place, but since a heat quantity equivalent to the latent heat for solidification (forming ice) has already been removed, the freezing proceeds quickly. As a result, the time from the freezing start to the end can be considerably shortened.
Due to the combination of the above two effects, the freezing process quickly passes through the temperature range of 0 to −20 degrees C. in which crystals are apt to grow during freezing. Therefore, the ice crystals of the free water are prevented from growing to be too large and rough, and instead become small and fine. With such small and fine ice crystals, it is possible to prevent as much as possible destruction of the cellular structures of an object-to-be-frozen during the freezing process, and thereby suppress dripping upon defrosting and preserve the freshness at a high standard.
Furthermore, since the magnetic field fluctuates, the magnetic flux is changed and electromagnetic induction occurs within an object-to-be-frozen. Then, free electrons are generated therein by the induced electromotive force caused by the electromagnetic induction. The object-to-be-frozen is reduced by these free electrons and is prevented from oxidization.
According to the present invention, an object-to-be-frozen is cooled with cold air having a wind velocity of 1 to 5 m/sec and a sound wave within the audio frequency range is superimposed onto the cold air. Since a sound wave is superimposed onto the cold air which contacts the object-to-be-frozen, the slight change in air pressure caused by the sound wave can effectively stir up an air boundary layer which is formed over the surface of the object-to-be-frozen or the surface of a pan onto which the object-to-be-frozen is placed, and which inhibits heat transmission. Therefore, heat transmission is improved and the cooling of the object-to-be-frozen caused by the cold air is accelerated, thereby enabling the temperature to drop quickly. As a result, the freezing process can quickly pass through the temperature range of 0 to −20 degrees C., in which ice crystals of free water become bulky. Therefore, the ice crystals can be prevented from growing to be too large.
Since the wind velocity of the cold air is set within the range of 1 to 5 m/sec, it is possible to realize a convection heat transfer effective enough to accelerate the cooling rate, while preventing oxidization on the surface of an object-to-be-frozen by keeping a bound water film on the surface of the object-to-be-frozen from evaporating. That is, when the wind velocity is too slow, the heat transfer between the cold air and the object-to-be-frozen will be little, therefore making it difficult to achieve freezing using the quick temperature drop; however, since the wind velocity is 1 m/sec or greater, this problem can be avoided as much as possible. On the other hand, when the wind velocity is over 5 m/sec, the bound water film will evaporate and the surface of the object-to-be-frozen will be exposed, causing oxidization of the surface; however, since the wind velocity is 5 m/sec or less, this problem can also be avoided.
When the electric field is applied to an object-to-be-frozen, water molecules and oxygen molecules within the freezing store are given electrons, and thereby turn into electron-added water (H2Oe) or superoxide anion (O2−). This electron-added water and superoxide anion produce hydroxyl radicals or the like, by which the cell membranes of microbes such as bacteria can be destroyed. Thus, by applying an electric field during freezing, it is possible to significantly reduce the number of living microbes, suppressing putrefaction of an object-to-be-frozen.
In sum, according to the present invention, freezing is carried out while adjusting the pressure, such as increasing the inside pressure to a pressure more than atmospheric pressure, decreasing the inside pressure to a pressure less than the atmospheric pressure, or decreasing it and then increasing it, as well as applying a fluctuating magnetic field and an electric field to the inside of the freezing store and also sending cold air onto which a sound wave is superimposed to an object-to-be-frozen. These arrangements make it possible to suppress as much as possible deterioration and deformation caused by a subtle reaction which occurs during a freeze-preservation process between an object-to-be-preserved and a gas in the preservation atmosphere surrounding the object, such as water evaporation and oxidization, or by harmful substances or the like emitted from the object itself, and therefore make it possible to realize freeze-preservation applicable to even a long-term preservation of a living tissue.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram illustrating a central section of an inside of a freezing store of a quick freezing apparatus according to the present invention.
FIG. 2 is a schematic diagram illustrating a transverse cross-section including the freezing store and an open/close door of the quick freezing apparatus according to the present invention.
FIG. 3A illustrates an electron microscope image of a mackerel thawed after being frozen-preserved using the quick freezing apparatus and method according to the present invention, and FIG. 3B illustrates an electron microscope image of a mackerel thawed after being frozen-preserved using a conventional quick freezing apparatus and method.
FIG. 4A illustrates an electron microscope image of a lobster thawed after being frozen-preserved using the quick freezing apparatus and method according to the present invention, and FIG. 4B illustrates an electron microscope image of a lobster thawed after being frozen-preserved using the conventional quick freezing apparatus and method.
DESCRIPTION OF THE REFERENCE NUMERALS
1 Quick Freezing Apparatus
3 Object-To-Be-Frozen
11 Freezing Store
13 Main Body
13 c Door
17 Freezer
21 Fluctuating Magnetic Field Generator
21 a Static Magnetic Field Generator
21 b Dynamic Magnetic Field Generator
31 Fan (Ventilator)
41 Sound Wave Generator
51 Electric Field Generator
60 Pressure Regulator
61 Pressurizer
61 a Pressurizing Pump
61 b Gas Introduction Path
62 Depressurizer
62 a Suction Pump
63 Circulating Path
65 Gas Purifier (Sterilizer, Oxygen Absorber)
66 Gas Supply Source
67 Gas Introducer
68 Actuation Controller
70 Gas Curtain Unit
DETAILED DESCRIPTION OF THE INVENTION
Best Mode for Carrying Out the Invention
A preferred embodiment of the present invention will be described in detail below with reference to the accompanying drawings. FIGS. 1 and 2 are schematic diagrams showing an exemplary embodiment of a super-quick freezing apparatus according to the present invention. FIG. 1 is a central section of the inside of a freezing store thereof, while FIG. 2 is a sectional side elevation thereof.
As shown in FIGS. 1 and 2 , a super-quick freezing apparatus 1 of the present embodiment includes a freezing store 11 capable of realizing an inside temperature of −30 degrees C. to −100 degrees C., a fluctuating magnetic field generator 21 for applying a fluctuating magnetic field to the central portion of the inside of the freezing store 11 , the fluctuating magnetic field fluctuating 5 Gs in the positive and negative directions relative to any fixed value set as a reference value such as 100 Gs, fans 31 serving as ventilators for circulating cold air in the freezing store 11 at a wind velocity of 1 to 5 m/sec, a sound wave generating device 41 serving as a sound wave generator for superimposing a sound wave onto the cold air circulated by the fans 31 , the sound wave having a sound pressure level of 2 Pa and a sound intensity level of 10-2 W/m2 and being within the audio frequency range, and an electric field generating device 51 serving as an electric field generator for applying an electric field ranging between 100 to 1000 kV/m to the central portion of the inside of the freezing store 11 .
The freezing store 11 includes a main body 13 having an open/close door 13 c at the front thereof, capable of being sealingly closed and being substantially rectangular solid in shape, and a freezer 17 for cooling the main body 13 .
The freezer 17 adopts a typical refrigeration cycle in which a compressor 17 a , a condenser 17 b , expansion valves (or capillary tubes) 17 c , and evaporators 17 d are sequentially circularly connected together, and a refrigerant is circulated therethrough. The evaporators 17 d , which generate cold air, and the expansion valves 17 c are arranged inside the main body 13 , while the compressor 17 a and the condenser 17 b are placed outside the freezing store.
The main body 13 has a double-wall structure comprising a freezing chamber defining wall 13 a , which defines the space inside the freezing store, and an outer wall 13 b , which surrounds the wall 13 a at some distance therefrom to define an outer portion. A heat insulating material (not shown) is arranged between the outer wall 13 b and the freezing chamber defining wall 13 a , and a far-infrared-ray absorbing material (not shown) is coated over the whole inner surface of the freezing chamber defining wall in order to enhance the cooling efficiency inside the freezing store.
Located in the substantially center portion of the inside of the freezing store is a rack 19 onto which an object-to-be-frozen 3 such as a food ingredient or a food product is placed. The rack 19 includes a grating-like framing 19 a wherein substantially U-shaped portal frames placed anteroposteriorly opposite each other are connected together by rod-like members such as angle irons, and pans 19 b which are supported by engaging members 19 c fixed onto the framing 19 a at appropriate intervals in the vertical direction. The pan 19 b , in turn, supports the object-to-be-frozen 3 thereon. The pans 19 b are detachably-attachably engaged onto the engaging members 19 c to form several detachable/attachable shelves in the framing 19 a . The before-mentioned evaporators 17 d are disposed on the right side of the rack 19 in FIG. 1 .
The evaporator 17 d is formed by folding a copper pipe several times. The inside of the freezing store is cooled by latent heat during evaporation of the refrigerant flowing through the evaporator, that is, cold air is generated by the evaporator 17 d . The evaporator 17 d is circularly connected to the before-mentioned outer compressor 17 a and condenser 17 b , and the expansion valve 17 c by piping or another method, and constructs a refrigeration cycle capable of realizing an inside temperature of −30 degrees C. to −100 degrees C.
The fans 31 , serving as ventilators for circulating cold air inside the freezing store, are arranged on the both sides of the rack 19 . The fans 31 on one side are located in front of the evaporators 17 d and send the cold air cooled by the evaporators 17 d horizontally towards objects-to-be-frozen 3 supported on the rack 19 . In order to supply a cold wind of a uniform velocity to each object-to-be-frozen 3 , the plurality of fans 31 are arranged at appropriate intervals in the vertical and depth directions. The wind velocity at an object-to-be-frozen 3 is adjustable within the range of 1 to 5 m/sec, and is determined depending mainly on the type of object-to-be-frozen.
Due to cold air having a wind velocity within the range of 1 to 5 m/sec, it is possible to realize a convection heat transfer effective enough to accelerate the cooling rate, while preventing oxidization on the surface of an object-to-be-frozen by keeping a bound water film on the surface of the object-to-be-frozen from evaporating. That is, when the wind velocity is too slow, the convention heat transfer will not be effective and the heat transfer between the cold air and the object-to-be-frozen will be little, therefore making it difficult to achieve quick freezing; however, since the wind velocity is 1 m/sec or greater, this problem can be avoided as much as possible. On the other hand, when the wind velocity is over 5 rn/sec, the bound water film will evaporate and the surface of the object-to-be-frozen will be exposed, causing oxidization of the surface; however, since the wind velocity is 5 m/sec or less, this problem can also be avoided.
The cold air itself is heated while cooling an object-to-be-frozen 3 . Thus, a circulation path is formed such that after contacting with an object-to-be-frozen 3 , the air ascends along the surface of the freezing chamber defining wall on the opposite side, and moves along the bottom surface of the ceiling and the surface of the freezing chamber defining wall behind the freezer 17 , and then returns to the evaporators 17 d.
The sound wave generating device 41 is disposed just beneath the bottom surface of the ceiling, which is a part of the above-mentioned circulation path. This sound wave generating device 41 generates a sound wave by producing air vibration using the vibration of an electromagnetic coil (not shown) connected to a commercial AC power source of 50 or 60 Hz. The thus-generated sound wave is a low-frequency sound within the audio frequency range that comprises a frequency equal to the frequency of the commercial AC power source, that is, 50 or 60 Hz, and a harmonic overtone with a frequency of its integer multiple. This sound wave is superimposed onto the circulated cold air and brought into contact with an object-to-be-frozen 3 . The sound wave causes a slight change in air pressure and thereby stirs up an air boundary layer which is formed on the surface of an object-to-be-frozen 3 and on the surface of the pan 19 b onto which the object-to-be-frozen 3 is placed. The air boundary layer inhibits heat transfer, so that stirring it up facilitates heat transfer.
Due to use of a sound wave in the audio frequency range, it is possible to prevent oxidization on the surface of an object-to-be-frozen 3 as much as possible without causing destruction of a bound water film formed on the surface of the object-to-be-frozen 3 . In other words, it is possible to prevent a bound water film on the surface of an object-to-be-frozen 3 from being stripped off, which would occur when the frequency is too high, such as in the ultrasonic range.
It is preferable to use a sound wave having a sound pressure level of 2×10-4 Pa to 60 Pa and a sound intensity level of 10-10 W/m2 to 10 W/m2. Using a sound wave in these ranges will prevent a bound water film from being stripped off and a noise from being emitted while enabling an air boundary layer to be effectively stirred up.
The before-mentioned electric field generating device 51 includes electrode plates disposed immediately above the respective pans 19 b of the rack 19 , an electrode plate disposed immediately beneath the undermost pan 19 b , a high-voltage alternating current potential generator 51 c which is connected to every other plate of the electrode plates to apply an alternating high-voltage potential or a high-voltage alternating current potential, and a ground portion 51 d connected to the remaining electrode plates that are not connected to the high-voltage alternating current potential generator 51 c . The electrode plates are broadly grouped into first electrode plates 51 a to which a high-voltage alternating current potential is applied by the high-voltage alternating current potential generator 51 c , and second electrode plates 51 b which are connected to the ground through the ground portion 51 d , the first and second electrode plates 51 a , 51 b being disposed alternately in the vertical direction. When a high-voltage alternating current potential is given to the first electrode plate, an electric field whose direction is inverted periodically is generated in the space between the first electrode plate and the second electrode plates facing this first electrode plate on the upper and lower sides thereof, and the electric field is applied in the vertical direction to the object-to-be-frozen 3 on the pan 19 b that is located in the space. Here it should be noted that, since the first and second electrode plates are disposed alternately, the electric field to be applied to the object-to-be-frozen 3 is applied to the vertically adjacent shelves in inverse directions, as indicated by broken lines in FIG. 21 . (Since a high-voltage alternating current potential is given to the first electrode plate, the direction of the electric field indicated by the broken line is inverted periodically.) The first electrode plates 51 a are fixed to the framing 19 a with electric insulators (not shown) therebetween, so that they are completely electrically insulated, except their connections to the high-voltage alternating current potential generator 51 c . Similarly, the second electrode plates 51 b are fixed to the framing 19 a with electric insulators (not shown) therebetween, so that they are completely electrically insulated, except their connections to the ground portion 51 d.
The strength of the electric field depends on the high-voltage alternating current potential applied to the first electrode plate 51 a , and the distance between the electrode plate 51 a and the pan 19 b , and the strength is adjusted within the range of 100 to 1000 kV/m by changing the high-voltage alternating current potential according to the type of object-to-be-frozen 3 . In addition, the high-voltage alternating current potential is adjusted so as to sinusoidally change in view of time.
When an electric field is applied to the inside the freezing store, water molecules and oxygen molecules within the freezing store are given electrons, and thereby turn into electron-added water (H2Oe) or superoxide anion (O2−). This electron-added water and superoxide anion produce hydroxyl radicals or the like, by which the cell membranes of microbes such as bacteria can be destroyed. Thus, by applying an electric field during freezing, it is possible to realize an antibacterial effect, preventing putrefaction of an object-to-be-frozen 3 and keeping the high quality thereof. It should be noted that, although the cells on the surface of an object-to-be-frozen 3 are destroyed by the hydroxy radicals as well, this amount is just negligible, considering the overall cells of the object-to-be-frozen.
As mentioned earlier, preferably, the strength of electric field is adjusted within the range of 100 to 1000 kV/m. That is because, if it is smaller than 100 kV/m, the number of hydroxy radicals produced will be too small to be effective for antibacterial action, while if it is over 1000 kV/m, the risk of electric discharge will become higher. However, in practical use, a strength within the range of 2 kV/m to 60 kV/m may be appropriate.
The fluctuating magnetic field generator 21 includes a static magnetic field generator 21 a for applying a static magnetic field to the central portion of the inside of the freezing store 11 , and a dynamic magnetic field generator 21 b for applying to the central portion of the inside of the freezing store a fluctuating magnetic field which has an amplitude amounting to 5% of the strength of the static magnetic field and fluctuates in the positive and negative directions relative to the static magnetic field. The static magnetic field generator 21 a is a permanent magnet 21 a which is made from a ferrite plate having a strength of 1500 Gs and formed into a rectangular strip of 1.0 m×0.1 m×0.05 m. One of the long sides thereof has a polarity of the N-pole, and the other long side has a polarity of the S-pole. Multiple permanent magnets 21 a are disposed in appropriately spaced apart relations on the outer surface of a side wall among the freezing chamber defining walls 13 a with their N-pole long sides up. The magnets are also disposed on the outer surfaces of the other three side walls so as to have the same polarity directions, and thereby a vertical static magnetic field is applied to objects-to-be-frozen 3 on the rack 19 located in the central portion of the inside of the freezing store. In the present embodiment, the strength of the static magnetic field at the central portion of the inside of the freezing store is adjusted to 100 Gs with the permanent magnets 21 a having strengths of 1500 Gs. However, the strength of the static magnetic field at the central portion can be changed by appropriately selecting the permanent magnet. The above-mentioned effect brought about by a magnetic field can be obtained if the strength is greater than the terrestrial magnetism (0.3 Gs to 0.5 Gs,). Thus, the magnetic field may have any strength of 1 Gs or over. Then, considering the limits in manufacturing a permanent magnet, it is appropriate to set the strength in the range of 1 to 20000 Gs.
The dynamic magnetic field generator is an electromagnetic coil 21 b that generates a magnetic field when an electric current is supplied thereto. The two electromagnetic coils 21 b are disposed outside of and lateral to the freezing chamber defining walls 13 a on the opposite sides of the freezing store. The electromagnetic coils 21 b are disposed so that the axes thereof extend in the vertical direction, and when an alternating current having a certain specific frequency runs through the electromagnetic coils 21 b , a magnetic field, which has the same frequency and fluctuates back and forth periodically and sinusoidally, is applied to the central portion of the inside of the freezing store in parallel to the above-mentioned static magnetic field. The static magnetic field and the non-static magnetic field, i.e. the dynamic magnetic field, are superimposed onto each other, and thereby a fluctuating magnetic field is applied to the central portion of the inside of the freezing store.
For example, in the present embodiment, an alternating current is supplied to the electromagnetic coils 21 b through a commercial AC power source 22 of 50 Hz or 60 Hz. Then, a dynamic magnetic field with a strength of ±5 Gs, which is equal to 5% of the strength of the static magnetic field, is generated. This dynamic magnetic field is superimposed onto the static magnetic field having a strength of 100 Gs, and a fluctuating magnetic field that fluctuates sinusoidally in the range of 95 to 105 Gs with a frequency of 50 Hz or 60 Hz is applied to the central portion of the inside of the freezing store.
In the present embodiment, the fluctuation range of the magnetic field is the range of the amplitude equal to 5% of the strength of the static field, i.e., the range of −5% to +5% relative to the strength of the static field. However, the larger amplitude is the better. However, considering electricity consumption of the electromagnetic coil, the range of 1 Gs to 100 Gs for the amplitude is appropriate in practical use.
Now, the effect of the magnetic field is described.
When the magnetic field is applied to an object-to-be-frozen 3 during cooling, the magnetic moments, which are generated by the electron spins and nuclear spins of the molecules constituting the object-to-be-frozen 3 and of the free water molecules contained therein, are aligned in one direction by the magnetic field. This makes it possible to rather quickly transmit cold to the inner portion of the object-to-be-frozen 3 . That is, the difference between inside and surface temperatures of the object-to-be-frozen 3 while the object 3 is being cooled, i.e., the nonuniformity in cooling, is significantly reduced, and even the inner portion is cooled quickly, and therefore the time elapsed from the freezing start to the freezing end can be reduced as much as possible.
Moreover, when cooling is carried out while a magnetic field is applied to an object-to-be-frozen 3 , the free water within the object-to-be-frozen 3 is brought into a supercooled state. (Meanwhile, at this time, as will be described later, the application of the magnetic field causes the clusters of the free water to become small, and thereby facilitates hydration of the clusters with the substrates of the food product to form hydration structures. As a result, the amount of the free water in the object-to-be-frozen is reduced, and thereby supercooling is facilitated.) A further cooling will initiate freezing to take place, but since a heat quantity equivalent to the latent heat for solidification (forming ice) has already been removed, the freezing proceeds quickly, and accordingly the temperature of the object-to-be-frozen 3 drops quickly.
As a result, the above two effects together contribute to significantly reducing the time elapsed from the start of freezing of the free water to the end thereof, that is, the freezing process quickly passes through the temperature range of 0 to −20 degrees C. in which ice crystals easily grow. Therefore, the ice crystals of the free water are prevented from growing to be too large and rough, and instead become small and fine. With such small and fine ice crystals, it is possible to prevent as much as possible destruction of the cellular structures of an object-to-be-frozen 3 during the freezing process, and thereby prevent dripping upon defrosting and preserve the freshness at a high standard.
In general, water clusters are turned into bound water by hydrogen bonding with polar groups which surface on the outsides of the tertiary structures of the proteins constituting an object-to-be-frozen 3 . Applying a magnetic field causes a water cluster, which is an aggregation of free water molecules, to be broken down into small groups, and then the small clusters closely and evenly attach to the outer surfaces of the tertiary structures to form an envelope-like covering. That is, the small clusters evenly attach over the whole outer surfaces in a monomolecular layer-like manner to form a bound water film. The thus-formed bound water film prevents the tertiary structures, i.e., the object-to-be-frozen 3 from being oxidized, and the freshness thereof can be preserved at a high standard.
Generally, the above-mentioned bound water does not freeze, because the bound water is strongly drawn to the tertiary structures and therefore its freezing point drops to the range of −10 to −100 degrees C. By forming small clusters, free water is bound to the outer surfaces of the tertiary structures thoroughly, and thus, most of the free water is turned into bound water. Therefore, the absolute amount of the free water is reduced, and it becomes possible to indirectly prevent free water crystals from growing to be too large and rough.
Further, by fluctuating the magnetic field, it is possible to reduce the counteraction against the action of the static magnetic field, i.e., demagnetizing field action, and enable the function imparted by the application of the main magnetic field to work efficiently, and considerably enhance the above-explained effect of the magnetic field.
Furthermore, by fluctuating the magnetic field, the magnetic flux is changed and electromagnetic induction occurs within an object-to-be-frozen. Then, free electrons are generated therein by the induced electromotive force caused by the electromagnetic induction. Therefore, the object-to-be-frozen is reduced by these free electrons and is prevented from oxidization.
The freezing apparatus 1 of the present embodiment that has been described until now has the same feature and configuration as those of the apparatus disclosed by the applicant of the present application in International Publication No. WO01/024647, which is herein presented as conventional art. However, the freezing apparatus 1 according to the present invention includes additional features, as will be described below.
The freezing store 11 further includes a pressure regulator 60 capable of adjusting a gas pressure within the freezing store. The pressure regulator 60 includes a function of increasing a gas pressure within the freezing store 11 , or conversely, a function of decreasing it. Preferably, the pressure regulator 60 may include both functions of increasing and decreasing a gas pressure. In the present embodiment, the pressure regulator 60 includes a pressurizer 61 for increasing a gas pressure inside the freezing store 11 by supplying a pressurized gas into the freezing store 11 so that the gas pressure exceeds the atmospheric pressure, and a depressurizer 62 for decreasing a gas pressure inside the freezing store 11 by drawing the gas inside the store 11 so that the gas pressure becomes below the atmospheric pressure.
Specifically, in the present embodiment, a pressurizing pump 61 a is used as the pressurizer 61 . The discharge side of the pressurizing pump 61 a is communicated with the inside of the freezing store 11 through a pressure regulating valve 61 c , and a pressure meter 61 d is provided on a discharge side communication path in order to monitor the pressurization level.
Similarly, in the present embodiment, a suction pump 62 a is used as the depressurizer 62 . The inlet side of the suction pump 62 a is communicated with the inside of the freezing store 11 through a pressure regulating valve 62 c , and a pressure meter 62 d is provided on an inlet side communication path 62 b in order to monitor a depressurization level.
There is provided a pipe 63 a connecting the discharge side of the suction pump 62 a with a gas introduction path 61 b of the pressurizing pump 61 a , forming a gas circulating path 63 through which a gas inside the freezing store 11 circulates. A gas purifier 65 is provided on the gas circulating path 63 , and open/close valves 64 , 64 are provided near the discharge side of the suction pump 62 a and the gas introduction path 61 b of the pressurizing pump 31 a , respectively. The gas purifier 65 eliminates germs contained in a circulating inside gas and reduces the amount of oxygen therein, and an oxygen absorber and a sterilizer are provided in the gas purifier 65 so as to exist on a gas circulating route. As the sterilizer, silver may be adopted. Silver as the sterilizer may be provided by, for example, coating it on the inner surface of the gas circulating route. Also, an additional sterilizer and oxygen absorber may be provided inside the freezing store 11 . The oxygen absorber (not shown) may be attached to the inner wall of the freezing store 11 in order to serve to reduce the oxygen level inside the store 11 . In addition, the sterilizer (for example, silver foil or leaf) may be attached to the inner wall of the freezing store 11 as well.
In the present embodiment illustrated herein, the gas circulating path 63 is shared by the pressurizer 61 and depressurizer 62 , but gas circulating paths independently provided for the pressurizer 61 and the depressurizer 62 may be arranged in parallel.
Further, on the gas introduction path 61 b of the pressurizing pump 61 a , a gas supply source 66 is arranged in parallel to the gas circulating path 63 . The gas supply source 66 supplies into the freezing store a gas selected according to the type of object-to-be-frozen, such as a nitrogen gas. The gas supply source 66 includes a plurality of tanks 66 a , in each of which a different gas is sealingly contained in a compressed state, and open/close valves 66 b for the tanks 66 a . According to the type of object-to-be-frozen 3 , the open/close valves 66 b of the tanks 66 a are selectively opened or closed to supply a gas suitable for the object 3 into the freezing store through the pressurizing pump 61 a . In other embodiments, one of the tanks may be replaced with an oxygen filter made by filling an oxygen absorber into a container, so that outside air can be taken in therethrough, and air containing little oxygen may be supplied as a safe gas source.
On the other hand, on the inlet side of the suction pump 62 a , there is provided a gas introducer 67 . The gas introduction source 67 , when a gas pressure inside the store 11 is lower than the atmospheric pressure and the door 13 c of the freezing store 11 needs to be opened, supplies into the store 11 a gas selected according to the type of object-to-be-frozen 3 such as a nitrogen gas, and increases the inside gas pressure to the same level as the atmospheric pressure prior to opening the door. The gas introduction source 67 includes a plurality of tanks 67 a , in each of which a different gas is sealingly contained in a compressed state, and open/close valves 67 b for the tanks 67 a , similar to the above-described gas supply source 66 provided on the side of the pressurizing pump 61 a . According to the type of object-to-be-frozen 3 , the open/close valves 67 b of the tanks 67 a are selectively opened or closed in order to supply a gas suitable for an object 3 into the freezing store 11 . The gas introduction source 67 is connected to the upstream side of the pressure regulating valve 62 c serving also as an open/close valve provided on the inlet side communication path 62 b . Also in this source, one of the tanks may be replaced with an oxygen filter made by filling an oxygen absorber into a container, so that outside air can be taken in therethrough, and air containing little oxygen may be supplied as a safe gas source.
In the present embodiment, an electromagnetic valve is used as the open/close valve 67 b , and the electromagnetic valve is opened or closed by operating a switch (not shown) attached on the door or another portion, and for example, is opened prior to opening the door.
The pressure regulator 60 further includes an actuation controller 68 which detects the temperature inside the freezing store 11 ; if the inside temperature is equal to or more than a predetermined temperature, actuates the suction pump 62 a of the depressurizer to decrease the inside gas pressure to a pressure equal to or less than the atmospheric pressure; and when the inside temperature drops below the predetermined temperature, stops the suction pump 62 a of the depressurizer and actuates the pressurizing pump 61 a of the pressurizer to increase the inside gas pressure to a pressure equal to or more than the atmospheric pressure. The actuation controller 68 includes a control unit 68 a comprising a microcomputer, a pressure sensor 68 b and a temperature sensor 68 c disposed inside the freezing store, and an operation panel 68 d . The actuator 68 controls actuations of the suction pump 62 a and the pressurizing pump 61 a in response to sensor signals sent from the sensors 68 b and 68 c.
A number of operation control programs catered to a number of types of objects-to-be-frozen are pre-stored in a storage of the control unit 68 a . The operation control program is automatically selected according to a type of object-to-be-frozen specified through the operation panel 68 d , and is executed. These operation control programs are roughly classified into three operation modes, that is, a continuously pressurizing operation mode with which the control unit 68 a increases the pressure inside the freezing store to a pressure over the atmospheric pressure from start to stop, a continuously depressurizing operation mode with which the control unit 68 a decreases the pressure inside the freezing store to a pressure below the atmospheric pressure from start to stop, and a pressurizing-depressurizing combination operation mode with which the control unit 68 a first decreases the pressure inside the freezing store to a pressure below the atmospheric pressure upon being actuated, and increases the inside pressure to a pressure over the atmospheric pressure once the inside temperature drops to a predetermined value. Information such as the type of gas to be pressurized or depressurized, the gas pressure change over time, and pressure levels are set and stored as control data in order to achieve an optimal condition for a freezing target such as the type of object-to-be-frozen 3 and the length of the freezing period.
More specifically, when the continuously pressurizing operation mode fits for the type of object-to-be-frozen inputted and set through the operation panel 68 d , the control unit 68 a has the pressurizing pump 61 a operate continuously or intermittently to maintain a specified inside pressure that is over the atmospheric pressure. When the continuously depressurizing operation mode fits for the type of object-to-be-frozen inputted and set, the control unit 68 a has the suction pump 62 a operate continuously or intermittently to maintain a specified inside pressure that is below the atmospheric pressure. When the pressurizing-depressurizing combination operation mode fits for the type of object-to-be-frozen inputted and set, the control unit 68 a , upon being actuated, has the suction pump 62 a operate continuously or intermittently to maintain a specified inside pressure below the atmospheric pressure until the inside temperature drops to a specified temperature, and once the inside temperature drops to the predetermined value, then the control unit 68 a has the pressurizing pump 61 a operate continuously or intermittently to maintain a specified inside pressure over the atmospheric pressure.
With the continuously pressurizing operation mode, the surface of an object-to-be-frozen is enclosed by a pressurized and cooled gas while cold is penetrating to the inside of the object-to-be-frozen, so that oxidization occurring during freezing is prevented and deformation is reduced. With the continuously depressurizing operation mode, it is possible to actively suck a deterioration-facilitating gas which is emitted from the surface and inside of an object-to-be-frozen 3 , so that it is possible to complete freezing with less deterioration and deformation. Further, with the depressurizing mode, cooling can reach the inside of an object-to-be-frozen 3 more quickly, so that tissue and cell deformation can be prevented as much as possible. Furthermore, before a gas emitted from an object-to-be-frozen 3 affects another object 3 next to it, the gas can be expelled, so that harmful influences between each object-to-be-frozen 3 and its neighboring object 3 can be eliminated.
With the pressurizing-depressurizing combination operation mode, in which a pressure inside the freezing store and therefore the oxygen amount is first decreased using the suction pump 62 a and then the inside pressure is increased using the pressurizing pump 61 a , the above-described quality-retention effects brought about by depressurizing and pressurizing are combined to produce a synergy effect, which contributes to stronger prevention of deterioration and deformation. Meanwhile, in pressurizing, instead of using air, a gas selected according to an object-to-be-frozen, such as a nitrogen gas, may be pressurized and compressed and then be actively supplied. With this arrangement, it becomes possible to efficiently and easily replace the gas inside of the freezing store with a gas having less harmful components.
FIG. 2 is a schematic diagram illustrating a transverse cross-section including the freezing store and the open/close door of the quick freezing apparatus according to the present invention. As shown in FIG. 2 , an opening is formed on the front surface of the main body 13 of the freezing store 11 to bring in or take out an object-to-be-frozen 3 . To this opening, the open/close door 13 c is provided to expose and cover the opening.
Meanwhile, there is possibility such that, while the door 13 c is opened to bring in or take out an object-to-be-frozen 3 , the outside air along with dust or the like might flow into the freezing store. It is necessary to prevent such an undesired inflow in order to maintain the inside gas in a clean and optimal state at any time. Here, if the inside pressure is more than the outside pressure, just the inside gas flows out of the freezing store, and as long as the pressurizing pump 61 a continues to supply a gas, there is no need to worry about the inflow of the outside air. However, if the inside pressure is equal to or below the outside pressure (atmospheric pressure), prevention of the inflow of the outside air should be taken care of.
Then, as one measure for this problem, in the freezing store near the door opening thereof, there is provided a gas curtain unit 70 which produces a layered gas flow A flowing from the upper side to the lower side. The gas flow A prevents the outside gas from mixing with the inside gas when the door 13 c is opened. The gas curtain unit 70 includes a gas supply source 71 , a pressurizer 72 for pressurizing a gas supplied from the gas supply source 71 , a discharge pipe 73 for leading a gas pressurized by the pressurizer 72 to the upper edge of the opening of the freezing store 11 , a suction pipe 74 including a suction port 74 a located at the lower edge of the door opening of the freezing store 11 , the suction port 74 a drawing a gas sent out from a discharge port 73 a at a tip of the discharge pipe 73 , and a sucker 75 for drawing a gas sent out from the discharge port 73 a through the suction pipe 74 . The discharge pipe 73 branches, and the suction pipe 74 also branches with the same number of branches as those of the pipe 73 (not shown). The discharge ports 73 a are respectively formed at the tips of the pipe 73 , and the suction ports 74 a are respectively formed at the tips of the pipe 74 . The ports 73 a and 74 a are aligned along the lateral direction of the door opening such that each of the ports 73 a is positioned vertically opposite each of the ports 74 a . Open/close valves 76 are provided in the discharge pipe 73 and the suction pipe 74 , respectively. Also, the open/close valve 76 is provided in a pipe connecting the gas supply source 71 and the pressurizer 72 .
In the present embodiment, an electromagnetic valve is adopted as the open/close valve 76 , and the electromagnetic valve is opened and closed by operating a switch (not shown) attached on the door 13 c or another portion. The same switch can also actuate the discharge pump 72 and the suction pump 75 simultaneously, and the pumps 72 and 75 are actuated so as to carry out an opening operation prior to opening the door 13 c . The before-described pressurizing pump 61 a and the suction pump 62 a , which are used for adjusting the inside pressure, may additionally serve as the discharge pump 72 and the suction pump 75 .
Having described the embodiment of the present invention, the invention should not be construed limited by any of the details of this description. The present invention can be changed and modified without departing from the scope of the claims.
FIG. 3A shows a microscope image of a section of a tissue of a mackerel thawed after being frozen-preserved using a quick freezing apparatus according to the present invention. FIG. 3B shows a microscope image of a section of a tissue of a mackerel thawed after being frozen-preserved using a conventional quick freezing apparatus. Both images are taken at 300× magnification using a scanning electron microscope.
As can be clearly seen from the comparison of these images, the image of the freezing technology of the present invention shows that the tissue is preserved in a good state without being destroyed. On the other hand, the image of the conventional freezing technology clearly shows that the ice remaining in the tissue cell compresses and damages its surrounding tissue. The black holes shown in the images are traces after the ice formed in the tissue has sublimed.
Similarly, FIG. 4A shows an electron microscope image of a section of a tissue of a lobster thawed after being frozen-preserved using the quick freezing apparatus according to the present invention. FIG. 4B shows an electron microscope image of a section of a tissue of a lobster thawed after being frozen-preserved using the conventional quick freezing apparatus.
As can be clearly seen from the comparison of these images, the image of the freezing technology of the present invention shows that the tissue is preserved in a good state without being destroyed. On the other hand, the image of the conventional freezing technology clearly shows that the ice remaining in the tissue cell compresses and damages its surrounding tissue. The black holes shown in the images are traces after the ice formed in the tissue has sublimed. | To provide a quick freezing apparatus and method making it possible to prevent a subtle reaction between an object-to-be-preserved and a gas inside its freezing store to prevent deformation and deterioration of the object-to-be-preserved as much as possible and freeze-preserve the object maintaining its freshness and quality at a high standard for a long term, and thereby applicable to a long-term preservation of a living tissue.
A quick freezing apparatus includes a freezing store 11 including a door for bringing in or taking out an object-to-be-frozen 3 , a freezer 17 capable of lowering a temperature inside the freezing store to a temperature equal to or less than approximately −30 degrees C., a pressure regulator 60 capable of adjusting a gas pressure inside the freezing store, and a ventilator 31 for sending cold air at a wind velocity of 1 to 5 m/sec toward the object-to-be-frozen placed inside the freezing store. The pressure regulator 60 includes an actuation controller 68 for detecting the temperature inside the freezing store; if the detected inside temperature is equal to or more than a predetermined value, then actuating a depressurizer 62 to decrease the inside gas pressure to a pressure equal to or less than the atmospheric pressure; and when the inside temperature drops below the predetermined value, stopping the depressurizer 62 and actuating the pressurizer 61 to increase the inside gas pressure to a pressure equal to or more than the atmospheric pressure. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to a method and a machine for cleaning a carpet tile in a continuous manner.
Carpet tiles are used typically as a floor surface covering and are generally rectangular in shape. Carpet tiles are most commonly square and are applied to a floor surface similarly as are conventional floor tiles, with the edges of each carpet tile being in abutment with the edges of another carpet tile or vertical surfaces such as walls. Typically, no adhesive is required for applying the carpet tile to the floor surface. The abutting interference fit between a carpet tile and those adjacent to it is sufficient for retaining the carpet tile substantially fixed relative to the floor surface during normal use. Once applied to a floor surface, the carpet tiles are generally removable therefrom by merely pulling them upward by hand from the floor surface.
One particular advantage of using carpet tiles is that when a path becomes worn across the carpeted surface, only those carpet tiles under the path need be replaced, thereby allowing carpet tiles which are not excessively worn to remain. This eliminates the need of recarpeting the whole flooring surface and allows for only those portions which are excessively worn to be selectively replaced.
Another advantage of using carpet tiles is that they may be readily pulled up from the floor surface, cleaned, and reapplied to the floor surface. This allows for an improved life and appearance of the carpet tiles while they remain suitable for use as a floor covering.
There are patented devices for cleaning substantially flat articles. For example, U.S. Pat. No. 3,396,422, granted to Haverberg, entitled, "Car Mat Washing Machine", discloses a machine which washes and dries automobile floor mats. The machine has a mat supporting grating and rotary brushes for conveying liquid to and scrubbingly engaging one side of an automobile floor mat through the grating. Infeed rolls are provided for feeding a floor mat to the rotary brushes. Also provided is a pressure plate pivotally mounted over the rotary brushes for holding a floor mat against the rotary brushes. Outfeed rollers impart a squeezing action to the floor mat when fed therebetween, and a fan is provided for blowing air over the floor mat for the drying thereof. Another cleaning machine for cleaning substantially flat articles is disclosed in U.S. Pat. No. 1,183,672, granted to Ritchey et al., which includes wire bristle rollers for cleaning baking pans transferred on a conveyor. Also, a sheet drying apparatus is disclosed in U.S. Pat. No 1,930,575, granted to Wynd et al., which includes infeed rollers, washer spray pipes, brush rollers, outfeed rollers, and a pressurized air nozzle assembly which are all used in conjunction for drying sheets of material, such as the glass and celluloid used in the manufacture of laminated glass.
Of the above patented devices, however, none is particularly adapted for automatically thoroughly cleaning, rinsing, and vacuuming carpet tiles.
SUMMARY OF THE INVENTION
The present invention recognizes and addresses such drawbacks of the prior art. Thus, it is a general object of the present invention to provide a machine for automatically cleaning carpet tiles.
Another object of the present invention to provide a machine which automatically wets a carpet tile with cleaning fluid, and then scrubs, rinses, and vacuums the carpet tile.
Another object of the present invention is to provide a carpet tile cleaning machine which can be readily installed in a variety of environments.
Still another object of the present invention is to provide a carpet tile cleaning machine which can clean a variety of sizes of carpet tiles.
Yet another object of the present invention is to provide a method for cleaning a carpet tile.
Various combinations of presently disclosed features may be provided in a given embodiment thereof in accordance with this invention. Generally, one such exemplary embodiment of the present invention includes a carpet tile cleaning machine comprising a frame structure, a loading station connected to the frame structure and adapted for receiving a carpet tile, and an unloading station connected to the frame structure and adapted for allowing removal of a carpet tile from the carpet tile cleaning machine. Scrubbing means are connected to the frame structure between the loading station and the unloading station and are adapted for scrubbing a carpet tile. Infeed means are connected to the frame structure between the loading station and the scrubbing means and are adapted for transferring a carpet tile from the loading station and about the scrubbing means. Wetting means are provided between the infeed means and the scrubbing means and are adapted for wetting a carpet tile with a cleaning fluid. Outfeed means are connected to the frame structure and are adapted for transferring a carpet tile from about the scrubbing means to the unloading station. Rinsing means are provided between the scrubbing means and the outfeed means and are adapted for rinsing a carpet tile with a rinsing fluid. Vacuum means are associated with the outfeed means and the unloading station and are adapted for vacuuming rinsing fluid from a carpet tile after exposure of the carpet tile to the rinsing means.
The present invention also includes a method of cleaning a carpet tile having a pile side and a backing side. The method comprises infeeding a carpet tile with infeed rollers into a carpet tile cleaning compartment of a carpet tile cleaning machine, wetting the pile side of the carpet tile with wetting nozzles in the carpet tile cleaning compartment of the carpet tile cleaning machine, the pile side of the carpet tile being wetted with a cleaning fluid by the wetting nozzles. The method further includes scrubbing the pile side of the carpet tile in the carpet tile cleaning compartment of the carpet tile cleaning machine with a rotary scrubbing brush after wetting of the pile side by the cleaning fluid of the wetting nozzles. After scrubbing, the method includes rinsing the pile side of the carpet tile with rinsing nozzles in the carpet tile cleaning compartment of the carpet tile cleaning machine, the pile side being rinsed by the rinsing nozzles with a rinsing fluid. After rinsing, the method further includes vacuuming the pile side of the carpet tile with a vacuum slot of the carpet tile cleaning machine for removing the rinsing fluid from the pile side thereof.
Other features of the present invention will be apparent from the following specification and the drawings appended thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing as well as other objects of the present invention will be more apparent from the following detailed description of a preferred embodiment of the invention, including the best mode thereof, when taken together with the accompanying drawings, in which:
FIG. 1 is a perspective view of a carpet tile cleaning machine constructed in accordance with the present invention;
FIG. 2 is a partial perspective view of features such as the infeed means, the scrubbing means and the outfeed means used in a carpet tile cleaning machine constructed in accordance with the present invention;
FIG. 3 is a righthand side elevational view, with parts cut away, of a carpet tile machine constructed in accordance with the present invention;
FIG. 4 is a plan view, with parts cut away of a carpet tile cleaning machine constructed in accordance with the present invention;
FIG. 5 is a rear elevational view, with parts cut away, of a carpet tile cleaning machine constructed in accordance with the present invention; and
FIG. 6 is a schematic representation of the carpet tile vacuum path and fluid paths in a carpet tile machine constructed in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings in detail, wherein like reference characters represent like elements and/or features throughout the various views, the carpet tile cleaning machine of the present invention is designated generally in FIG. 1 by the reference character 10. As illustrated in FIGS. 1, 2, and 4, carpet tile cleaning machine 10 includes a frame structure, generally 12, a loading station, generally 14, an unloading station, generally 16, scrubbing means, generally 18, infeed means, generally 20, wetting means, generally 22, outfeed means, generally 24, rinsing means, generally 26, and vacuum means, generally 28.
Frame structure 12 includes substantially vertical frame members, generally 30 spaced apart from one another and substantially horizontal frame members, generally 32, spanning therebetween. Vertical frame members 30 and horizontal frame members 32 are connected to one another by welding, nuts and bolts, screws, or some other suitable fastening means, and can be constructed of stainless steel, alloys, or any other suitable material. Attached to frame structure 12 are end covers 34, a front cover 36, a back cover 38, and a hinged top cover 40. Top cover 40 is hinged about an upper portion of frame structure 12 by hinge 42 and is movable between a horizontal position for covering machine 10 and a vertical position, shown in FIGS. 1 and 3, for accessing the inside of machine 10. Covers 34, 36, 38, and 40 serve, among other things, to isolate the inside of carpet tile cleaning machine from dirt, dust, and the elements, and also to hide the inside thereof from view.
Extending outwardly from the front 44 of carpet tile cleaning machine 10 is the substantially horizontal loading station 14, and extending from the back 46 of carpet tile cleaning machine 10 is the substantially horizontal unloading station 16. Loading station 14 and unloading station 16 are also preferably constructed of stainless steel, although any other suitable material could be used. Loading station 14 and unloading station 16 are provided with surfaces 48, 50 respectively, and side walls 52, 54, respectively which together are configured for supporting and guiding a carpet tile 56 as it travels to the entrance 58 and from the exit 60 of carpet tile cleaning machine 10. Loading station 14 and unloading station 16 allow for an operator of machine 10 to manually load a carpet tile 56 into the machine 10 and remove it therefrom.
Infeed means 20 includes substantially horizontally disposed rollers 62, 64 which rotate in opposite directions with respect to one another to form a nipping zone therebetween for a carpet tile 56. Rollers 62, 64 are rotated via drive shafts connected to sprockets 66, 68. Rollers 62, 64 are preferably constructed of polyvinylchloride (PVC), but could be constructed of any other suitable material. As illustrated in FIGS. 1 and 3, roller 62 is journaled in bearing blocks 70. Bearing blocks 70 are biased downwardly by springs 72 which are connected between bearing blocks 70 and upper horizontal frame members 74.
Scrubbing means 18 includes a scrubbing roller 76 having a plurality of rows of bristles 78 extending radially outwardly therefrom. Scrubbing roller 76 is connected via a drive shaft to a sprocket 80 for rotation therewith. Scrubbing roller 76 contacts a pile side 82 of a carpet tile 56 as the carpet tile is propelled into the carpet tile cleaning compartment, generally 84, by rollers 62, 64. It is to be noted here that roller 62 contacts the backing 86 side of carpet tile 56 while roller 64 contacts the pile side 82 thereof.
Between infeed means 20 and scrubbing means 18, wetting means 22 is positioned for wetting pile side 82 of carpet tile 56 as it passes from infeed means 20 to scrubbing means 18. As shown in FIG. 4, wetting means 22 includes a series of high-pressure nozzles 88 provided in a row in a nozzle bank 90. Nozzles 88 emit high pressure streams of cleaning fluid, such as a detergent/water mixture, or other suitable cleaning fluid mixture, for soaking pile side 82 of carpet tile 56 prior to carpet tile 56 contacting scrubbing roller 76. Thus, as carpet tile 56 is propelled into carpet tile cleaning compartment 84 by rollers 62, 64, pile side 82 is first subjected to the high-pressure cleaning fluid spray emitted from nozzle bank 90 and is then subsequently subjected to a physical scrubbing through contact with bristles 78 of scrubbing roller 76 on its flow path, indicated by arrows 91 in FIG. 6, through compartment 84.
As carpet tile 56 passes over scrubbing roller 76, it is forced against scrubbing roller 76 by a pressure plate assembly 92 having an angled bottom surface 94 which forces pile side 82 of carpet tile 56 into close proximity with bristles 78 of scrubbing brush 76 as carpet tile 56 is propelled by rollers 62, 64 through compartment 84. Pressure plate assembly 92 is preferably constructed of stainless steel, although any other suitable material may be used. Handles 96 are provided on an upper portion of pressure plate assembly 92 for allowing pressure plate assembly 92 to be inserted between upper horizontal frame members 74 and adjacent scrubbing roller 76. Pivoting latch handles 98 are pivotably attached to upper horizontal frame members 74 for engaging an upper surface 100 of pressure plate assembly 92 and served to retain pressure plate assembly 92 in position above scrubbing roller 96 when pivoted such that flanges 102 of latch handles 98 engage upper surface 100. Pivoting latch handles 98 allow for pressure plate assembly 92 to be easily secured in or removed from the machine 10. In FIGS. 1, 2, 4, and 5, pressure plate assembly 92 is shown removed from machine 10, whereas pressure plate assembly 92 is shown in place in FIGS. 3 and 6.
After passing over scrubbing rollers 76, pile side 82 of carpet tile 56 is next subjected to a rinsing spray emitted from rinsing nozzles 104 of a rinsing nozzle bank 106. The rinsing spray serves to rinse the cleaning fluid from pile side 82 which was applied by nozzles 88 of wetting means 22.
After passing over rinsing nozzle bank 106, carpet tile 56 is received by outfeed means 24. Outfeed means 24 includes substantially horizontally disposed rollers 108, 110 which are positioned relative to one another to form a nipping zone therebetween. Rollers 108, 110 are rotated oppositely relative to one another via drive shafts acting through sprockets 112, 114, respectively. Upper roller 108 is journaled in bearing blocks 116 likewise as roller 62 is journaled in bearing blocks 70. Spring 118 are provided between bearing blocks 116 and upper horizontal frame members 74 for biasing roller 108 downwardly against roller 110. It is to be noted that roller 64 of infeed means 20 and roller 110 of outfeed means 24 are both journaled beneath rollers 62, 108, respectively, for rotation in a conventional manner. It is also to be noted that bolts 120 are provided for attaching bearing blocks 70 and bearing blocks 116 to upper horizontal frame members 74, and that springs 72, 118 surround bolts 120 in biasing bearing blocks 70, 116 downwardly.
Outfeed rollers 108, 110 serve to both propel a carpet tile 56 outwardly to unloading station 16 and also to provide a squeezing action against the carpet tile 56 for squeezing residual fluid therefrom to enhance drying.
A drain pan unit 122 is provided beneath carpet tile cleaning compartment 84 for receiving cleaning fluid and rinsing fluid which is not retained by a carpet tile 56 as it passes through compartment 84. The fluid not retained by a carpet tile 56 could be that which is not absorbed thereby or that which is squeezed out by rollers 108, 110. Drain pan 122 is angled inwardly toward a central drain 124 which is connected to a drain conduit 126. Drain conduit 126 is connected to a discharge conduit 128 which is connectable with a conventional residential or commercial drainage and/or sewer system.
After a carpet tile 56 passes through outfeed means 24, it is subjected to vacuum means 28 which includes a vacuum slot 130 which is defined in surface 50 of unloading station 16. Vacuum slot 130 is connected via a vacuum conduit 131 to the intake side of blower or vacuum pump means, generally 132. Vacuum pump means 132 may include a single mechanical or electric pump or blower or one or more pumps or blowers connected in series for pulling a vacuum through vacuum slot 130. The fluid pulled from a carpet tile 56 through vacuum slot 130 flows in the direction of arrows 135, as shown in FIGS. 3 and 6, and accumulates in a vacuumed fluid reservoir 134 which will be described in more detail hereinafter.
Infeed means 20, outfeed means 24, and scrubbing means 18 are all powered by a single drive means, generally 136. As illustrated in FIGS. 2 through 5, drive means 136 includes a reversible electric motor 138 connected to a conventional reduction drive unit 140. Extending from reduction drive unit 140 is a drive shaft 142 which has a large sprocket 144 and a small sprocket 146 attached thereto. Large sprocket 144 is connected via a chain 148 to sprocket 80 of scrubbing roller 76 for the rotation thereof upon the rotation of drive shaft 142. Small sprocket 146 is connected to a sprocket 150, which is attached to the drive shaft of outfeed roller 110, via a chain 152, such that rotation of drive shaft 142 causes corresponding rotation of sprocket 150 and outfeed roller 110. A chain 154 connects sprocket 114 of roller 110 to sprocket 68 of roller 64 for rotating same. A chain 156 is provided which is connected to a sprocket 158 of roller 110, sprocket 66 of roller 62, sprocket 112 of roller 108, and an idler sprocket 160.
Thus, upon actuation of motor 138, drive shaft 142 of reduction drive unit 140 rotates sprockets 144, 146, which in turn provide rotation to scrubbing means 18, infeed means 20, and outfeed means 24. Due to the relationship of the sprocket diameters (large sprocket 144 driving sprocket 80 and small sprocket 146 driving sprocket 150, as illustrated in FIG. 2), sprocket 80 and scrubbing roller 76 are rotated faster than sprocket 150 of the outfeed means 24. Roller 64 of infeed means 20 is rotated at the same speed as roller 110 of outfeed means 24 due to the identical sizes of sprockets 68 and 114 (as also illustrated in FIG. 2) which are rotatably connected via chain 154, thereby allowing the carpet tile 56 to pass smoothly through the machine 10. This arrangement ensures that the scrubbing roller 76 effectively scrubs the pile side 82 of the carpet tile 56 as it passes through the cleaning compartment 84. Drive means 136 is mounted by conventional mounts 162 to frame structure 12.
Turning again to wetting means 22, the cleaning fluid flow system will now be described. As best shown in FIG. 6, water from a central supply such as a city water source is introduced to a water reservoir 164 via a conduit 166, as shown by arrow 167 in FIG. 5. A conventional float actuated switch 168 having a float 169 is provided in reservoir 164 for controlling the water flow into reservoir 164 through conduit 166 in a conventional manner relative to the water level 170 within reservoir 164. When water level 170 is below a predetermined level, float 169 is in a lowered position, which in turn causes activation of switch 168 to allow water into water reservoir 164. When water level 170 again reaches the predetermined level, float 169 is in a raised position, which in turn causes deactivation of switch 168.
Two outlets 172, 174 are provided reservoir 164. A chemical supply 176, such as a drum of cleaning fluid or detergent, is provided for supplying chemicals through a conventional flow metering means 178 in conduit 179 into outlet 172. This allows for a detergent or other suitable cleaning fluid to be mixed with water emitted from outlet 172. A conventional pulsation dampener 180 is provided in a conduit 182 for improving the flow characteristics therein. Conduit 182 connects outlet 172 to washer nozzle bank 90 for emitting the cleaning fluid from nozzles 88 onto the pile side 82 of a carpet tile 56. As illustrated in FIG. 5, a pump 184 is provided for pumping fluid through conduit 182 and, accordingly, outwardly through nozzles 80 of nozzle bank 90.
Extending from outlet 174 of reservoir 164 is a conduit 186 which is connected to rinsing nozzle bank 106 for emitting plain water through nozzles 104 for rinsing the pile side 82 of a carpet tile 56. Another conventional pulsation damper 188 is provided in conduit 186 and functions similarly as does pulsation damper 180 to improve the flow characteristics in conduit 186. A pump 190, as shown in FIG. 5, is provided for pumping fluid upwardly through conduit 186 and outwardly from rinsing nozzles 104. Both pumps 184, 190 are connected by drive belt 192, 194, respectively, to an electric pump drive motor 196 mounted in a lower portion of carpet tile cleaning machine 10 to frame structure 12.
The vacuumed fluid path is illustrated in FIGS. 3 and 6. Fluid vacuumed from carpet tile 56 through vacuum slot 130 flows through a vacuumed fluid conduit 198 into vacuumed fluid reservoir 134. Vacuumed fluid reservoir 134 includes a conventional mercury float switch 199 which, when fluid level 200 in reservoir 134 reaches a certain height, works through a conventional control switching means 201 to actuate an electric pump 202 for pumping fluid therefrom through a conduit 204 to discharge conduit 128. Thus, the operation of mercury float switch 199 provides that the fluid level 200 in reservoir 134 will be maintained below a level which would impede the vacuum action of blower means 132 acting through vacuum slot 130, i.e., below the level where vacuumed fluid conduit 198 enters vacuumed fluid reservoir 134 at baffled entrance 205. As illustrated in FIG. 6, vacuum means 132 includes two vacuum pumps or electric blowers 206, 208 mounted in series such that the suction sides of blowers 206, 208 pull a vacuum through vacuumed fluid reservoir via conduit 209, as shown by arrows 211. The discharge side of blower 208 is directed downwardly through conduit 213 to the atmosphere in a lower portion of the machine 10.
The amount of cleaning and rinsing fluid applied to a carpet tile 56, the squeezing action of outfeed means 24, and the vacuum action of vacuum means 28 are interdependent upon one another and, acting together, allow for a carpet tile 56 to be cleaned and substantially dry when it exits machine 10. Consequently, upon exiting machine 10, carpet tiles 56 are ready to be reapplied to a floor surface. Thus, the present invention provides that the carpet tiles may be removed from the floor surface, cleaned, substantially dried, and reapplied to the floor surface in only a minimal amount of time. The size and configuration of machine 10 allows for it to be installed in a variety of locations and in a variety of environments.
When cleaning a carpet tile which is of narrower width than vacuum slot 130, vacuuming action of fluid from the carpet tile by vacuum slot 130 is reduced as air is pulled in around the edges of the narrower carpet tile. For this reason, an auxiliary outlet 210 is provided in vacuum fluid conduit 198 for allowing vacuum to be pulled selectively therefrom using an auxiliary vacuuming unit (not shown), instead of through vacuum slot 130 upon the actuation of handle 212. Handle 212 is attached to a lever 214 which is pivotally connected to the machine 10. Opposite to handle 212 of lever 214, a linkage rod member 216 is pivotally connected thereto. Linkage rod member 216 includes at the opposite end thereof a slide valve plate 218 which may be selectively introduced into vacuumed fluid conduit 198 for allowing the vacuum to be pulled either from vacuum slot 130 or outlet 210.
The auxiliary vacuuming unit for vacuuming an undersized carpet tile is not shown, but is a hand held device having a hose connectable to outlet 210 which is attached to a vacuum head similar to a conventional vacuum cleaner head. When the auxiliary vacuuming unit is not in use, it can be inserted in a storage shelf 220 provided in unloading station 16.
A reversing switch 222 is provided for allowing the rotation of drive means 136 to be reversed such that should a carpet tile become jammed within machine 10, the drive means 136 can be reversed for reversing scrubbing means 18, infeed means 20, and outfeed means 24 to allow the carpet tile to be backed out.
A control panel 224 is provided on the front 44 of the machine 10 and includes metering means 178, pump control switches for controlling pumps 184, 190, and vacuum control switches for controlling the vacuum operation of machine 10. A power shut-off switch 230 is provided for deactivating the machine entirely. Also provided, but not shown, is an interlock switch which is contactable with top cover 40 when top cover 40 covers machine 10. The interlock switch shuts down the operation of machine 10 upon the opening of top cover 40.
In operation, a carpet tile 56 is placed with pile side 82 down on loading station 14 and advanced manually until received in the nipping zone formed by rollers 62, 64. Rollers 62, 64 propel the carpet tile over wetting means 22 which subject the pile side of the carpet tile to a cleaning fluid spray via nozzles 88. The carpet tile is then propelled by rollers 62, 64 over scrubbing roller 76 which physically scrubs the pile side 82 of the carpet tile. After passing over scrubbing roller 76, the pile side is rinsed with a rinsing fluid spray emitted from nozzles 104. The carpet tile is then received in the nipping zone of rollers 108, 110, which serve to both propel the carpet tile from the carpet cleaning compartment 84 and also to squeeze excess fluid therefrom. Upon exiting rollers 108, 110, the carpet tile passes over vacuum slot 130 which further removes fluid remaining in the carpet tile such that the carpet tile is relatively moisture free after passing over vacuum slot 130. The carpet tile is then delivered finally to the unloading station 16 where it is then manually removed therefrom.
Should a carpet tile be narrower in width than the vacuum slot 130, the handle 212 can be actuated for allowing the auxiliary vacuuming unit to be connected to auxiliary vacuum outlet 210. Then, the carpet tile can be manually vacuumed with the auxiliary vacuuming unit.
It is to be understood that various couplings, fittings, connections, controls, etc., which are within the purview of one of ordinary skill in the art, can be used in the construction of carpet tile cleaning machine 10.
From the foregoing, it can be seen that the present invention provides a carpet tile cleaning machine for automatically cleaning, rinsing, and vacuuming carpet tiles in a manner which meets the objectives set forth above.
While one preferred embodiment of the invention has been described using specific terms, such description is for present illustrative purposes only, and it is to be understood that changes and variations to such embodiment, including but not limited to the substitution of equivalent features or parts, and the reversal of various features thereof, may be practiced by those of ordinary skill in the art without departing from the spirit or scope of the following claims. | A method and apparatus for cleaning carpet tiles is disclosed. The apparatus which accomplishes the present method includes a machine having a frame structure, a loading station connected to the frame structure and adapted for receiving a carpet tile, and an unloading station connected to the frame structure and adapted for allowing removal of a carpet tile from the machine. Infeed rollers are provided a cleaning compartment of the machine for continuously propelling a carpet tile from the loading station and over a nozzle bank which subjects the pile side of the carpet tile to a cleaning fluid spray. A scrubbing roller then scrubs the pile side of the carpet tile, and the carpet tile is next propelled over rinsing nozzles which rinse the cleaning fluid therefrom. After passing over the rinsing nozzles, the carpet tile is propelled from the cleaning compartment and to the unloading station by outfeed rollers which both squeeze excess fluid from the carpet tile and move the carpet tile over a vacuum slot which vacuums residual fluid therefrom. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to Korean Patent Application Number 10-2008-0121884 filed Dec. 3, 2008, the entire contents of which application is incorporated herein for all purposes by this reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a washer device of a headlamp for a vehicle, and more particularly, to a washer device of a headlamp for a vehicle that opens a nozzle cover to which a nozzle unit is integrally mounted by using a washer liquid circulating structure inside the nozzle unit and the hydraulic pressure of a washer motor.
[0004] 2. Description of Related Art
[0005] In general, headlamps of high luminance are mounted to opposite lateral sides of the front of a vehicle in order to allow a driver to secure a sufficient visual field when there is a difficulty in securing a visual field during night or due to foggy, snowy, or rainy weather.
[0006] In recent years, washer devices are increasingly mounted to headlamps of high luminance such as HID headlamps in order to solve a problem in securing a frontal visual field caused by contamination of lens surfaces of the headlamps like washer devices applied to windshield glasses.
[0007] Currently, separate telescopes are being applied to washer devices of headlamps for almost all vehicles in order to solve problems such as blocking of ejection nozzles due to introduction of foreign substances.
[0008] Since such a washer device of a headlamp for a vehicle uses a separate cover, it has an excellent appearance. In addition, since it solves blocking of an ejection nozzle due to introduction of foreign substances, it is excellent in quality.
[0009] Korean Patent Laid-Open No. 2006-61540 discloses a washer device of a headlamp in which a rotary motor and a rotational force transferring mechanism are separately used instead of a telescope.
[0010] However, a washer device of a headlamp to which a telescope is applied needs a gap between a housing and a piston for upward and downward movement of the piston, and when moisture introduced into the gap is frozen, the operation of the washer device becomes impossible, secondarily causing loosing of a bumper and a nozzle cover and unsafe closing drive of a cover after use of the washer device.
[0011] In addition, such a washer device requires a telescope, a separate bracket for fixing the telescope, a housing, and a piston, causing additional costs.
[0012] Moreover, since Korean Patent Laid-Open No. 2006-61540 has a problem in that the rotational force transferring mechanism is corroded by a washer liquid introduced between a bumper and a nozzle cover or moisture introduced during washing of the vehicle or in a rainy day, a separate cover for preventing introduction of moisture needs to be mounted to a gear unit and a fixing bracket, causing disadvantages in the aspect of layout and additional costs.
[0013] Furthermore, since the nozzle cover is opened and closed by applying a separate rotary drive motor for driving the rotational force transferring mechanism, a motor is required in addition to a washer motor, causing disadvantages in weight and costs.
[0014] The information disclosed in this Background of the Invention section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
BRIEF SUMMARY OF THE INVENTION
[0015] Various aspects of the present invention are directed to provides an economical washer device of a headlamp for a vehicle in which a nozzle unit is integrally mounted to a nozzle cover and a washer liquid is ejected as the nozzle cover is opened when a slide drive unit is automatically rotated and driven using the washer liquid circulation structure inside the nozzle unit and the hydraulic pressure of a washer liquid.
[0016] In an aspect of the present invention, the washer device of a headlamp for a vehicle may include a nozzle unit integrally mounted onto a nozzle cover, the nozzle unit including a washer discharging opening and a washer introducing opening, wherein a washer liquid is fed through the washer introducing opening and selectively discharged through the discharging opening, and a slide drive unit integrated with the nozzle unit and configured and dimensioned to rotatably support the nozzle unit when the nozzle unit is rotated by an ejection pressure of the washer liquid discharged.
[0017] The nozzle unit may include a valve disposed in a housing, an elastic member, one side of which is fixed to the valve and the other side of which is fixed to the housing so as to elastically support the valve, and a washer liquid circulating channel having an input passage fluid-connected to the washer liquid introducing opening and an output passage fluid-connected to the washer liquid discharging opening, wherein the valve is disposed between the input passage and the output passage and configured and dimensioned to selectively block a fluid flow therebetween according to an elastic force of the elastic member and a pressure of the washer liquid introduced through the washer liquid introducing opening.
[0018] An ejection nozzle may be disposed between the valve and the washer liquid discharging opening to form the output passage of the washer liquid circulating channel, wherein the ejection nozzle is aligned along a tangential direction of a rotational locus of the nozzle unit.
[0019] The washer liquid circulating channel of the nozzle unit may be provided on the opposite side of the elastic member with respect to the valve, in which the washer liquid introducing opening is formed in a central portion of the housing in a lateral side thereof, and in which washer liquid discharging opening is spaced from the washer liquid introducing opening with a predetermined distance in a lateral direction of the housing.
[0020] The nozzle unit may further include a valve stopper configured and dimensioned to receive the valve between the valve stopper and the ejection nozzle to restrict a movement locus of the valve.
[0021] In another aspect of the present invention, the slide drive unit may include a lower guide bracket fixed to a vehicle body, and an operation bracket slidably coupled to the lower bracket and to which the nozzle unit is integrally mounted so that nozzle unit mounted to the operation bracket is slidably guided along a contour of the lower guide bracket, wherein the operation bracket includes a first guide groove to which the lower guide bracket is slidably coupled and wherein the operation bracket include a front protrusion and a rear protrusion spaced each other with a predetermined distance and the lower guide bracket includes stopper-mounting holes to receive stoppers therein so that a movement distance of the operating bracket is limited within a predetermined distance of the stoppers.
[0022] The first and second protrusions of the operation bracket may be disposed between the stoppers of the lower guide bracket,
[0023] The lower guide bracket may include a plurality of stopper-mounting holes to receive the stoppers therein so that the movement distance of the operating bracket can be adjusted, wherein the cross section of the first and second protrusions is smaller than the cross section of the stopper-mounting holes,
[0024] In further another aspect of the present invention, the washer device may further include an upper guide bracket fixed to the lower guide bracket to slidably receive the operation bracket therebetween, wherein the upper guide bracket includes a guide slot formed along a longitudinal direction of the upper guide bracket so that the nozzle unit is fixed to the operation bracket through the guide slot and slides along the guide slot without interference, wherein a nozzle mounting hole is formed in the operation bracket so that a bottom portion of the nozzle unit is inserted and fixed therethrough and wherein the upper guide bracket includes a second guide groove into which the operation bracket is slidably coupled so that the operation bracket is slidably guided between the upper and lower guide brackets.
[0025] As mentioned above, since the washer device of a headlamp for a vehicle according to the present invention is driven in a rotary manner using an ejection pressure of a washer liquid instead of being driven by a telescope or a rotary drive motor, it is advantageous in the aspects of layout and costs.
[0026] The methods and apparatuses of the present invention have other features and advantages, which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description of the Invention, which together serve to explain certain principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a side view illustrating an exemplary washer device of a headlamp for a vehicle according to the present invention.
[0028] FIG. 2 is a sectional view taken along line A-A′ of FIG. 1 .
[0029] FIG. 3 is an exploded perspective view illustrating an exemplary slide drive unit according to the present invention.
[0030] FIG. 4 is a perspective view illustrating the slide drive unit according to the present invention.
[0031] FIG. 5 is a view illustrating the operation of an exemplary nozzle unit according to the present invention.
[0032] FIG. 6 is a view illustrating the operation of the exemplary washer device of a headlamp for a vehicle according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0033] Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it will be understood that present description is not intended to limit the invention(s) to those exemplary embodiments. On the contrary, the invention(s) is/are intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.
[0034] FIG. 1 is a side view illustrating an exemplary washer device of a headlamp for a vehicle according to the present invention. FIG. 2 is a sectional view taken along line A-A′ of FIG. 1 . FIG. 3 is an exploded perspective view illustrating a slide drive unit according to the present invention. FIG. 4 is a perspective view illustrating the slide drive unit according to the present invention.
[0035] The present invention relates to an economical washer device of a headlamp for a vehicle in which a nozzle unit 10 is integrally mounted into a nozzle cover 110 and which drives a nozzle unit 10 and a slide drive unit 20 by removing a conventional telescope or rotary drive motor and using a washer liquid circulating structure inside the nozzle unit 10 and the hydraulic pressure of a washer motor.
[0036] As illustrated in FIG. 1 , the washer device includes a nozzle unit 10 integrally mounted into a nozzle cover 110 and to which a nozzle pipe 10 a through which a washer liquid is fed is connected and a slide drive unit 20 integrated with the nozzle unit 10 and exposing an ejection nozzle to the outside when it is rotated by the ejection pressure of a washer liquid during the operation of a washer switch.
[0037] As illustrated in FIG. 2 , a conic compression spring 12 is fixed to the rear wall of the nozzle unit 10 and a plate-like valve 11 is installed in front of the compression spring 12 . A washer liquid circulating channel 13 is provided on the other side of the compression spring 12 with respect to the valve 11 .
[0038] A washer liquid introducing opening 14 is provided in a central passage 131 of the washer liquid circulating channel 13 , and a washer liquid discharging opening 15 is provided in side passages 132 formed on opposite sides of the central passage 131 .
[0039] In a normal state, the central passage 131 and the side passages 132 are blocked from each other by the valve 11 . On the other hand, during the operation of a washer switch, the valve 11 is opened to the position of a valve stopper 16 by the pressure of the introduced washer liquid so that the central passage 131 can be communicated with the side passages 132 .
[0040] In the structure of the nozzle unit 10 , after the washer liquid is introduced into the nozzle unit 10 , the slide drive unit 20 is rotated by itself in a round configuration by the hydraulic pressure of the washer liquid while presses the valve 11 inside the nozzle unit 10 against the elastic force of the compression spring 12 and is discharged to the outside to be ejected through an ejection nozzle 132 .
[0041] As illustrated in FIGS. 3 and 4 , the slide drive unit 20 includes an operation bracket 21 having a rounded plate-like shape to which the nozzle unit 10 is integrally mounted and having first guide grooves 211 on opposite sides thereof, an upper guide bracket 22 having second guide grooves 221 into which the operation bracket 21 are inserted so that the operation bracket 21 can be slidably guided and being located on the upper guide bracket 22 , and a lower guide bracket 23 having fixing brackets 231 inserted into the first guide grooves 211 of the operation bracket 21 so that the operation bracket 21 can be slidably guided along the lower guide bracket 23 .
[0042] The upper guide bracket 22 is fixed to the lower guide bracket 23 which is attached to a stationary member such as a vehicle body by a bolt 24 so that the operation bracket 21 disposed between the upper guide bracket 22 and the lower guide bracket 23 can move relatively therebetween.
[0043] In various embodiments of the present invention, the upper guide bracket 22 may be removed so that the operation bracket 21 is slidably guided only along the lower guide bracket 23 .
[0044] A nozzle mounting hole 212 is formed in the operation bracket 21 so that the nozzle unit 10 can be inserted therethrough to be fixed, and ribs 213 restricting slide of the operation bracket 21 are formed on front and rear sides of the nozzle mounting hole 212 in the operation bracket 21 .
[0045] A guide slot 222 along which the nozzle unit 10 is guided is formed in the upper guide bracket 22 along the lengthwise direction of the upper guide bracket 22 so that the nozzle unit 10 and the operation bracket 21 can be slid upward and downward without interference.
[0046] Slotted stopper mounting holes 232 through which stoppers 233 are inserted to be fixed are disposed in the lower guide bracket 23 at an interval along the lengthwise direction of the lower guide bracket 23 , so that when the ribs 213 of the operation bracket 21 are caught and interfered with by the stoppers 233 , the radius of rotation of the operation bracket 21 is restricted.
[0047] Hereinafter, the principle of the washer device of a headlamp for a vehicle including the nozzle unit 10 and the slide drive unit 20 will be described in detail with reference to the accompanying drawings.
[0048] FIG. 5 is a view illustrating the operation of the nozzle unit 10 according to the present invention, and FIG. 6 is a view illustrating the operation of the washer device of a headlamp for a vehicle according to the present invention.
[0049] The present invention has a structure by which operation time is delayed so that a washer liquid cannot be ejected until the operation bracket 21 is rotated along the upper and lower guide brackets 22 and 23 by the operation of the mechanical valve 11 until the ribs 213 of the operation bracket 21 are stopped by the stoppers 233 fixed to the lower guide bracket 23 . As illustrated in FIGS. 5 and 6 , when the washer liquid is introduced into the nozzle unit by a strong pressure during the operation of the washer motor after the washer switch is operated, the washer liquid is ejected to the outside of the nozzle unit 10 via the washer liquid circulating channel 13 by the washer liquid structure.
[0050] Then, after the washer liquid is introduced into the nozzle unit 10 and presses the valve 11 of the nozzle unit 10 , the nozzle unit 10 and the operation bracket 21 of the slide drive unit 20 are rotated along the upper and lower guide brackets 22 and 23 while the valve 11 is opened and the washer liquid is discharged to the outside through the passage.
[0051] Here, since the resilient force of the compression spring 12 supporting the valve 11 inside the nozzle unit 10 sets the applied force by which the operation bracket 21 of the slide drive unit 20 is rotated to be higher, the valve 11 is not opened during the rotation of the operation bracket 21 .
[0052] In this state, if the nozzle unit 10 is not rotated further by the catching structure of the ribs 213 of the operation bracket 21 and the stoppers 233 of the lower guide bracket 23 while the operation bracket 21 is being rotated by the pressure of the washer liquid, the pressure of the washer liquid overcomes the resilient force of the compression spring 12 and the valve 11 is moved rearward at the same time.
[0053] Accordingly, when the central passage 131 and the side passages 132 are communicated with each other, the washer liquid is ejected.
[0054] The ejection angle and time of the washer liquid are adjusted by the positions of the stoppers 233 of the lower guide bracket 23 and the shape of the nozzle unit 10 and the slide drive unit 20 .
[0055] The nozzle unit 10 may be return to its original position by an elastic member that may be coupled to an end portion of the operation bracket 21 after the pressure of the washer liquid is reduced.
[0056] For convenience in explanation and accurate definition in the appended claims, the terms “upper”, “lower”, “front”, and “rear” are used to describe features of the exemplary embodiments with reference to the positions of such features as displayed in the figures.
[0057] The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents. | Disclosed is an economical washer device of a headlamp for a vehicle includes a nozzle unit integrally mounted onto a nozzle cover, the nozzle unit including a washer discharging opening and a washer introducing opening, wherein a washer liquid is fed through the washer introducing opening and selectively discharged through the discharging opening, and a slide drive unit integrated with the nozzle unit and configured and dimensioned to rotatably support the nozzle unit when the nozzle unit is rotated by an ejection pressure of the washer liquid discharged. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to power actuator arrangements and in particular power actuator arrangements for providing a child safety on/off feature, a lock/unlock feature or a superlock/unsuperlock feature on a car door latch.
When known power actuator arrangements are used for locking and unlocking of a vehicle door latch, a provision is made for manual override. Thus a vehicle door latch which has been power unlocked by a central door locking system can subsequently be manually locked by the driver depressing a cill button or the like. Under such circumstances the cill button preferably has to be provided with a detent position to ensure that the cill button stays in either a filly raised or fully lowered position and not in a midway position. Under such circumstances the motor of the power actuator arrangement has to be powerful enough to not only drive the latch mechanism between lock and unlock but also has to overcome the detent forces.
In particular the detent forces have to be sufficiently high to provide a good tactile feel and also to ensure that inertia forces resulting from a road traffic accident do not overcome the detent forces and change the state of the lock.
SUMMARY OF THE INVENTION
Thus according to the present invention there is provided a power actuator arrangement including a power drive assembly having a first powered position and a second powered position and an output means, the output means being moveable by the power drive assembly between a first detent position corresponding to the first powered position and a second detent position corresponding to the second powered position following powered operation, the output means being retained in the first or second detent positions by a detent bias force provided by a detent arrangement, the output means being independently moveable by a independent force between the first and second detent positions, the independent force acting to overcome the detent bias force such that during independent movement the independent force substantially does not act to move the power drive assembly between its first powered and second powered positions.
According to a further aspect of the present invention there is provided a power actuator arrangement including a power drive assembly and an output means, the output means being movable by the power drive assembly between first and second positions and being independently movable by an independent force between the first and second positions such that the first and second positions are detent position and during independent movement between the first and second positions the independent force has to overcome a detent force in which the power drive assembly has to overcome a reduced detent force when moving the output means between the first and second positions.
These and other features of the present invention will be best understood from the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The various features and advantages of the invention will become apparent to those skilled in the art from the following detailed description of the currently preferred embodiment. The drawings that accompany the detailed description can be briefly described as follows:
FIG. 1 is a front view of the power actuator arrangement according to the present invention during powered operation;
FIG. 2 is an isometric view of the output means of FIG. 1;
FIG. 2A is a partial cut away view of FIG. 1;
FIGS. 3, 4 , 5 and 6 are front, isometric, rear and side views of the power actuator arrangement of FIG. 1 being used to actuate a child safety arrangement of a door latch; and
FIG. 7 is a view of a further power actuator according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIGS. 1 and 2 there is shown a power actuator arrangement 10 which includes a power drive assembly 12 , an output means 14 and a detent arrangement 84 . The power drive assembly includes a power actuator in the form of a motor 16 driving a pinion 18 which engages and drives gear 20 . Gear 20 is rotationally fast with a drive abutment in the form of a crank pin 32 . The drive pin 18 , gear 20 and crank pin 32 combine to form a transmission path of the power drive assembly.
The detent arrangement 84 includes a first member in the form of a cam 22 and a second member in the form end portion 23 of output means 14 .
The cam 22 is secured rotationally fast to gear 20 . Cam 22 has a cam surface 24 being profiled with base circle portion 26 and 27 (also known as third and fourth outwardly facing surfaces) and two symmetrically diametrically opposed cam lobes 28 and 30 (also known as first and second outwardly facing surfaces).
End portion 23 includes a twin lobed recess 34 having first arcuate portion 36 and second arcuate portion 38 , the centres of arcuate portions 36 and 38 being different. The first and second arcuate portions combine to form a wasted region 40 of width W.
Accurate portion 36 includes portion B (see FIG. 2A) ie that portion of arcuate portion 36 abutted by one of the cam lobes (in the case of FIG. 3, cam lobe 30 ) when the output means 14 is in the lowered position. A similar portion C of arcuate portion 38 can be defined as that portion abutted by one of the cam lobes when the output means is in the raised position. Corresponding portions D of arcuate portion 36 and E of arcuate portion 38 can be defined as those portions contacted by one of the cam lobes 28 and 30 when the output means 14 is in the lowered and raised position respectively. The combination of portions B and C combine to form a first inwardly facing surface F of the end portion 23 and the combination of portions D and E combine to form a second inwardly facing surface G of the end portion 23 .
Wall 33 defines the twin-lobbed recess 34 and is relatively thin. Proximate and facing the twin lobbed recess 34 is a flange portion 42 having a driven recess 44 and a first and second stop abutments 46 and 48 .
An arm 50 of output means 14 is integrally formed with the wall 33 and flange portion 42 and includes at its distal end 52 an arcuate slot 54 . The cam 22 is positioned within the recess 34 .
The output means 14 can be moved reciprocally in the direction of arrow A by selective operation of the motor between a lowered first detent position (as shown in FIGS. 1 and 3) and a raised second detent position. Additionally the output means 14 can be manually moved between the first and second detent positions by actuation of the pin 80 , situated in slot 54 , in the direction of arrow A.
The power drive assembly has a first powered position as shown in FIG. 3 wherein crank pin 32 is situated at the 12 o'clock position and a second powered position wherein crank pin 32 is situated at the 6 o'clock position when viewing FIG. 3 . As described below when the output means is moved by the power drive assembly between the first detent position and second detent position, these detent positions correspond respectively to the first and second powered positions of the power drive assembly.
However, as further described below, following independent movement of the output means the output means can be moved to its second detent position whilst the power drive assembly remains in its first powered position and similarly the output means can be moved to its first detent position whilst the power drive assembly remains in its second powered position.
With the actuator arrangement positioned as shown in FIG. 3 the crank pin 32 abuts first stop abutment 46 and the cam lobe 28 and 30 are positioned horizontally relative to each other when viewing FIG. 3 and are in contact with first arcuate portion 36 of twin lobed recess 34 .
It should be noted that the diameter across cam lobes 28 and 30 is substantially the same as the diameter across first arcuate portion 36 and second arcuate portion 38 , and that the diameter across the base circle portion 36 is substantially similar to distance W across the wasted region 40 .
Lifting of pin 80 (as described below) causes the output means 14 to move upward when viewing FIG. 3 such that the wasted region 40 rides over cam loads 28 and 30 thus springing wall 33 apart. Continued movement of the output means upward results in the cam lobes 28 and 30 snapping into engagement with second arcuate portion 38 .
Thus the cam lobes 28 and 30 in conjunction with waste portion 40 provide for an upper and lower detent position of the output means 14 .
It should be noted that the cam lobes 28 and 30 are symmetrical as is either side of the wasted portion. Thus manual movement of the output means 40 between its first and second position does not produce any turning moment on cam 22 . Thus there is no tendency for cam 22 to rotate during manual movement.
With the power actuator arrangement 10 positioned as shown in FIG. 3 the motor can be energised such that it rotates in a clockwise direction causing the gear 20 to rotate in an anti-clockwise direction. Thus crank pin 32 will move from the twelve o'clock position anti-clockwise, in the direction of arrow R, to the four o'clock position as shown in FIG. 1 whereupon it will engage driven recess 44 and cause the output means 14 to move from its first lower to its second raised position. Continued energization of the motor will cause the crankpin 32 to continue to move in an anticlockwise direction past the twelve o'clock position and around to the six o'clock position whereupon it will abut second stop abutment 48 .
It should be noted that the crank pin 32 has just started to engage in recess 44 when crank pin 32 is at the four o'clock position and consequently the output means 14 is fully raised when the crank pin 32 is in the two o'clock position. Note that cam lobe 28 moves between a seven o'clock and five o'clock position and cam lobe 30 moves between a one o'clock and eleven o'clock position during movement of the output means 14 from its first to second position and that wasted portion 14 thus only has to pass over base circle portion 26 . Since the width W of wasted portion 40 is substantially the same as the diameter of the base circle portion 26 there is no detent force to overcome when the output means is moved between its first and second positions by the motor 16 .
With the output means raised to its second position by the motor 16 . Actuation of the motor in an anticlockwise direction will cause drive gear 20 to rotate through 540° in a clockwise direction such that crank pin 32 moves one and half turns from a six o'clock to the twelve o'clock position moving the output means 14 from its raised second position to its lowered first position.
In the event of manual movement of output means 14 from its lowered first position as shown in FIG. 3 to its raised second position, in the absence of movement of the motor, subsequent actuation of the motor in a clockwise direction will result in anti clockwise rotation of the gear 20 . However the crank pin 32 will only move through until such time as it contacts second stop abutment 48 which has been moved to a raised position as a result of manual movement of the output means.
As described above, in this case the power actuator arrangement drives a vehicle car door latch between a child safety on and a child safety off position as described below.
A latch arrangement 8 includes the power actuator arrangement 10 mounted on a chassis 60 . An inside handle lever 62 (connected to an inside door handle) and an inside release lever 64 are both pivotally mounted on the chassis 60 about pivot 66 . A child safety link 68 lies substantially parallel to the inside handle lever 62 and inside release lever 64 and includes at an upper portion a clutch pin 70 which slideably engages slot 72 of inside handle lever 62 . Projecting on other side of child safety link 78 is pin 80 which engages slot 54 as described above.
A lower portion of the child safety link 68 engages with a crank pin 74 of child safety operating crank 76 .
Operation of an inside door handle causes inside handle lever 62 to rotate anticlockwise as shown in FIG. 6 such that clutch pin 70 contacts clutch abutment 78 of inside release lever 64 causing inside lever 64 to also rotate anticlockwise resulting in opening of the door.
However when the clutch pin 70 is moved to an upper portion of slot 72 operation of the inside door handle results in clutch pin 70 passing over clutch abutment 78 resulting in a door that cannot be opened by operation of the inside door handle (child safety on).
Clutch pin 70 can be moved up or down slot 72 either by actuation of the motor or by manual means as follows.
Motor actuation causes output means 14 to move between first and second positions. The co-operation of pin 80 with arcuate slot 54 causes the child safety link 68 to move to a raised or lowered position thus positioning clutch pin 70 in a raised or lowered position. Raising or lowering of the child safety link 68 by the motor has the result of rotating the child safety-operating crank.
Alternatively rotation of the child safety operating crank by insertion of a screwdriver or the like into slot 82 causes clutch pin 70 to move between an upper and lower position. Such manual movement causes pin 80 to drive the output means 14 between its lower first position and upper second position. Because the first and second positions of the output means 14 are detent positions, the detent can be felt by an operator rotating the child safety operating crank with a screwdriver or the like. Thus the operator can be confident that the child safety is on or off as appropriate.
As mentioned above the power actuator arrangement is not limited to changing the state of a latch between a child safety on and child safety off condition.
Furthermore the output means need not operate in a linear manner but could be arranged as a lever 14 ′ (see FIG. 7) pivotable about axis 11 .
The foregoing description is only exemplary of the principles of the invention. Many modifications and variations of the present invention are possible in light of the above teachings. The preferred embodiments of this invention have been disclosed, however, so that one of ordinary skill in the art would recognize that certain modifications would come within the scope of this invention. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specially described. For that reason the following claims should be studied to determine the true scope and content of this invention. | A power actuator arrangement including a power drive assembly having a first powered position and a second powered position and an output device, the output device being unmoveable by the power drive assembly between a first detent position corresponding to the first powered position and a second detent position corresponding to the second powered position following powered operation, the output device being retained in the first or second detent positions by a detent bias force provided by a detent arrangement, the output device being independently movable by an independent force between the first and second detent positions, the independent force acting to overcome the detent bias force such that during independent movement the independent force substantially does not move the power drive assembly between its first powered and second powdered positions. | 8 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to a device for storing and dispensing endless machining belts, especially grinding belts, for a machining installation comprising a robot arm.
[0002] The robot arm is equipped with one or more machining belts which must be regularly replaced to change the type of belt used or to replace a worn belt with a new one.
DESCRIPTION OF THE PRIOR ART
[0003] Document FR-A1-2677289 discloses a machining installation comprising a dispenser of endless grinding belts comprising a plurality of belt support platforms mounted in a vertical cage with a vertical and horizontally mobile system for extending the platforms from the cage one after the other toward a robot arm. One problem with that dispenser is its complexity and the large number of operations that have to be carried out to change one abrasive belt on the robot, with the result that belt changes are time-consuming and can require the intervention of an operator.
SUMMARY OF THE INVENTION
[0004] It is a particular object of the invention to provide a simple, effective and inexpensive solution to this problem.
[0005] To this end, the invention provides a device for storing and dispensing endless machining belts for a robotic installation, comprising means for supporting a plurality of machining belts and means for locating these belts on the supporting means, in which device the supporting and locating means comprise a support rotating about a vertical axis and having radial arms, each equipped with means for locating a machining belt, and means for the stepwise rotation of the rotating support, in order to bring each arm in turn to a station where the belt may be fitted onto a robot arm.
[0006] The star configuration of the device of the invention means that changing a belt on a robot arm takes little time and very few operations, because all that is required is to rotate the support of the radical arms a fraction of a revolution to present a new belt in a position where this belt can be picked up by the robot arm.
[0007] The device comprises for example twelve radial arms set out at regular intervals around the vertical axis.
[0008] In accordance with another feature of the invention, the belt locating means comprise retractable pins guided in housings in the arms and engaged in the ends of the belts, and return springs urging these pins toward their belt holding position.
[0009] The locating pins are engaged in the belt carried by the radial arm and make it possible to keep this belt in a position in which the belt is slightly tensioned, so that the belts are stored on the radial arms in the same position. It is therefore no longer necessary for an operator to check that the belts are correctly positioned in the device. The retractable pins are permanently urged by the return springs toward their belt holding position.
[0010] The top ends of the belt locating pins form contact surfaces that are pushed by the bottom ends of two pulleys of a robot arm to depress the pins and engage the belt on the pulleys of the robot.
[0011] The fitting of a belt to the robot arm is done automatically by placing the robot arm in such a way that the pulleys push down on the pins to depress the pins and release a belt. The pulleys of the robot arm which are engaged in the ends of the belt are then moved further apart from each other so that the belt is tensioned between the pulleys. The robot arm can then move away with the belt to perform machinery operations.
[0012] Each radial arm may comprise for example an elongate plate supporting the edges of a belt and comprising orifices at its ends for the locating pins to pass through.
[0013] This plate preferably comprises an elongate guide slot extending between the two edges of the belt, to allow the descent of part of the robot arm and facilitate the positioning of the latter when the pulleys of the arm are being moved apart from one another.
[0014] The device preferably comprises at least one sensor for detecting the presence of machining belts on the radial arms. The sensor can detect the presence of a belt on the radial arm present in the station where belts are fitted to the robot arm. If this radial arm is not carrying a belt, the rotating support is turned one step so that a new radial arm is situated in the fitting station and the sensor can detect the presence of a belt on this arm. If there is still no belt, the operation is repeated until a belt is found in the fitting station.
[0015] An operator can intervene on the device to install new belts. This operation may also be carried out by an automatic unit.
DESCRIPTION OF THE DRAWINGS
[0016] The invention will be understood more clearly and other advantages and features of the invention will become apparent from the following description, which is given by way of non-restrictive example with reference to the appended drawings in which:
[0017] FIG. 1 is a schematic top view of the device for storing and dispensing endless machining belts according to the invention;
[0018] FIGS. 2 and 3 are schematic perspective views of a radial arm of the device seen in FIG. 1 ;
[0019] FIGS. 4-6 are highly schematic side views of a radial arm of the device according to the invention, and illustrate steps in a process of fitting a belt to a robot arm.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Referring initially to FIG. 1 , this shows in schematic form an embodiment of the device 10 according to the invention for storing and dispensing endless machining belts for a machining installation comprising a robot arm 40 .
[0021] The device 10 comprises a plurality of belt supporting and locating arms 12 that extend radially around a vertical axis 14 and that are distributed at regular intervals about this axis 14 . The radial arms 12 are fixed by screws 15 or the like to a circular platform 16 rotated stepwise about the axis 14 by drive means. The device also includes a base for supporting and guiding the rotary platform 16 .
[0022] In the example illustrated, the radial arms 12 are twelve in number and the platform is turned stepwise in steps of 300.
[0023] The machining belts may be of any type such as grinding belts for example. Belts mounted on the robot arm 40 must be replaced at regular intervals, especially to replace a worn belt with a new one. The stepwise rotation of the platform 16 is controlled by a robot arm control unit so that the platform is rotated in response to the needs of the robot arm for belts.
[0024] The device also includes one or more detectors 17 for detecting the presence of belts on the radial arms 12 : these detectors transmit signals to the robot arm control unit.
[0025] Each radial arm 12 (more clearly visible in FIGS. 2 and 3 ) comprises means for supporting a belt 18 and means for locating this belt on the support means in such a way that the belt can be picked up directly by the robot arm without operator assistance.
[0026] The locating means comprise an elongate parallelepiped-shaped box 20 having a large upper face 22 at whose longitudinal ends are two orifices 24 for two retractable cylindrical pins 26 to pass through. The belt 18 will be wrapped around these pins 26 .
[0027] The pins 26 are approximately parallel to and at a distance from each other, the distance between the pins being such that the belt 18 wrapped around the pins is in an elongated or slightly tensioned condition in which it comprises two long belt portions that are approximately straight, mutually parallel, and close together.
[0028] Return springs (represented schematically by dashes 28 ) are held inside the box 20 and extend between the bottom face of the box and the bottom ends of the pins 24 so as to tend to push these pins out of the box, into their belt holding position. Means are provided to limit the movement of the pins into and out of the box, through the orifices 24 .
[0029] The top ends of the pins 26 form contact surfaces on which a robot arm can push, as will be described later in more detail.
[0030] The means of supporting a belt on the radial arm 12 comprise a flat elongate plate 30 whose dimensions in terms of breadth and length are approximately the same as those of the upper face 22 of the box 20 , and which is fixed over the top of and at a distance from this face by means of screws 32 . The distance between the plate 30 and the face 22 of the box is determined for example by tubes 34 of predetermined length engaged around the screws and mounted between the plate 30 and the upper face 22 of the box 20 .
[0031] At the longitudinal ends of the plate 30 are two orifices 36 for the pins 26 to pass through, the inside diameter of these orifices being greater than the outside diameter of the pins.
[0032] The pins 26 can be moved axially between first and second positions and are permanently urged toward the first position by the return springs 28 .
[0033] In the first position, shown in FIG. 2 , the top end parts of the pins 26 pass through the orifices 36 of the plate 30 and project above this plate. In this position the pins are engaged in the machining belt 18 placed on the plate 30 and keep this belt in an elongate or slightly tensioned condition.
[0034] In the second position, shown in FIG. 3 , the pins 26 have been pushed down beneath the plate 30 and are no longer engaged in the belt 18 , which is resting on the plate and is therefore free to be picked up by a robot arm. The distance between the plate and the box 20 is such that the pins no longer project above the plate when the pins are in their second position.
[0035] As will be described in more detail below with reference to FIGS. 4-6 , the movement of the pins from their first position to their second is caused mechanically by the robot arm.
[0036] The robot arm 40 , shown partially and highly schematically in FIG. 4 , comprises an actuator 42 whose cylinder 44 is mounted on the robot arm and whose piston 46 is connected to a driven pulley 48 mounted so as to rotate freely on a spindle perpendicular to the longitudinal axis of the actuator. The robot arm also has a drive pulley 50 which extends parallel to the first pulley, behind the actuator, and whose axis is parallel to the axis of the actuator 42 . This pulley 50 is turned by a motor mounted on the robot arm.
[0037] In a first step of fitting a belt 18 to the robot arm, shown in FIG. 4 , the actuator 42 of the robot arm is in a retracted position in which the distance between the axes of the pulleys 48 , 50 is approximately equal to the distance between the axes of the pins 26 . The robot arm 40 is positioned above a radial arm 12 of the device on which a belt is fitted ( FIG. 1 ), until the pulleys 48 , 50 are aligned with the pins 26 . The robot arm 40 is then moved vertically toward the radial arm 12 until the pulleys 48 , 50 of the robot arm engage in the belt 18 and move the pins 26 from their first position to their second by pushing on the top ends of the pins ( FIG. 5 ). The piston 46 of the actuator is then extended to move the pulleys 48 , 50 further apart until the belt 18 is tensioned between the pulleys. The belt can then be removed to carry out machining work ( FIG. 6 ). The pins 26 are returned to their first position by the return springs 28 . A new belt 18 can be placed on the pins 26 by an operator or by an automatic unit.
[0038] The control unit of the robot arm controls the movement of the robot arm and of the platform 16 in response to information transmitted by the sensor 17 . The platform 16 is driven stepwise about the axis 14 until a radial arm 12 fitted with a belt is in a predetermined belt pick-up position, so that the belt can be fitted on the robot arm by carrying out the steps shown in FIGS. 4-6 .
[0039] As is visible in FIGS. 1-3 , the plate 30 of each radial arm 12 may include an elongate slot 51 extending along the edges of the belt 18 and connected at one end to one of the aforementioned orifices 36 through which the pins 26 can pass, in such a way as to facilitate the engagement of the actuator 42 of the robot arm in the belt 18 and guide the actuator piston 46 as it extends.
[0040] In one particular illustrative embodiment of the invention, the device also comprises a vertical wall 52 separating the device shown in FIG. 1 into two groups of six radial arms each, one group being accessible to one robot arm 40 and the other group being accessible to an operator for the purpose of installing new machining belts. Each time the platform 16 turns one step about the axis 14 , one of the radial arms 12 of the first group moves into the second group, and one of the arms 12 of the second group moves into the first group. | A device ( 10 ) for storing and dispensing endless machining belts for a robotic installation, comprising a support ( 16 ) rotating about a vertical axis ( 14 ) and having radial arms ( 12 ), each equipped with means for locating a machining belt, and means for the stepwise rotation of the rotating support, in order to bring each arm in turn to a station where the belt may be fitted onto a robot arm ( 40 ). | 1 |
BACKGROUND
[0001] 1. Technical Field
[0002] The disclosure generally relates to power control devices, and more particularly, to a power control device including a snubber circuit.
[0003] 2. Description of the Related Art
[0004] A typical power control device of electronic devices includes a power supply unit (PSU) and a buck converter. The PSU supplies direct current (DC). The buck converter converts the DC voltage of the PSU down to one or more preset voltages which may be supplied to the electronic device. A typical buck converter includes a first switch and a second switch alternately closing and opening. When the buck converter is under a heavy load (for example, when the output voltage of the PSU is high (e.g., greater than 20 volts)), the first switch and the second switch turn on and turn off at a high frequency which would result in generation of a voltage spike that may damage the first switch and the second switch.
[0005] A commonly used snubber circuit includes a resistor and a capacitor connected in series, and the snubber circuit is connected in parallel with the second switch to decrease the voltage spike. However, when the buck converter is under a light load (for example, when the output voltage of the PSU is low (e.g., less than 10 volts), the snubber circuit is idle and increases power loss of the power control device.
[0006] Therefore, there is room for improvement within the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Many aspects of an exemplary power control device can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the exemplary power control device. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views. Wherever possible, the same reference numbers are used throughout the drawings to refer to the same or like elements of an embodiment.
[0008] FIG. 1 is a circuit diagram of a power control device, according to an exemplary embodiment.
[0009] FIG. 2 is a circuit diagram of a peak detecting circuit of the power control device of FIG. 1 .
DETAILED DESCRIPTION
[0010] FIG. 1 is a circuit of power control device 100 of one embodiment. The power control device 100 supplies power to an input terminal 200 of an electronic device (not shown). The power control device 100 includes a buck converter 10 , a power supply unit (PSU) 12 , a peak detecting circuit 30 , a snubber circuit 50 , and a logic circuit 70 . The PSU 12 provides a direct current voltage Vin to the buck converter 10 . The buck converter 10 includes a controller 11 which is utilized to output a stable working voltage for the input terminal 200 . The peak detecting circuit 30 is electronically connected between the buck converter 10 and the logic circuit 70 . The peak detecting circuit 30 detects a voltage Vx of the buck converter 10 . The buck converter 10 provides the voltage Vx to a load (not shown) of the input terminal 200 . The voltage Vx varies with the load presented by the input terminal 200 . For example, if the load of the input terminal 200 becomes greater, the voltage Vx must become greater to make sure that the input terminal 200 is in a normal working state.
[0011] The snubber circuit 50 is electrically connected to the buck converter 10 . The logic circuit 70 is electrically connected to the snubber circuit 50 and defines a reference voltage value Vref. The logic circuit 70 compares the reference voltage value Vref with the voltage Vx detected by the peak detecting circuit 30 to generate a comparison and controls the snubber circuit 50 to work or to stop working based on the result of the comparison.
[0012] When the peak detecting circuit 30 detects that the voltage Vx is high, the logic circuit 70 determines that the buck converter 10 is under a heavy load and controls the snubber circuit 50 to work so as to protect the buck converter 10 . When the peak detecting circuit 30 detects that the voltage Vx is low, the logic circuit 70 determines that the buck converter 10 is under a light load and controls the snubber circuit 50 to stop working so as to cancel the drain of power taken by the snubber circuit 50 itself.
[0013] The buck converter 10 includes the controller 11 , a first switch Q 1 , a second switch Q 2 , an inductor L, and a filter capacitor C 1 . In this embodiment, the first switch Q 1 and the second switch Q 2 are field-effect transistors. Gate electrodes of the first switch Q 1 and the second switch Q 2 are electronically connected to the controller 11 . The controller 11 adjusts voltages of the gate electrodes to selectively close or open the first switch Q 1 and the second switch Q 2 . In this embodiment, the controller 11 is a pulse width modulation integrated circuit (PWM IC) chip. The controller 11 sends pulse width modulation signals to the first switch Q 1 and the second switch Q 2 , and adjusts duty ratio of the pulse width modulation signals to regulate turn-on times of the first switch Q 1 and the second switch Q 2 .
[0014] The first switch Q 1 and the second switch Q 2 are connected in series between the PSU 12 and the ground to obtain a node 13 between the first switch Q 1 and the second switch Q 2 , and a voltage of the node 13 is equal to the voltage Vx. A drain electrode of the first switch Q 1 is electronically connected to the PSU 12 , and a source electrode of the first switch Q 1 is electronically connected to a drain of the second switch Q 2 . A source electrode of the second switch Q 2 is grounded. A first end of the inductor L is electronically connected to the drain electrode of the second switch Q 2 , and a second end of the inductor L is electronically connected to ground through the filter capacitor C 1 . The input terminal 200 is connected in parallel with the filter capacitor C 1 .
[0015] When the controller 11 allows the first switch Q 1 to close (turn on), and allows the second switch Q 2 to open (turn off), the PSU 12 provides power to the input terminal 200 via the first switch Q 1 and the inductor L, and the inductor L stores electromagnetic energy. When the controller 11 allows the first switch Q 1 to open (turn off), and allows the second switch Q 2 to close (turn on), the inductor L acts like a voltage source and provides power to the input terminal 200 . Therefore, the first switch Q 1 alternately opens or closes and the voltage Vx is generated as PWM signals as shown in FIG. 2 .
[0016] The peak detecting circuit 30 defines a detecting terminal 301 and an output terminal 302 . The detecting terminal 301 is electrically connected to the node 13 of the buck converter 10 and is utilized to detect the voltage Vx. The output terminal 302 is electrically connected to the logic circuit 70 . As shown in FIG. 2 , the peak detecting circuit 30 converts the voltage Vx having an irregular waveform into an output voltage Vout having a sawtooth and more regular waveform and the output terminal 302 outputs the output voltage Vout.
[0017] In the embodiment, a time difference between peaks of the sawtooth waveform is very small and the output voltage Vout is similar to a smooth and constant voltage. In other words, the peak detecting circuit 30 converts the voltage Vx into a DC voltage Vout, the DC voltage Vout is proportional to the peak value of the voltage Vx, therefore, as the peak value of the voltage Vx becomes greater, the output voltage Vout also becomes greater. The logic circuit 70 compares the output voltage Vout with the reference voltage value Vref to determine whether the buck converter 10 is under a heavy load or the light load.
[0018] Referring to FIG. 2 , the peak detecting circuit 30 includes a follower 31 , an amplifier 32 , and an RC circuit 33 . The RC circuit 33 is an integral circuit. The RC circuit 33 is composed of a resistor Ra and a capacitor Ca connected in parallel. The follower 31 tracks the voltage Vx to be integrated within the RC circuit 33 and outputs the sawtooth waveform voltage Vout to the logic circuit 70 .
[0019] The snubber circuit 50 includes a resistor R and a snubber capacitor C 2 connected in series. The drain electrode of the second switch Q 2 is connected to the resistor R. The snubber capacitor C 2 is connected to ground via the logic circuit 70 .
[0020] The logic circuit 70 includes a comparator 71 and a control switch 73 . The comparator 71 includes a first input terminal 701 , a second input terminal 702 , and an output terminal 703 . The control switch 73 includes a control terminal 731 , a first open terminal 732 , and a second open terminal 733 . The first input terminal 701 is electrically connected to the output terminal 302 of the peak detecting circuit 30 . The second input terminal 702 is electrically connected to the reference voltage Vref. The output terminal 703 is electrically connected to the control terminal 731 . The first open terminal 732 is electrically connected to the snubber capacitor C 2 and the second open terminal 733 is grounded.
[0021] The comparator 71 compares the output voltage Vout of the peak detecting circuit 30 with the reference voltage Vref. When the output voltage Vout of the peak detecting circuit 30 is greater than the reference voltage Vref, the comparator 71 controls the control switch 73 to close, and the snubber circuit 50 is activated and works to protect the buck converter 10 . When the output voltage Vout of the peak detecting circuit 30 is less than the reference voltage Vref, the comparator 71 controls the control switch 73 to open, and the snubber circuit 50 is cut off and stops working to avoid power being consumed by the snubber circuit 50 .
[0022] In the embodiment, the first input terminal 701 is a normal phase one and the second input terminal 702 is an abnormal phase one. The control switch 73 is a NMOS transistor. When the output voltage Vout of the peak detecting circuit 30 is greater than the reference voltage Vref, the buck converter 10 is under the heavy load, and the comparator 71 outputs a high level signal and controls the control switch 73 to close. When the output voltage Vout of the peak detecting circuit 30 is less than the reference voltage Vref, the buck converter 10 is under the light load, and the comparator 71 outputs a low level signal and controls the control switch 73 to open.
[0023] The working process of the power control device 100 is described as below. The PSU 12 provides the input voltage Vin to the buck converter 10 , and then the controller 11 sends PWM signals to the first switch Q 1 and the second switch Q 2 to selectively close or open the first switch Q 1 and the second switch Q 2 . The peak detecting circuit 30 detects the voltage Vx, and the logic circuit 70 compares the voltage Vx with the reference voltage Vref. If the voltage Vx is greater than the reference voltage Vref, the buck converter 10 is deemed to be under the heavy load. The peak detecting circuit 30 triggers the comparator 71 to close the control switch 73 . Thus, the snubber circuit 50 is connected in parallel with the second switch Q 2 to decrease and protect against any voltage spike of the voltage Vx. If the voltage Vx is less than the reference voltage Vref, the buck converter 10 is deemed to be under the light load. The peak detecting circuit 30 triggers the comparator 71 to open the control switch 73 and thus disconnect the snubber circuit 50 . Thus, the snubber circuit 50 is disconnected from the second switch Q 2 and power loss is avoided.
[0024] The peak detecting circuit 30 determines whether the buck converter 10 is under the heavy load or the light load. If the buck converter 10 is under the heavy load, the peak detecting circuit 30 triggers the comparator 71 to allow the snubber circuit 50 to connect in parallel with the second switch Q 2 , to decrease any voltage spike. If buck converter 10 is under the light load, the peak detecting circuit 30 triggers the comparator 71 to allow the snubber circuit 50 to be disconnected from the second switch Q 2 and the power drain represented by the snubber circuit 50 is avoided.
[0025] It is to be understood, however, that even though numerous characteristics and advantages of the exemplary disclosure have been set forth in the foregoing description, together with details of the structure and function of the exemplary disclosure, the disclosure is illustrative only, and changes may be made in detail, especially in the matters of shape, size, and arrangement of parts within the principles of exemplary disclosure to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | An energy-efficient power control device, which employs a snubber circuit only during the risk of voltage spikes during fast switching, includes a buck converter, a power supply unit (PSU), a peak detecting circuit, a snubber circuit, and a logic circuit. The power control device supplies power to an input terminal of an electronic device. The snubber circuit is connected to the buck converter. The logic circuit is connected between the peak detecting circuit and the snubber circuit and determines whether the buck converter is under the heavy load or a light load according to the voltage, and connects the snubber circuit when the buck converter is under the heavy load, and disconnects the snubber circuit when the buck converter is under the light load. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to U.S. provisional application Ser. No. 61/231,266 filed Aug. 4, 2009 and to U.S. 61/361,843 filed Jul. 6, 2010.
FIELD OF THE INVENTION
[0002] The invention has to do with provision of powered linear motion to equipment by a motor. It is known in the art to provide reciprocating linear motion powered remotely to tools such as a pump in a well. Typically, such pumps may have spring-returns, a variety of one-way valves, solenoids if powered by electricity, and generally speaking are provided at one end of an assembly comprising the motor, its reciprocation-controlling componentry, and a pump, assembled in a sequence.
[0003] Typical motors of this type have a driven shaft which operates under compression, requiring large amounts of materials to defeat buckling forces.
[0004] As well, the larger drive shaft results in greater mass, the direction of motion of which involves defeating greater inertia, and larger collision forces. Some motors have complex latch-releases or are powered in one direction opposing a spring which powers them in another direction. Still others have stall positions within the travel of their components, resulting in the potential of accidental stalls from which the motors cannot recover without being physically retrieved and serviced or pushed somehow past the stall point of travel in the reciprocating movement's path. Others suffer from blow-by and have difficulties maintaining seals to isolate working parts from harsh environments and contaminants. Most have larger numbers of moving parts, with excessive susceptibility to wear. Some require the power source to switch, others require carefully controlled pressures and volumes of motive power fluids.
[0005] A need is recognized to provide short length, small diameter linear motors driven by pressurized fluid in one-directional unswitched flow, with few moving parts, provided with useful seals and isolating small tolerance piston/cylinder arrangements from the motor's working environment.
SUMMARY OF THE INVENTION
[0006] The present invention relates to valve assemblies that can convert one directional flow of fluid power medium into mechanical reciprocating action.
[0007] This invention provides in one embodiment a motor for providing powered reciprocating linear drive motion using a pressurized power fluid flow, the motor comprising: a housing having a first end and a second end; a first chamber provided in the housing proximate the first end of the housing, the first chamber having a first piston and operative to provide motive linear power during a power stroke of the first piston; a second compression chamber provided in the housing proximate the second end of the body, the second compression chamber having a second piston and operative to provide motive linear power during a power stroke of the second piston, the second piston connected to the first piston such that a power stroke of the first piston causes an exhaust stroke of the second piston and a power stroke of the second piston causes an exhaust stroke of the first piston; the first chamber in fluid communication with the power fluid flow during a power stroke of the first piston and in fluid communication with a first exhaust port during an exhaust stroke of the first piston; and a second chamber in fluid communication with the power fluid flow during a power stroke of the second piston and in fluid communication with a second exhaust port during an exhaust stroke of the second piston; the motor in one embodiment further comprising a reversing sleeve provided between the first piston and the second piston, the reversing sleeve having a first end partially defining the first chamber and a second end partially defining the second chamber, wherein the reversing sleeve is operative to expose the first chamber to the first exhaust port during an exhaust stroke of the first piston and to block the first exhaust port during a power stroke of the first piston, and wherein the reversing sleeve is operative to expose the second chamber to the second exhaust port during an exhaust stroke of the second piston and block the second exhaust port during a power stroke of the second piston; wherein the reversing sleeve has a first reversing sleeve exhaust port, in fluid communicating with the first chamber, that substantially aligns with the first exhaust port during an exhaust stroke of the first piston and a second reversing sleeve exhaust port, in fluid communication with the second chamber, that substantially aligns with the second exhaust port during an exhaust stroke of the second piston; the sleeve further comprising a first inlet port in fluid communication with the power fluid flow and a second inlet port in fluid communication with the power fluid flow, wherein the first chamber is in fluid communication with the first inlet port during a power stroke of the first piston and the second chamber is in fluid communication with the second inlet port during a power stroke of the second piston, and where the reversing sleeve blocks the first chamber from the first inlet port during an exhaust stroke of the first piston and the reversing sleeve blocks the second chamber from the second inlet port during an exhaust stroke of the second piston, the motor in an embodiment further comprising: a reversing spool provided within the reversing sleeve and having a first end and a second end, the reversing sleeve and the reversing spool partially defining the first chamber and the second chamber; wherein when the first piston in its motion is proximate an end of a power stroke, the second piston contacts the second end of the reversing spool, forcing the reversing spool towards the first piston, and moving the reversing sleeve towards the first piston causing the reversing sleeve to place the second chamber in fluid communication with the power fluid flow and venting the first chamber to exhaust, and wherein when the second piston in its motion is proximate an end of its power stroke, the first piston contacts the first end of the reversing spool, forcing the reversing spool towards the second piston and causing the reversing sleeve to place the first chamber in fluid communication with the power fluid flow and venting the second chamber to exhaust, where the reversing spool includes a position piston to hold the reversing spool in position and a balancing pressure piston to counteract pressure forces on the reversing spool, wherein the first piston, the first chamber, a connecting rod connected between the first piston and the second piston, the second piston and the second compression chamber are all aligned in a single line and the housing and the outer housing are cylindrical, wherein the first chamber and second chamber are in fluid isolation from each other, and where in one embodiment the motor is configured for seal-less operation; yet in another embodiment the motor further comprises a first sealing ring encircling the first piston and separating the motor's environment from the first chamber and a second sealing ring encircling the second piston and separating the motor's environment from the second chamber.
[0008] The invention further comprises a method of providing reciprocating linear motion powered by one directional fluid flow, the method comprising: providing a motor having a first piston defining a first chamber, a second piston defining a second chamber, the first piston and the second piston connected with a connecting rod so that the first piston and the second piston move in unison one pulling the other, the first chamber and the second chamber positioned between the first piston and the second piston; supplying power fluid under pressure to the first chamber to drive the first piston through a power stroke and the second piston through an exhaust stroke; when the first piston reaches an end of its power stroke, supplying power fluid to the second chamber to drive the second piston through a power stroke of its own; and when the second piston has reached the end of its power stroke, again supplying power fluid to the first chamber; in one embodiment the motor energizes equipment placed down a well casing to operate or condition the well; in another, the motor is inserted in a well casing with a tubing string supplying power fluid to the motor; in another where used power fluid is exhausted from the motor into a first annulus between the tubing string and well casing; in another embodiment, a second tubing string is provided inside the tubing string and power fluid is supplied to the motor through the second tubing string, and used power fluid is exhausted to a second annulus formed between the tubing string and the second tubing string.
[0009] A further embodiment of the invention further provides a motor with a hydraulic/pneumatic valve for converting one directional flow of power medium (fluid being a liquid or gas) into mechanical reciprocating motion, the motor comprising: a first piston, acting at the same time as an attaching platform to a mechanism to be powered by the motor, defining a first compression chamber and a second piston, acting at the same time as an attaching platform to the mechanism to be powered by the motor, defining a second compression chamber, the pistons connected together with a connecting rod so that the first piston and the second piston are forced to move in conjunction; their movement being coordinated by tension on the rod; around the connecting rod, a valve comprising a reversing spool provided within a reversing sleeve and having a first end and a second end, the reversing sleeve and the reversing spool partially defining the first compression chamber and the second compression chamber; the reversing sleeve having a first end partially defining the first compression chamber and a second end partially defining the second compression chamber, operating to open the first compression chamber to the power fluid and open the second compression chamber to an exhaust vent during the first piston power stroke, and to open the second compression chamber to the power fluid and open the first compression chamber to the exhaust vent during the second piston power stroke; when the first piston is proximate an end of its power stroke, the second piston contacts the second end of the reversing spool, forcing the reversing spool towards the first piston, and moving the reversing sleeve towards the first piston causing the reversing spool to place the second valve chamber in fluid communication with the at least one power fluid supply and venting the first chamber to exhaust and forcing the reversing sleeve towards the first piston; and when the second piston is proximate an end of its power stroke, the first piston contacts the first end of the reversing spool, forcing the reversing spool towards the second piston and causing the reversing spool to place the first compression chamber in fluid communication with the at least one power fluid supply and venting the second compression chamber to exhaust and forcing the reversing sleeve towards the second piston; where the valve's reversing spool also includes a position piston to hold the reversing spool in position and a balancing pressure piston to counteract pressure forces on the reversing spool, wherein the first piston, the first compression chamber, the connecting rod connected between the first piston and the second piston, the second compression chamber and the second piston are all aligned in a line.
[0010] In yet a further embodiment, the invention provides a method of inducing a reciprocating movement to a motor's connecting rod, the method comprising: providing a valve having a first piston defining a first compression chamber, a second piston defining a second compression chamber, the first and the second piston connected with a connecting rod so that the first piston and the second piston move in unison, the first chamber and the second chamber positioned between the first and the second piston; supplying power fluid to the first chamber to drive the first piston through a power stroke and the second piston through an exhaust stroke; when the first piston reaches an end of the power stroke, supplying power fluid to the second chamber to drive the second piston through a subsequent power stroke; and when the second piston has reached the end of the subsequent discharge stroke, supplying power fluid to the first chamber.
[0011] In another embodiment, a reciprocating linear motor powered by one directional fluid flow is provided, having small external diameter, optimized for shortened overall length, with few moving parts and effective seals, low mass and thus low inertia in direction changes. The motor provides reciprocating linear powered motion for use by attached equipment such as a pump, chisel, hammer, valve, remote actuator, or other machine requiring such power.
[0012] It is to be understood that other aspects of the present invention will become readily apparent to those skilled in the art from the following detailed description. As will be realized, the invention is capable for other and different embodiments and its several details are capable of modification in various other aspects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Referring to the drawings, wherein like reference numerals indicate similar parts throughout, the several views are illustrated by way of example, and not by way of limitation.
[0014] FIG. 1 is a schematic illustration of an embodiment of a valve assembly;
[0015] FIG. 2 is a schematic illustration of the valve assembly of FIG. 1 , during a power stroke by a top piston;
[0016] FIG. 3 is a schematic illustration of the valve assembly of FIG. 1 , during a changing of direction of motion by the top piston;
[0017] FIG. 4 is a schematic illustration of the valve assembly of FIG. 1 , during a reversal of motion;
[0018] FIG. 5 is a schematic illustration of the valve assembly of FIG. 1 , during a discharge stroke by the top piston.
DETAILED DESCRIPTION
[0019] This invention herein provides a motor comprised of a valve assembly that can convert one directional flow of a power medium into powered reciprocating motion of power rods. The reciprocating movement of these rods can be in turn applied in a mechanism that requires such powered reciprocating motion, e.g. pumps, hammers, chisels, compactors, jacks, remotely controlled valves, actuators, remote hydraulic/pneumatic servo mechanisms and the like.
[0020] The invention contemplates in one embodiment a form of reciprocating control valve which at the limits of its stroke causes the reversal of fluid flow under pressure to a piston assembly. The invention is also concerned with the aspects of automatic and positive control and in accordance with or in response to the valve piston assembly travel, the retention of the valve in either its two operative or pressure fluid transmitting positions by providing an arrangement for valve blocking, in the nature of exposing auxiliary pistons to the system pressure by which to positively position the valve in one or the other functional position with no dead, stalled, or equilibrium position.
[0021] FIGS. 1-5 are schematic illustrations of a valve assembly in a first aspect. Pistons 7 A and 7 B with power rods 6 A and 6 B the body of which extends through the center of the motor as attaching the two pistons 7 A and 7 B in tension and not necessarily in compression, the reciprocating movement of the rods 6 A and 6 B can be attached to and utilized by a mechanism that requires such reciprocating motion, e.g. pumps, hammers, chisels, compactors, jacks, remotely controlled valves, actuators, remote hydraulic/pneumatic servo mechanisms and the like.
[0022] Valve assembly 1 can have a first end 2 , a second end 3 , an outer housing 4 , and an inner housing 5 provided within the outer housing 4 . The inner housing 5 can contain a first compression chamber 15 A and a second compression chamber 15 B, wherein the first compression chamber 15 A may be positioned adjacent the first piston 7 A, and the second compression chamber 15 B maybe positioned adjacent the second piston 7 B. The first piston 7 A and the second piston 7 B maybe connected together with a connecting rod 28 so that the first piston 7 A and second piston 7 B can be forced to move in conjunction by the connecting rod 28 . The first piston 7 A and the second piston 7 B may be provided with extrusions i.e. power rods 6 A and 6 B, respectively. The reciprocating movement of the power rods 6 A and 6 B, depending on the application, can be used to power various mechanisms or tools.
[0023] In FIGS. 1-5 , the outer housing 4 is shown with a power fluid supply conduit 9 that may run between the outer housing 4 and the inner housing 5 and supply power fluid to drive the assembly 1 . A fluid discharge conduit 11 may be provided within the outer housing 4 , but outside the inner housing 5 , a power fluid may be exhausted directly to the motor's surroundings by bents 27 A, 27 B.
[0024] Power fluid can be directed in an alternating way into the first compression chamber 15 A and the second compression chamber 15 B to drive the connecting rod of assembly 1 . To drive the first piston 7 A through a power stroke, power fluid may be directed into the first compression chamber 15 A and to drive the second piston 7 B through a power stroke, power fluid may be directed into the second chamber 15 B.
[0025] In a preferred embodiment, the connector between pistons operates moving in a linear manner concentrically through the motor's control valve system, comprised of a reversing spool 16 concentrically inside a reversing sleeve 22 , within the motor's body which also comprises an inner housing 5 and an outer housing 4 .
[0026] The annulus between inner 5 and outer 4 housings may provide fluid conduits for supply and, optionally exhaust of a power fluid flow under pressure during operation of the motor. The annulus between the inner housing 5 and the reversing sleeve 22 provides a positioning 17 and a balancing 18 piston and corresponding cylinder arrangements, with conduits 20 , 21 through the sleeve 22 to provide power fluid to those pistons, the respective conduits 20 , 21 being opened or closed, respectively, by positioning of the sleeve 22 , to provide pressurized power fluid to one side or the other of piston 18 to exert a force toward one end or the other 2,3 of the assembly 1 .
[0027] Several advantages of this arrangement become apparent: the direction control over fluid flow takes place between the two cylinders decreasing the length of the assembly 1 from end-to-end (2 to 3); there is no catchment, spring, mechanical détente or similar biasing means to prevent the motor from reaching a stall or equilibrium position, also reducing the parts count and complexity, as well as wear points and mass of parts in motion and thus reducing inertial changes required in each reciprocation's direction change; improving maintainability, serviceability and useful life-cycle. Further, the two main pistons 7 A and 7 B are joined by a connector which operates in tension during both power strokes, and need not be built to withstand compressive forces of the pistons' motion, thus reducing mass, inertia change, collision forces in operation and stress on material, improving motor efficiencies and life-span.
[0028] Note that the only physical contact required is between the pistons 7 A or 7 B and the reversing spool 16 . The reversing sleeve 22 is moved not by the physical contact but by the hydraulic force produced by redirecting of the hydraulic pressure through the respective movement of the reversing spool 22 . Therefore the entire process is relatively shock free since the hydraulic medium will cushion the impact. Shock forces of collision between powered pistons 7 A or 7 B with the sleeve and spool of the assembly 1 at the end of a power stroke may be absorbed by fluid reservoirs within the power fluid deployed in the balancing or position pistons' chambers eliminating dead-stop collisions and reducing shock stress changes to materials.
[0029] With only 3 moving parts (pistons 7 A, 7 B and connector; reversing sleeve 22 ; and reversing spool 16 ) assembly, disassembly, and maintenance of the motor is simplified.
[0030] A reversing spool 16 may have a position piston 17 and a balancing pressure piston 18 . The balancing pressure piston 18 can equalize forces acting on the reversing spool during the operation of the assembly 1 , exerting a force on the reversing spool 16 acting in an opposite direction to the force exerted by power fluid on either the first end 19 A or the second end 19 B of the reversing spool 16 . A first balancing pressure piston passage 20 and a second balancing pressure piston passage 21 may be provided in the reversing sleeve 22 . Based on the position of the reversing sleeve 22 , either the first balancing pressure piston passage 20 or the second balancing pressure piston passage 21 may be placed in fluid communication with power fluid supply conduit 9 to supply power fluid to one of the sides of the balancing pressure piston 18 . If the reversing sleeve 22 is positioned so that the first balancing pressure piston passage 20 is provided in fluid communication with the power fluid supply conduit 9 , the power fluid passing through the first balancing pressure piston passage 20 to the balancing pressure piston 18 exerts a force on the balancing pressure piston 18 towards the second end 3 of the assembly 1 . If the reversing sleeve 22 is positioned so that the second balancing pressure piston passage 21 is provided in fluid communication with the power fluid supply conduit 9 , the power fluid passing through the second balancing pressure piston passage 21 to the pressure balancing piston 18 exerts a force on the balancing pressure piston 18 towards the first end 2 of the assembly 1 .
[0031] Power fluid in either the first compression chamber 15 A or the second compression chamber 15 B can apply a force to first end 19 A of the reversing spool 16 or the second end 19 B of the reversing spool 16 , respectively. The balancing pressure piston 18 can exert a force on the reversing spool 16 in an opposite direction from the force exerted by the power fluid in either the first compression chamber 15 A or the second compression chamber 15 B. By adjusting the surface area of the first end 19 A and the second end 19 B of the reversing spool 16 with the surface area of the balancing pressure piston 18 , the forces placed on the reversing spool 16 can be substantially balanced, with the pressure balancing piston 18 substantially counteracting the forces placed on the reversing sleeve 16 by the power fluid in either the first compression chamber 15 A or the second chamber 15 B.
[0032] With the force exerted on either the first end 19 A of the second end 19 B of the reversing spool 16 substantially counteracted by the balancing pressure piston 18 , the reversing spool 16 may be held in place by the position piston 17 . Power fluid from the power fluid supply conduit 9 maybe routed to either side of position piston 17 to hold the reversing spool 16 in place. A first fluid supply passage 23 A maybe provided in the inner housing 5 in fluid communication with the power fluid supply conduit 9 . A second fluid supply passage 23 B maybe provided in the reversing sleeve 22 that may align with the first fluid supply passage 23 A. A first slot 24 A and a second slot 24 B maybe provided on the position piston 17 which can route power fluid from the fluid supply 9 and the fluid supply 23 B to either side of the position piston 17 , depending on the position of the reversing spool 16 . By altering the surface area of the position piston 17 , the amount of force required to shift the reversing spool 16 can be adjusted.
[0033] In this manner, the pressure balancing piston 18 can counteract the forces on the reversing spool 16 from the first compression chamber 15 A and the second compression chamber 15 B, wherein the position piston 17 can hold the reversing spool 16 in position and the motor by tailoring how much force is required to shift the reversing spool 16 .
[0034] A reversing sleeve piston 25 may be provided to shift the reversing sleeve 22 .
[0035] Referring to FIG. 1 , the assembly 1 is shown during a power stroke of the first piston 7 A and a discharge stroke of the second piston 7 B. The reversing sleeve 22 maybe initially positioned towards the second end 3 of the assembly 1 , exposing the power fluid inlet port 26 A to the first compression chamber 15 A, placing the first compression chamber 15 A in fluid communication with the power fluid supply conduit 9 , while blocking the exhaust port 27 A. At the same time, the reversing sleeve 22 can expose the second exhaust port 27 B to the second compression chamber 15 B while blocking the power fluid inlet port 26 B from the second compression chamber 15 B. With power fluid entering the first compression chamber 15 A adjacent the first piston 7 A and fluid being vented from the second chamber 15 B adjacent the second piston 7 B, the first piston 7 A may be driven through a power stroke while the second piston 7 B may be pulled along by the connecting rod 28 .
[0036] During the power stroke of the first piston 7 A, the power fluid may exert a force on the first piston 7 A as well as a first side 19 A of the reversing spool 16 and a first side 29 A of the reversing sleeve 22 . The force exerted on the first side 19 A of the reversing spool 16 by the power fluid in the first compression chamber 15 A maybe substantially counteracted by the force exerted on the reversing spool 16 by the pressure balancing piston 18 with the position piston 17 exerting a force on the reversing spool 16 towards the second end 3 of the assembly 1 and pressing the reversing spool 16 against the reversing sleeve 22 . The reversing sleeve 22 maybe pressed against a bumper 30 in the inner housing 5 .
[0037] When the first piston 7 A reaches the top of a power stroke, the reversing sleeve 22 and the reversing spool 16 may act in conjunction to reverse the direction of motion of the first piston 7 A and the second piston 7 B.
[0038] Referring to FIG. 2 , as the first piston 7 A reaches an end of the power stroke, a bottom of the second piston 7 B may come into contact with the second end 19 B of the reversing spool 16 . Because of the balancing of the forces on the reversing spool by the balancing pressure piston 18 , the second piston 7 B may only have to exert a force on the reversing spool 16 to overcome the force exerted on the reversing spool 16 towards the second piston 7 B by the position piston 17 . With the first piston 7 A overcoming the force placed on the reversing spool 16 by the position piston 17 , the reversing spool 16 maybe shifted by the second piston 7 B towards the first end 2 of the assembly 1 .
[0039] Referring to FIG. 3 , with the reversing spool 16 shifted towards the first end 2 of the assembly 1 , power fluid maybe directed to the other side of the position piston 17 which can cause the force exerted on the reversing spool 16 by the position piston 17 to act in the direction of the force exerted on the reversing spool 16 by the second piston 7 B. The shifting of the reversing spool 16 may move the first slot 32 A away from the reversing sleeve piston passage 31 and place the second slot 32 B in fluid communication with the reversing sleeve piston passage 31 which can route power fluid from the power fluid supply conduit 9 to the other side of the reversing sleeve piston 25 . The force exerted on the other side of the reversing sleeve piston 25 can drive the reversing sleeve 22 towards the first end 2 of the assembly 1 , shifting the reversing sleeve 22 , as shown in FIG. 4 .
[0040] Referring to FIG. 5 , when the reversing sleeve 22 has been shifted towards the first end 2 of the assembly 1 until the reversing sleeve 22 has been stopped by the bumper 30 A, the reversing sleeve 22 can expose the second power fluid inlet port 26 B, which allows power fluid to enter the second compression chamber 15 B, while at the same time can align the first housing exhaust port 27 A with the exhaust port 33 A which can allow fluid in the first compression chamber 15 A to be vented. With power fluid entering the second compression chamber 15 B and the first compression chamber 15 A being vented, the second piston 7 B maybe driven by the power fluid in the second compression chamber 15 B through a power stroke, while the first piston 7 A maybe pulled through a discharge stroke by the connection rod 28 .
[0041] When the second piston 7 B reaches a bottom of the power stroke, the reversing sleeve 22 and the reversing spool 16 may act in conjunction to change the direction of motion of the first piston 7 A and the piston 7 B.
[0042] It will be obvious that the stroke length can be altered to suit the characteristics required by the equipment the motor is to power. Similarly, a number of motors could be arranged in gangs to provide power in small diameter settings. While particularly well suited to be deployed downhole in a well to power a reciprocating pump with a pump chamber at either or both ends of the motor, it is apparent that the motor may be used in other settings to power other equipment. Power fluids can be any one or more of a variety of suitable fluids, including for example liquids or gases of suitable compressibility to transfer fluid flow at pressures and volumes sufficient to power the motor in operation remotely from the pressurized fluid's source.
[0043] Additionally, the invention provides that the working chambers of the pistons and cylinders of the motor may always be kept at higher pressures than the motor's environment, thus isolating the motor's moving parts within an environment provided by the power fluid, which can be significantly cleaner and qualitatively controlled than the motor's external environment. Seals, if any, between the moving components of the motor, are similarly operative in a controlled environment, with higher pressure on the same side of each seal between the motor and its environment (the motor's side) during all strokes, with any leakage essentially flushing the seals' path of motion. It is to be noted that alterations to the diameter of the connecting rod, the exposed surface areas of the sleeve and spool, and the hydraulically active surface areas of the various position and balancing pistons and chambers, the volumes of the various active chambers and relative surface areas of the pistons in the motor will permit the alteration of motor operating parameters such as stroke, power, reciprocation speed, stall and the like, and to power fluid pressure and volumes required for specific motor outputs.
[0044] Similarly, unbalanced situations may be desired, and variance of conduit size or duration of conductivity during a stroke might provide more or less power or speed to one stroke versus the stroke in the opposite direction. As well, more than one power piston might be deployed on one or both sides of the valve arrangement.
[0045] The detailed description of the valve assembly is provided to enable any person skilled in the art to make or use the present invention. Various modifications to this invention will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiment shown herein, but is to be accorded the full scope consistent with the claims, wherein reference to an element in the singular, such as by use of the article “a” or “an” is not intended to mean “one and only one” unless specifically so stated, but rather “one or more”. All structural and functional equivalents to the elements of the embodiment described throughout the disclosure that are known or later come to be known to those ordinary skill in the art are intended to be encompassed by the elements of the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. | A reciprocating linear motor powered by one directional fluid flow is provided, having small external diameter, optimized for length, with few moving parts and effective seals, low mass and thus low inertia in direction changes. The motor provides reciprocating linear powered motion for use by attached equipment such as a pump, chisel, hammer, valve, or other machine requiring such power. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a U.S. National Phase Application of PCT International Patent Application Number PCT/EP2013/002000, filed Jul. 6, 2013, which claims priority benefit of DE 10 2012 5 107 019.9, filed Aug. 1, 2012, each of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The invention relates to a vehicle wheel rim, in particular for use on a motor vehicle, having a wheel rim well, an inner wheel rim flange and an outer wheel rim flange, wherein the wheel rim well is delimited at its axial end regions by in each case one of the wheel rim flanges.
BACKGROUND
Nowadays, motor vehicles generally make contact with the ground via vehicle wheels. These wheels consist of a wheel rim and of a tire mounted on the wheel rim.
In general, the motive power of the vehicle is transmitted to the ground exclusively via the wheels. The wheels and the tires and hence also the wheel rims are therefore subjected to large forces.
In order to achieve secure seating of the tire on the wheel rim, wheel rims have a wheel rim flange on the inner flank oriented toward the vehicle and a wheel rim flank on the outer flank oriented away from the vehicle, said wheel rim flanges being intended to prevent the tire from slipping sideways off the wheel rim.
In the prior art, configurations of both the outer wheel rim flange and of the inner wheel rim flange which project outward in a radial direction in order to prevent the tire from slipping off sideways are disclosed. DE 195 33 612 A1 discloses this design.
However, the disadvantage here is that radial deflection of the tire is not effectively prevented by this known design, this being attributable to the radial stiffness of the wheel.
SUMMARY
It is therefore an object of the present invention to provide a vehicle wheel rim having an inner wheel rim flange, which wheel rim allows radial guidance, with maximum stiffness, of the tire on the receiving region of the tire.
An object of the present invention is achieved by a vehicle wheel rim, in particular for use on a motor vehicle, having a wheel rim well, an inner wheel rim flange and an outer wheel rim flange, wherein the wheel rim well is delimited at its axial end regions by in each case one of the wheel rim flanges, wherein the wheel rim flanges are formed by a radially encircling wall, said walls extending in each case at a predefinable angle with respect to the wheel rim well, characterized in that the vehicle wheel rim comprises a C-shaped pocket, wherein the C-shaped pocket is formed at least in part from constituent parts of the wheel rim flange and of the wheel rim well.
An illustrative embodiment of the invention relates to a vehicle wheel rim, in particular for use on a motor vehicle, having a wheel rim well, an inner wheel rim flange and an outer wheel rim flange, wherein the wheel rim well is delimited at its axial end regions by in each case one of the wheel rim flanges, wherein the wheel rim flanges are formed by a radially encircling wall, said walls extending in each case at a predefinable angle with respect to the wheel rim well, and wherein the vehicle wheel rim comprises a C-shaped pocket, which is formed at least in part from constituent parts of the wheel rim flange and of the wheel rim well.
Here, the inner wheel rim flange in each case denotes the wheel rim flange which is arranged on the end of the wheel rim well closer to the vehicle. The wheel rim flange further away from the vehicle is referred to as the outer wheel rim flange.
The wheel rim flanges prevent a tire fitted on the wheel rim from sliding off sideways. The wheel rim flanges furthermore enable the vehicle to be driven with the tire at a high filling pressure, this entailing advantages as regards rolling noise and rolling resistance.
It is also expedient if the angle between the wheel rim well and a section of the inner wheel rim flange which extends away from the wheel rim well, as viewed from the central axis of the wheel rim, is between 45° and 135°, preferably being in a range of between 70° and 120°, preferably in the range of 85° to 105°.
The angle between the wheel rim flange and the wheel rim well is ideally in a range in which the tire can both be mounted easily and also achieves secure seating on the wheel rim. Moreover, an angle is to be preferred which does not lead to the tire being damaged by the wheel rim flange.
A preferred illustrative embodiment is characterized in that the inner wheel rim flange is formed by an upper section, which extends away from the central axis of the wheel rim, starting from the wheel rim well, and by a lower section, which extends in the direction of the central axis, starting from the wheel rim well.
The design described above ensures that the wheel rim well is connected to the wheel rim flange at only one connection point. It is thereby possible to ensure that the wheel rim flange is raised inward toward the center of the wheel rim well by virtue of the forces acting and thus ensures improved seating of the tire on the wheel rim flange. At the same time, it is possible to achieve a lightweight, material-saving construction of the wheel rim by means of the described configuration of the wheel rim flange.
It is furthermore advantageous if the lower section of the inner wheel rim flange is formed by a substantially rectilinear continuation of the upper section, wherein the lower section has a subsection angled in the direction of the center of the wheel rim well.
By designing the wheel rim and, in particular, the wheel rim flange with walls that are as thin as possible and material thicknesses that are as small as possible, it is possible to reduce and thus optimize the overall weight of the wheel rim. At the same time, the design described makes it possible to absorb the occurring forces in an optimum manner. Moreover, the seating of the tire on the wheel rim is improved.
It is furthermore to be preferred if the angled subsection of the lower section of the inner wheel rim flange extends substantially parallel to the wheel rim well and forms a C-shaped pocket with the latter.
This design leads to higher stability of the wheel rim and, in particular, of the wheel rim flange and, at the same time, to a weight which is, as far as possible, optimum.
According to another favorable development, it can be envisaged that, in the region situated adjacent to the inner wheel rim flange, the wheel rim well has a thickened portion of material, which is arranged on the surface of the wheel rim well which faces away from the central axis of the wheel rim.
The thickened portion of material prevents the tire from sliding toward the center of the wheel rim well. This is helpful particularly in driving situations in which large side forces act on the flanks of the tire. The tire is held in position in the wheel rim well between the inner wheel rim flange and the thickened portion of material.
It is furthermore expedient if the region of the wheel rim well between the inner wheel rim flange and the thickened portion of material forms the receiving region for a flank of a tire.
As already described above, a receiving region for a flank of the tire, in which the tire can be positioned securely on the wheel rim, is produced by the thickened portion of material and the wheel rim flange.
In a particularly favorable configuration of the invention, it is furthermore envisaged that the inner wheel rim flange is formed by a section which, starting from the wheel rim well, extends away from the central axis of the wheel rim and is divided at a distance from the wheel rim well into a first leg and a second leg, with the result that the wheel rim flange has a t-shaped cross section.
This configuration represents an alternative embodiment. By virtue of the fact that the wheel rim flange is directed only upward, i.e. away from the central axis of the wheel rim, an additional pocket that could hold dirt and foreign bodies is no longer formed underneath the wheel rim well. Moreover, damage to the pocket due to mechanical influences from the outside is excluded.
It is also to be preferred if the first leg extends substantially parallel to the wheel rim well and forms with the latter a C-shaped pocket, which is arranged on the surface of the wheel rim well which faces away from the central axis of the wheel rim.
The formation of the pocket between the upper side of the wheel rim well and the wheel rim flange leads to the pocket being better protected against dirt and damage since it is inside the tire in the fully assembled state. Nevertheless, the wheel rim flange is still connected to the wheel rim well only by one connection point, which leads to raising of the wheel rim flange owing to the acting forces and hence to more secure seating of the tire on the wheel rim.
It is furthermore advantageous if the second leg extends at a predefinable angle with respect to the section which extends between the wheel rim well and the division of the wheel rim flange into the first leg and the second leg.
By means of the alignment of the second leg, the seating of the tire in the wheel rim well can be further optimized. Depending on the angle chosen, the mounting of the tire is thereby simplified and/or the seating is thereby improved.
It is furthermore expedient if the first leg, which extends substantially parallel to the wheel rim well, has, in a region adjacent to the second leg of the inner wheel rim flange, a thickened portion of material which is oriented away from the central axis of the wheel rim.
This thickened portion of material prevents the tire from sliding toward the center of the wheel rim well.
Another preferred illustrative embodiment is characterized in that the region of the first leg, which extends substantially parallel to the wheel rim well, forms a receiving region for a flank of a tire between the second leg of the inner wheel rim flange and the thickened portion of material.
The receiving region, which is formed between the second leg and the thickened portion of material, improves the seating of the tire in the wheel rim well. The absorption of forces which act laterally on the flank of a tire, in particular, is optimized here.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in detail below by means of an illustrative embodiment with reference to the drawing, in which:
FIG. 1 shows a section, parallel to the central axis of the wheel rim, through an inner wheel rim flange,
FIG. 2 shows a section, parallel to the central axis of the wheel rim, of an alternative embodiment of an inner wheel rim flange, and
FIG. 3 shows another section, parallel to the central axis of the wheel rim, to illustrate the principle of action.
DETAILED DESCRIPTION
FIG. 1 shows a section through the center plane of a wheel rim, along the central axis. It shows a detail view, being the section through a wheel rim well 1 having a wheel rim flange 7 arranged laterally on the wheel rim well 1 .
The wheel rim well 1 extends further to the right beyond the subsection illustrated in FIG. 1 . Adjoining the figure shown at the bottom is a wheel disk, which can be rotated about the central axis (likewise not shown) of the wheel rim, which extends in the plane of the drawing. The wheel rim is formed essentially from the wheel rim well 1 and the wheel disk.
The wheel rim well 1 consists essentially of an axial extent, which is formed by a wall. Laterally adjoining an end region of said wheel rim well 1 is the wheel rim flange 7 . The wheel rim flange 7 shown in FIG. 1 forms the inner wheel rim flange of the wheel rim. Here, the term “the inner wheel rim flange” refers to the wheel rim flange which is arranged on the side of the wheel rim which faces the vehicle.
The wheel rim flange 7 shown in FIG. 1 is formed essentially from two sections 6 , 8 . The upper section 6 of the wheel rim flange 7 projects at a predefinable angle 5 from the wheel rim well 1 . The upper section 6 extends from the surface 2 which represents the surface of the wheel rim well 1 which faces away from the central axis of the wheel rim. The predefinable angle 5 between the wheel rim well 1 and the upper section 6 of the wheel rim flange 7 is somewhat greater than 90° in FIG. 1 and corresponds approximately to an angle of 100°.
In alternative embodiments, the angle 5 can also assume different values but it is advantageously above 90° in order to ensure the action according to the invention of the wheel rim flange. The angle 5 should be chosen according to the respective demand on the wheel rim flange 7 .
A thickened portion of material 3 is arranged on the surface 2 of the wheel rim well 1 adjacent to the upper section of the wheel rim flange 7 . Together with the upper section 6 , this thickened portion of material 3 forms a receiving region 4 . This receiving region 4 serves subsequently to receive a flank of a tire.
Here, the thickened portion of material 3 contributes in particular to securing the flank of the tire against slipping to the right toward the center of the wheel rim well 1 . This safeguard against slipping sideways has the effect that a tire can absorb higher lateral forces on its flanks without slipping out of its predetermined position.
The upper section 6 of the wheel rim flange 7 serves for the lateral fixing of a tire flank which can be introduced into the receiving region 4 . In particular, the upper section 6 prevents the tire flank from slipping sideways off the wheel rim.
Starting from the wheel rim well 1 , the wheel rim flange 7 is furthermore continued downward by section 8 . Section 8 extends substantially as a rectilinear continuation of the upper section 6 . In alternative embodiments, however, it is entirely conceivable to arrange section 8 at an angle with respect to section 6 .
Section 8 has an angled subsection 9 , which extends substantially parallel to the wheel rim well 1 . With its angled subsection 9 and the wheel rim well 1 , the lower section 8 thus forms a C-shaped pocket 10 , which is arranged on the surface 11 of the wheel rim well 1 which faces the central axis of the wheel rim.
The entire embodiment, illustrated in FIG. 1 , of the wheel rim well 1 and of the wheel rim flange 7 is characterized in that all transitions in the shape are formed by radii which are as gentle as possible. The use of sharp edges is very largely avoided in order to avoid introducing disruptive notching effects into the wheel rim well 1 or the wheel rim flange 7 , which could have a negative effect on the durability of the entire wheel rim. Moreover, the aim is a thickness of the material which is matched to the occurring loads and is as small as possible in order in this way to produce a wheel rim which is as far as possible optimized in terms of weight.
FIG. 2 shows an alternative embodiment of a wheel rim well 29 . As a departure from FIG. 1 , the wheel rim flange 30 is now formed only from sections which are arranged above the wheel rim well 29 , on the surface 20 of the wheel rim well 29 which faces away from the central axis.
The wheel rim flange 30 adjoins the wheel rim well 29 laterally. The first section 31 of the wheel rim flange 30 projects upward from the wheel rim well 29 . In this arrangement, section 31 is arranged at a predefinable angle 27 with respect to the wheel rim well 29 . The lower section 31 is followed by a division of the wheel rim flange 30 into a T-shaped structure, which has a first leg 23 and a second leg 26 .
Here, the first leg 23 extends substantially parallel to the wheel rim well 29 . The second leg 26 adjoins the lower section 31 of the wheel rim flange 30 at a predefinable angle 25 . In the embodiment shown in FIG. 2 , the second leg 26 extends approximately at a right angle to the wheel rim well 29 .
Adjacent to the second leg 26 , the first leg 23 has a thickened portion of material 22 . Between this thickened portion of material 22 and the second leg 26 , a receiving region 24 is formed, which can subsequently receive the flank of a tire. In this arrangement, the thickened portion of material 22 serves to secure the tire flank against slipping toward the center of the wheel rim. At the same time, the second leg 26 prevents the tire flank from slipping sideways off the wheel rim.
The first leg 23 , which extends substantially parallel to the wheel rim well 29 , forms a C-shaped pocket between the surface 20 of the wheel rim well 29 that lies on the surface 28 of the wheel rim well 29 which faces away from the central axis and the lower section 31 of the wheel rim flange 30 . In contrast to the embodiment shown in FIG. 1 , this C-shaped pocket 21 is now arranged on the surface 28 of the wheel rim well 29 which faces away from the central axis of the wheel rim.
In the illustrative embodiment in FIG. 2 too, all the transitions have a radius profile which is as gentle as possible. In the illustrative embodiment in FIG. 2 too, the introduction of sharp edges from which a notching effect can emanate is eliminated.
FIG. 3 shows another schematic illustration of a wheel rim flange 42 , which is connected laterally to a wheel rim well 48 . A receiving region 41 is likewise formed between the wheel rim flange 42 and a thickened portion of material 40 on the surface of the wheel rim well 48 which faces away from the central axis. Here, the wheel rim flange 42 extends at a predefinable angle 43 with respect to the wheel rim well 48 in a first section 51 .
Here too, the receiving region 41 serves to receive the flank of a tire.
In the mounted state, i.e. with a wheel fitted on the wheel rim, forces due inter alia to the air filling of the tire and the weight of the vehicle occur at the wheel rim and the tire and hence also at the wheel rim well 48 and the wheel rim flange 42 .
Particularly owing to a radial load which acts in this case, a shear center 49 arises to the left of the wheel rim flange 42 , below the wheel rim well 48 . The position of the shear center 49 gives rise to a moment 50 which acts upward in a clockwise direction from the outside on the wheel rim flange 42 . Owing to this moment 50 , the wheel rim flange 42 is subject to a force which bends the wheel rim flange 42 to the right toward the center of the wheel rim well 48 and thereby raises it. The acting moment 50 reduces the angle 43 between the wheel rim well 48 and the wheel rim flange 42 .
This gives rise to an effect of the wheel rim flange 42 which is equivalent to a C-shaped profile. A C-shaped profile 45 of this kind is illustrated in the lower part of FIG. 3 . It consists of a wheel rim flange 44 which extends through a first section 52 from the indicated wheel rim well 46 . The C-shaped design gives rise to a pocket 47 which is formed by the wheel rim flange 44 and the wheel rim well 46 .
By virtue of the raising of the wheel rim flanges 7 , 30 , 42 and the resulting effect similar to that of a C profile 45 , the seating of the tire in the receiving regions 4 , 24 , 41 is 5 improved and, in addition to the prevention of slipping off sideways, radial lifting of the tire is also prevented in an effective manner by the wheel rim flange 7 , 30 , 42 .
FIG. 3 serves merely to illustrate the principle of action and does not form an embodiment according to the invention. It serves to illustrate that a shear center positioned as shown in FIG. 3 causes a force to act on the wheel rim flange 7 , 30 , 42 which has the effect of raising the wheel rim flange 7 , 30 , 42 . | A vehicle wheel rim for use on a motor vehicle, having a wheel rim well ( 1, 29 ), having an inner wheel rim flange ( 7, 30 ) and having an outer wheel rim flange, wherein the wheel rim well ( 1, 29 ) is delimited at its axial end regions by in each case one of the wheel rim flanges ( 7, 30 ), wherein the wheel rim flanges ( 7, 30 ) are formed by a radially encircling wall, said walls extending in each case at a predefinable angle ( 5, 27 ) with respect to the wheel rim well ( 1, 29 ). | 8 |
This nonprovisional application claims priority under 35 U.S.C. § 119(a) on Patent Application No. 92113592 filed in Taiwan on May 20, 2003, which is herein incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to a cabinet door buffer bar for controlling moving speed of a moving mechanism and serving as a damping buffer and particularly to a buffer bar to prevent a cabinet door from generating annoying noise and being damaged while closing.
BACKGROUND OF THE INVENTION
A buffer bar generally is used to control the speed of door opening/closing and a moving mechanism. The most common application is a door check for automatically and slowly closing the door without generating a big noise or damaging the door or door frame. It also may be adopted on other movable mechanisms that have a returning force and also need a resistant force against the movement to serve as a damping buffer. In general, the buffer resistant force generated by the buffer bar has two types of sources: a pneumatic type and an oil pressure type, or the so-called air pressure bar and oil pressure bar.
The conventional buffer bar has a big drawback, i.e. oil leakage or air leakage. This problem could cause dysfunction of the buffer bar. When used on cabinet windows or doors, in addition to the aforesaid problem, the factors of outside appealing and ornamental effect also have to be considered. The huge noise of the pneumatic bar and oil leakage of the oil pressure bar are problems not acceptable for general cabinets. While the huge noise of the pneumatic bar makes the cabinet not appealing, oil leakage of the oil pressure bar tends to smear the cabinet and articles held in the cabinet.
Hence the cabinet generally is not equipped with the buffer bar. As a result, a big noise is generated when the cabinet door is closed, and the cabinet door or cabinet is easily damaged. Because of the appealing consideration, someone introduced a buffer bar in a conventional hinge. However, while the hinge thus made has a buffer function, it is still not effective. And the problems mentioned above still exist.
SUMMARY OF THE INVENTION
Therefore the present invention aims to resolve the aforesaid problems and provide a cabinet door buffer bar that has a required buffer force to prevent the cabinet door from generating annoying noise and being damaged while closing.
The cabinet door buffer bar according to the invention includes a hollow tube, a shaft and an elastic element. The hollow tube is to house the shaft and enables the shaft to be movable therein. The elastic element provides a returning force for the relative movement. The buffer resistant force is generated by the interference between a resilient member located outside the shaft and the inner wall surface of the hollow tube.
In one aspect, the front end of the shaft and the inner wall of the hollow tube have a gap, which varies in the axial direction of the shaft. Hence the resilient member on the front end of the shaft can generate a different degree of friction when it slides in different directions, thereby it creates a buffer effect desired.
In another aspect, a coupling ring made from a buffer material is provided that has one end fastened to the shaft and another end coupled with a sliding member. The sliding member is made of a hard material so that when the shaft is moved relative to the hollow tube, the sliding member is slid through the coupling ring, and the coupling ring is extended without generating friction with the inner wall surface of the hollow tube. When the shaft is moved inwards, the coupling ring compresses the sliding member and results in deformation and radial expansion of the coupling ring. As a result, interference occurs between the coupling ring and the inner wall surface of the hollow tube, to provide a buffer resistant force.
Another object of the invention is to provide a buffer bar that has an adjustable buffer resistant force.
The damping unit includes an adjustment element for adjusting the moving interval of the sliding member. Thus the movable range of the sliding member is altered when the buffer bar returns to enable the coupling ring to generate a different degree of expansion, thereby changing the buffer resistant force of the buffer bar.
The foregoing, as well as additional objects, features and advantages of the invention will be more readily apparent from the following detailed description, which proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
FIGS. 1A and 1B are schematic views of the invention in use conditions.
FIG. 2 is a schematic view of a first embodiment of the invention.
FIGS. 3A and 3B are schematic views of the first embodiment in operating conditions.
FIG. 4A is a schematic view of a second embodiment of the invention.
FIG. 4B is a schematic view of a third embodiment of the invention.
FIGS. 5A and 5B are schematic views of the third embodiment in operating conditions.
FIG. 6 is a schematic view of a third embodiment of the invention including an adjustment mechanism.
FIG. 7 is a schematic view of a fourth embodiment of the invention.
FIG. 8 is a schematic view of the invention in use.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The cabinet door buffer bar 1 according to the invention aims to be installed on a cabinet wall 72 of a cabinet door 71 (referring to FIGS. 1A and 1B ) to provide a buffer when the cabinet door 71 is closed (referring to FIG. 1A ). When the cabinet door is closed in normal conditions, it provides an elastic force smaller than the closing force of the cabinet door 71 (referring to FIG. 1B ), to maintain the cabinet door in the closed condition.
Refer to FIG. 2 for a first embodiment of the invention. It includes a hollow tube 10 , a shaft 20 , an elastic element 30 (mostly a spring, the drawing shows merely an example) and a resilient member 221 . The hollow tube 10 has a housing compartment 11 to house the shaft 20 . The shaft 20 has a tongue 21 located at the bottom end and is extended outside. The elastic element 30 is housed in the housing compartment 11 , pressing the bottom of the shaft 20 to provide a returning elastic force. The hollow tube 10 has a bottom end to allow the tongue 21 to be extended and exposed without the entire shaft 20 escaping. The shaft 20 has a front end forming a housing section 22 , which has a top end close to the inner wall of the hollow tube 10 to form different gaps G 1 and G 2 in the axial direction of the shaft 20 . The resilient member 221 is located on the housing section abutting the gaps and is in contact with the inner wall of the hollow tube 10 in normal condition, and is made from a resilient and cushion material such as rubber, which is deformable.
When in use, and the cabinet door 71 is opened (referring to FIG. 1A ), the shaft 20 is pushed by the elastic element 30 and the tongue 21 is extended and exposed outside the hollow tube 10 (referring to FIG. 3B ). When the shaft 20 is moved outwards, a friction force occurs between the resilient member 221 and the inner wall of the hollow tube 10 . As the gap G 2 between the housing section 22 and the inner wall of the hollow tube 10 is greater, the resilient member 221 is deformed with relatively less constraint, and the friction force is smaller. Hence the tongue 21 reaches a desired position quickly.
On the other hand, when the cabinet door 71 is closed (referring to FIG. 1B ), the tongue 21 is compressed by the cabinet door 71 and moved inwards (referring to FIG. 3A ). The contact between the tongue 21 and the cabinet door 71 generates a friction. Hence the distal end of the tongue 21 is formed with a curved shape to avoid damaging the cabinet door 71 . Meanwhile, a friction occurs between the resilient member 221 and the inner wall of the hollow tube 10 . As the gap G 1 between the housing section 22 and the inner wall of the hollow tube 10 is smaller, the space for deformation of the resilient member 221 is limited. Hence the friction force is much greater, thus a buffer effect is achieved. Of course, the forces of the elastic element 30 and the resilient member 221 have to be smaller than the force of closing the cabinet door 71 , to allow the cabinet door 71 to be closed as desired.
Refer to FIG. 4A for a second embodiment of the invention. A sliding member 23 is located on the outer side of the shaft 20 . The sliding member 23 also forms different gaps with the inner wall of the hollow tube as the previous embodiment does. It also is coupled with the resilient member 221 . And it is connected to the shaft 20 through a flexible element 24 which may be made from plastics, steel wire, or the like so that the shaft 20 is connected to the sliding member 23 without restricting its motion. Refer to FIG. 4B for a third embodiment. In this embodiment, the flexible element 24 is replaced by a coupling ring 25 made from a buffer material (such as rubber).
The coupling ring 25 has one end fastened to the shaft 20 and the other end connected to a sliding member 23 . When the cabinet door 71 is opened as shown in FIG. 1A , it is pushed by the elastic element 30 , and the tongue 21 is exposed outside the hollow tube 10 , and the coupling ring 25 is driven to move the sliding member 23 (referring to FIG. 5B ). As the sliding member 23 is rigid and only connected to the coupling ring 25 , when the coupling ring 25 moves the sliding member 23 , the coupling ring 25 is extended and deformed and its outer diameter shrinks slightly, therefore the friction between the coupling ring and the inner wall of the hollow tube 10 decreases. Thus the tongue 21 may return easier. In order to protect the coupling ring 25 from being damaged because of over extension, a hard circular ring 27 may be fastened to the top end of the shaft 20 to limit the maximum extension length of the coupling ring 25 . When the cabinet door 71 is closed as shown in FIG. 1B , the tongue 21 will be pushed and the shaft 20 will slide inwards in the hollow tube 10 . The sliding member 23 remains stationary, due to its rigidity when the shaft 20 is just moved inwards. The coupling ring 25 is pushed by the shaft 20 and the front side is stopped by the sliding member 23 , thus the coupling ring 25 is compressed and deformed to slightly expand its outer diameter (referring to FIG. 5A ), and an interference occurs in the interior of the hollow tube 10 to generate a required buffer resistant force. In this embodiment, both the resilient member 221 and the coupling ring 25 provide buffer forces. The shaft 20 has a neck section 222 to couple with an adjustment member 26 to adjust the sliding distance of the sliding member 23 as shown in FIG. 6 so that the deformation of the coupling ring 25 may be altered to adjust the buffer force.
Refer to FIG. 7 for a fourth embodiment of the invention. The resilient member 221 is dispensed with. The buffer force is provided by the coupling ring 25 only. Of course an adjustment mechanism may also be provided. On the other hand, also see FIG. 2 , the gaps G 1 and G 2 on two sides may also be altered to adjust the buffer force generated. In applications, besides being fastened directly to the cabinet wall 72 , the invention may also be mounted on a bracket 42 (not shown in FIG. 7 ). Referring to FIG. 8 , a bracket 42 is mounted on a hinge seat 73 , which has an annular member 41 on one side. The annular ring 41 is hollow to house and fasten a cabinet door buffer bar 1 . The bracket 42 has a hook section 421 to couple on the hinge seat 73 . Then screws 51 through fastening holes 422 fasten the bracket. Such a design is more convenient.
While the preferred embodiments of the invention have been set forth for the purpose of disclosure, modifications of the disclosed embodiments of the invention as well as other embodiments thereof may occur to those skilled in the art. Accordingly, the appended claims are intended to cover all embodiments, which do not depart from the spirit and scope of the invention. | A cabinet door buffer bar includes a hollow tube, a shaft, an elastic element and a sliding member. The sliding member and the inner wall of the hollow tube form different intervals there between so that a resilient member mounted thereon receives varying constraints and generates different buffer forces in different moving directions thereby provides the cabinet door a required buffer force to avoid generating annoying noise and incurring damages during closing of the cabinet door. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a national stage entry under 35 U.S.C. §371 from International Application No. PCT/EP01/04130, filed Apr. 10, 2001, in the European Patent Office; additionally, Applicants claim the right of priority under 35 U.S.C. §119(a)-(d) based on patent application No. MI2000A000841, filed Apr. 14, 2000, in the Italian Patent Office; further, Applicants claim the benefit under 35 U.S.C. §119(e) based on prior-filed, copending provisional application No. 60/231,698, filed Sep. 11, 2000, in the U.S. Patent and Trademark Office; the contents of all of which are relied upon and incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for processing mixtures and compounds made from rubber and various ingredients, used to obtain tires and components thereof such as tread bands and the like: the invention is especially advantageous when used in connection with the production of rubber compounds reinforced with silica.
More particularly, the compounds which may be prepared with the method according to said invention are those of the type comprising a polymeric base having an unsaturated chain that can be crosslinked with sulphur in hot conditions, added to at least one silica filler and a silica bonding agent containing at least one sulphur atom.
The polymeric base may be any polymer or mixture of polymers, non-crosslinked, of natural or synthetic type, able to assume all the chemical/physical and mechanical features of elastomers after suitable crosslinking.
2. Description of the Related Art
European patent application No. 99.830189.9, in the name of the Applicant of the present invention, discloses a method for producing the abovementioned compounds including at least a first operating step intended for mixing the various basic ingredients so as to obtain a mixture.
This step is performed in a closed discontinuous mixer, i.e. a known device which basically comprises a container internally housing a pair of rotors turning in opposite directions, so as to mix up the ingredients introduced into the container from the top thereof.
For this purpose, said device is provided with a pneumatic cylinder located in the upper part of the container and a piston movable upwards to open the container, thereby allowing the introduction of the ingredients via special loading hoppers, and downwards so as to exert a pressure on the material processed by the rotors and located above them.
A pneumatic system located on the bottom of the container allows discharging of the mixture at the end of the mixing cycle by opening a suitable outlet.
As mentioned above, the devices likes the one described above are well known in the art: they are indeed referred to as “Banbury®” or “Intermix®”, depending on whether the rotors operate tangentially relative to each other or are inter-penetrating.
Hereinbelow the material processed during the various operating steps will be indicated by the term “mixture” in order to distinguish it from the “compound”, which is instead the product obtained by adding the vulcanizing system to the mixture.
The method claimed in the abovementioned patent application is aimed at providing substantially constant characteristics for those compounds having identical composition, but being produced discontinuously in separate batches, namely with the new charging of basic ingredients into the mixer after it has been emptied of the previous contents.
Indeed, not infrequently it happens that in the known processing methods, the final compounds produced from successive batches have physical and mechanical properties which are also significantly different from each other, despite being produced from the same basic ingredients and using the same recipes.
For this purpose, in the prior method there are defined at least two indirect process parameters, for example the power applied to the pair of opposing rotors and the temperature of the mixture processed by them, together with at least two direct parameters such as the speed of the rotors and the pressure exerted by the piston of the discontinuous mixer.
Thereafter, in order to obtain the desired result, the method according to the aforementioned application suggests to periodically detect one or both of the indirect parameters and, if necessary, to correct their progression over time, by varying one or both of the direct parameters.
This operating method allows to achieve the object of producing in a repeatable manner, compounds with constant characteristics or in any case that fall within a predefined range of variation.
However, this method relates only to the operating steps which occur within the discontinuous mixer and does not analyse the manufacturing process of the mixtures as a whole; in other words, the method described in European patent application No. 99.830189.9 does not analyse the consequences brought by the non-compliance with the predefined limit values for the (direct and indirect) mixing process parameters, on the other steps of the mixture and compounds processing cycle (for example on additional steps involving mixing with other mixtures in order to obtain the so-called “blends”, on vulcanization, etc.).
For instance, reference should be made to the case where malfunctioning of a machine or human error could result in the temperature of the mixture or the power used by the rotors at a given instant, deviating from the predefined values: what are the consequences and what steps may be taken in order to remedy this situation?
It should be noted that the answer to said questions is of considerable importance because, as will be seen, it avoids the production of large quantities of material which must then be discarded at the end of the manufacturing process, together with all the negative consequences arising therefrom.
SUMMARY OF THE INVENTION
The object of the present invention is therefore to solve this problem by providing a method for processing mixtures and rubber compounds, whereby it is possible to operate immediately on line in order to correct or limit the negative consequences arising from fluctuations of the process parameters, beyond the predefined tolerance limits.
The invention comes from Applicant's perception that the operating steps which make up the cycle for processing of the mixtures and compounds are of varying importance for obtaining the desired features in the end product.
Consequently, in accordance with the present invention, a processing method has been developed whereby at first reference values with associated deviation tolerances for the process parameters, during one or more operating steps, are defined.
These parameters may be the energy used by the rotors, the temperature of the mixture and the duration of mixing within the mixer or, downstream of the latter, the duration of the cycle for extraction of the semi-finished product in sheet form (hereafter also referred to in short as “extrusion”), as well as any other parameter according to the circumstances.
Thereafter, coefficients indicating the weight (or importance) of compliance with the tolerances, in order to achieve the desired final characteristics in a given compound, are assigned.
Throughout the manufacturing process, the aforementioned process parameters are measured for each batch and respective evaluation coefficients are attributed, depending on the values measured; finally, the coefficients attributed are added together and, on the basis of the result obtained, a classification of the semi-finished products obtained with the various batches of material is determined.
This classification provides a qualitative evaluation of the semi-finished product and, on the basis thereof, it becomes possible to operate directly along the production line in order to prevent any defective mixtures or compounds from causing damage to subsequent production.
For instance it could be considered the case where a mixture to be discarded is mixed together with other defect-free mixtures, thereby adversely affecting the “blend” obtained: this might require to discard large quantities of the material produced.
In particular, the method according to the invention is specifically used for the production of silica-reinforced compounds which comprise the following ingredients in variable quantities, per hundred parts by weight of polymeric base (phr), between the following limits:
Polymeric base
100
Carbon black
0-80
Silica
10-80
Silica bonding agent
4%-15% of silica
Zinc oxide (ZnO)
1-3
Stearic acid
0-3
Anti-degradation agents
1-3
Plasticizing oil
0-30
Anti-ozone wax
0.5-3
Specific chemical ingredients
0-15
In accordance with this aspect of the invention, the tolerance ranges of the process parameters are predefined for each type of compound to be produced.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characterising features of the present invention and the advantages deriving therefrom will appear more clearly from the description provided herein below, relating to a preferred and a non-exclusive embodiment thereof illustrated in the accompanying drawings wherein:
FIG. 1 illustrates in a diagramatic form the typical processing steps of a mixture using the method according to the present invention;
FIG. 2 shows in simplified form a discontinuous mixer used in the method according to the invention;
FIG. 3 shows, in the form of a Cartesian diagram, the variations over time of the main process parameters during working in the mixer of FIG. 2;
FIGS. 4 and 5 show respective tables for evaluation of semi-finished products obtained with the method according to the invention;
FIG. 6 shows a further table relating to the characteristics of two compounds produced using the method according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the figures listed above, the first of them shows in schematic form the main steps which make up the processing cycle for the preparation of a mixture starting from basic ingredients; the general features of these steps are already known since they are normally used for the production of tyre compounds.
The first of said steps, indicated by 1 , consists in weighing the various ingredients and feeding them to a discontinuous mixer which will be better described below.
Said mixer, during step 2 , performs mixing of the various ingredients in accordance with predetermined process parameters and the mixture thus obtained is conveyed to an extruder where step 3 is performed.
The extruder may be of the double-screw or single-screw type; in both cases, at the extruder outlet, the mixture is rolled by using a pair of calendering rolls (visible sidewise in step 3 of FIG. 1) so as to form it into sheets of predefined width (60-80 cm) and thickness (6-10 mm).
In accordance with a preferred embodiment of the invention, the calendering rolls are of the variable friction type so that it is possible to vary their torque and operating speed.
As an alternative to the extruder system plus calendering rolls, for performing the mixture into sheet it is also possible to use mixers of the open type, where the mixture is poured from above with respect to a pair of counter-rotating drums which roll it, and then wound it onto one of them.
The sheets obtained then undergo a “batch-off” treatment (step 4 ) wherein they are wetted with a liquid solution which reduces their surface adhesion; following this step they are cooled and dried, being hung up in festoons within special ventilated chambers.
The sheets thus treated are then arranged on benches, waiting for further processing thereof (step 5 ).
More specifically, in accordance with the method of the invention the strip-like sheets are sorted out onto various benches, depending on the degree to which the predefined process parameters have been complied with during the process; the manner in which this selection is performed will be described in greater detail below.
It must be pointed out here, however, that as a result of sorting the sheets on the various benches following to the quality degree of the product, respective uses may be envisaged for the various selected sheets to prevent those which are defective or in any case do not perfectly satisfy the necessary requirements, from being subsequently mixed with sheets which are defect-free.
Consequently, the sheets of one bench may undergo processing operations different from those of another bench; for example some sheets (those regarded as satisfying the necessary requirements) will be further processed in a discontinuous mixer together with the vulcanizing agent so as to form the final raw compound, other sheets (considered to be defective) will be combined with further mixtures so as to obtain a desired blend, whereas finally other sheets (considered to be unacceptable) will be discarded.
The further processing operations may be performed with the same means used for steps 2 - 5 or also in different installations.
The tables of FIGS. 4 and 5 show some values indicating the tolerances with respect to nominal reference values, applicable to certain process parameters being respectively monitored during the corresponding steps H-N; these nominal values and the associated tolerances may be obtained in an experimental manner and obviously depend on the type of mixture being processed.
These values therefore depend on the composition of the mixture and on the features thereof to be obtained during the various processing steps.
For example, with a discontinuous mixer 10 such as that shown in FIG. 2 (Banbury® type), provided with a pair of tangential rotors 11 and 12 which have an interrupted-spiral profile and which rotate in opposite directions inside a chamber 13 , and a pneumatic (or hydraulic) cylinder 14 which operates a piston 16 by means of a rod 15 so as to compress the mixture 17 , it is possible to perform a mixing operation such as that shown in FIG. 3 .
In this mixer, indeed, the pressure exerted by the piston 16 on the mixture 17 may be varied by raising or lowering said piston: this consequently also allows variation of the power needed to provide rotation of the rotors 11 , 12 and therefore the energy used by the system; the energy appears as an increase or decrease in the temperature of the mixture.
In order to carry out the method of the invention, the indirect process parameters such as the energy used by the pair of rotors 11 , 12 , are monitored during processing in a predetermined time sequence; generally, the time interval between two successive monitoring operations is lower than two minutes, preferably not greater than 30 seconds and, even more preferably, not greater than 15 seconds so as to be able to correct in real time any oscillation within the predefined tolerance intervals.
Where considered necessary or appropriate, these indirect process parameters are monitored at even shorter intervals, lower than one second, during the different processing stages mentioned above so as to minimize the degree of deviation of the values of said parameters from the predefined nominal value.
At the start of the working cycle, the piston 16 is fully raised so as to allow the introduction, through a side hopper 18 of the mixer, of a charge of material comprising at least one polymer or a mix of polymers, a reinforcing filler comprising silica in combination with, or instead of, carbon black and a bonding agent for the white filler.
In this connection it must be pointed out that in the present description “white reinforcing fillers” are meant those ingredients of inorganic type, such as gypsum, talc, kaolin, bentonite, titanium dioxide, alumina and various silicates and silica, used in tyre compounds for example in order to increase the roadholding in wet conditions or reduce the rolling resistance of the tyre.
For the sake of brevity said white fillers have been referred to, and will be referred to, generally by the term “silica” or “silica fillers”; however, this term must nevertheless be understood in the broadest sense of its meaning.
The quantity of material loaded, depending on the volume of the mixer, in this case is preferably between 220 and 250 kg.
As can be noted from the graph of FIG. 3, during loading the curve of the adsorbed mechanical power has a minimum value since the pair of rotors has not yet started mechanical processing of the materials; along this section the curve of the temperature shows a downward trend due to the fact that the thermocouples measure the temperature inside the chamber 13 which is cooling, following the unloading of the previous mixture and the subsequent introduction of new material at the environmental temperature.
The entire quantity of silica may be introduced at the start of the processing cycle or preferably during at least two separate steps of the abovementioned cycle.
When loading of the material has been completed, the piston 16 is lowered so as to compress the material inside the chamber 13 ; here and in the following of the description the movements of the piston are regarded as being substantially instantaneous.
Following this lowering movement, the adsorbed mechanical power rapidly increases until it reaches a peak value (after 30 seconds) since the rotors 11 and 12 , which are kept rotating at constant revolutions, exert the maximum force required to break up and mix together the components of the mixture which still have high viscosity values; also the temperature starts to rise. Subsequently, as mixing proceeds and the temperature increases, the viscosity, and consequently also the power consumption, diminishes.
At point C of the processing cycle the number of revolutions of the rotors undergoes a first reduction (of the order of 10%) and at the same time the piston is raised so that the power adsorbed is reduced to a corresponding minimum value: however, after a few moments the piston is lowered again, thereby giving rise to a new peak value of the adsorbed power (point D along the abscissa), following which the value falls again owing to the gradual reduction in viscosity, also linked to the continuous increase in temperature which reaches a value of about 100° C.
Raising the piston also has the effect to let to fall towards the rotors those batch portions which have not been incorporated in the mixture and have accumulated on the closing surface of the device as dust between the piston body and the container wall. The various percentages of the mixture components are thus brought to their predetermined values, thereby fulfilling an essential precondition for achieving the final properties of the mixture.
As mentioned above, the operation of controlling processing of the mixture by means of the piston allows the temperature progression to be kept, over time, within the desired values necessary for correct formation of the final product.
Indeed, raising of the piston, by reducing the pressure on the material being processed, ensures a graduated increase in the temperature with a predetermined gradient and in any case has the effect of keeping this parameter within acceptable limits, so as not to adversely affect the properties of the mixture being processed.
At the same time the variation in the number of revolutions of the rotors is used to optimize both the mechanical processing and the temperature control.
The overall working time from the start of the cycle until the point E, for compounds containing silica fillers may be between 95 and 115 seconds.
Once this point has been reached, incorporation of the silica filler into the polymeric matrix is considered to be adequate; therefore, further ingredients are introduced into the mixer. Preferably, during this step a residual quantity of silica, equal to about 25% of the overall quantity, is introduced.
The operation is performed by raising the piston and keeping it in this position for the whole of the time required: during this operation the power consumption falls to minimum values (E-F) and also the mixture temperature drops, not only due to elimination of the piston pressure, but also following the introduction of ingredients at room temperature, which ingredients may include in particular liquid ingredients, such as plasticizing oil, which favours this cooling effect.
Once loading has been completed (point F), the piston is lowered again and kept pressed against the mixture causing a renewed increase in the adsorbed power and a corresponding increase in temperature.
The overall working time from the start of the cycle until this increase, in the case of compounds with a silica filler, may be between 150 and 195 seconds.
Subsequently, other (one or more) adjustments of the direct process parameters are performed, that is, variations in the number of revolutions of the rotors (for example two reductions of the value of about 40% each) and/or movements of the pressing piston, with consequent increases in the adsorbed power, in combination with or separately from each other and of predefined duration, in order to complete dispersion and homogenization both of the silica and of the further ingredients just added, within the polymeric matrix.
It is assumed that at the end of this processing phase, beginning with the start of the cycle until the point indicated by M along the abscissa axis in connection with the last lowering movement of the piston, an optimum dispersion of the fillers in the polymeric matrix has been achieved: this phase is referred to as the silicization step.
At the end of this phase, in accordance with the invention the temperature of the mixture has reached its maximum value, of the order of 140° C., along a thermal profile which always remains within a range of predefined values.
Now starts the so-called silanization phase which occupies the whole of the successive period until the end of the cycle and during which the chemical reaction between silane, silica and polymer mainly occurs.
This reaction consists in chemical bonding of the silica to the polymeric matrix by means of the silane.
During this phase the pair of rotors rotate at a low number of revolutions (preferably of the order of about 5 to 10 revs/min.) so as to keep the temperature substantially constant; this is possible since dispersion of silica and other components in the polymeric matrix had already been performed, and it is no longer necessary to perform a high degree of mechanical working of the mixture.
In accordance with the invention, the temperature parameter is kept at a substantially constant value during this phase; this is due to the heat stored during the previous steps and to the action of the piston which corrects only any deviation of the temperature from the predefined mean value, in particular deviations greater than the permitted range of fluctuation with respect to said mean value.
Once silanization has been completed, the mixture is unloaded.
This operation is performed by opening the discharge outlet 19 located at the bottom of the chamber 13 and by increasing the number of revolutions of the pairs of rotors so that it is preferably brought again to the value of the starting of the cycle.
During this step, the adsorbed power immediately registers a new peak value (point N on the abscissa axis) which immediately decreases following discharging of the mixture; the energy used on average during the whole working cycle described, indicated by the corresponding curve in FIG. 3, is in this example of about 0.12 kWh per kg of compound produced.
The mixture extracted from the mixer is at the temperature of about 140° C. and, as mentioned previously, it is extruded in sheet form and cooled to room temperature.
Processing of the material within the closed mixer 10 , in particular for the production of silica-reinforced compounds, influences the characteristics of the material (compound) obtained during the subsequent steps.
The acceptability range, within which the process parameters may fluctuate, is fixed taking into account the variability of the physical and mechanical properties suitable for a reference compound in view of its precise intended use.
Hereby with the expression “reference compound” it is meant a compound with such physical and mechanical properties as to determine, when the compound forms part of the end product, the performances required by said product, for example the performances of a tread band.
The characteristics of a “reference compound” comprise those of the mixture at the outlet of the mixer 10 , those of the raw compound extracted from a second mixer where the mixture coming out from the first mixer has been mixed with the crosslinking system, and those of the vulcanized compound.
Among the most important characteristics of the mixture extracted from the first mixer there are the viscosity and the percentage of silanization, whereas among those of the raw compound at the outlet of the second mixer there are again the viscosity and the percentage of silanization as well as the rheometric characteristics, while among those of the vulcanized compound the density, the hardness and the static and dynamic moduli.
Let us now assume that the method described above with the aid of FIGS. 3 and 4 is the optimum cycle for defining the method of production of a compound and that it is required to determine the acceptability range of the process parameters.
The method for determining this acceptability range is performed as described below.
Under uniform conditions of the raw materials and under optimum efficiency of the plant and machinery, a significant number of batches, both of the mixture and of the compound, are produced several times using the optimum process.
The characteristics of the produced items are measured and respectively compared with those of the reference compound and mixture obtained using the abovementioned optimum method, as well as with the values of the process parameters used.
Using a calculation method of the statistical type, the limits within which each process parameter may vary in order to obtain product characteristics included within the predefined limits, are determined.
Purely by way of a non-limiting example, the quantitative limits within which there is a variation in the ingredients of the composition of a typical compound that can be produced using the process according to the invention, are indicated hereinbelow.
The quantities of the ingredients are expressed as parts by weight per hundred parts of polymeric material (phr):
Polymeric base
100
Carbon black
0-80
Silica
10-80
Bonding agent
4%-15% of silica
Zinc oxide (ZnO)
1-3
Stearic acid
0-3
Anti-degradation agents
1-3
Plasticizing oil
0-30
Anti-ozone wax
0.5-3
Specific chemical ingredients
0-15
In addition thereto there will be included the crosslinking system, in quantities known per se depending on the composition of the mixture, usually comprising sulphur (from 0.5 to 2.5 phr) and vulcanization accelerators.
Among the polymeric bases, preference is given to polymers or copolymers with an unsaturated chain obtained by means of polymerization of conjugated dienes and/or aliphatic or aromatic vinyl monomers.
Given the above, by way of example some tables relating to the reference values for a given compound composition and acceptability ranges of the process parameters are provided hereinbelow.
Thus Table 1 shows the values of the characteristics of the raw compound at the outlet of a mixer such as that shown in FIG. 2, while Table 2 shows some characteristics of the vulcanized compound. In both cases the tolerance ranges are defined by the deviation limits from the (central) reference values, indicated with the symbol ±.
The tables relate to processing of a batch of material of 230 kg optimized with respect to the volume of the mixer and the mixture density; the material introduced into the mixer 10 has a composition chosen from those indicated above and in particular formed as specified hereinbelow:
RECIPE
(phr)
Natural rubber
8.00
Polybutadiene
20.00
SBR “in solution”
72.00
Plasticizing oil
5.00
Silica
63
Stearic acid
2
Zinc oxide
2.5
Processing aid
2.00
Silane (50% predispersed)
10.00
Wax
1
Amino anti-oxidant (type TMQ)
1.00
Amino anti-degradation agent (type 6PPD)
2.00
Sulphur
1.20
Accelerator: sulphenamide (type CBS)
2.00
Accelerator: diphenylguanidine (80% active)
0.80
TABLE 1
Rheometric
Central
Deviation
characteristics
value
tolerances
M L (dNm)
2.20
±0.30
M H (dNm)
20.50
±2.00
t 30 (min)
0.82
±0.60
t 60 (min)
1.74
±0.13
The rheometric characteristics are measured in his case in accordance with the standards ISO 6502 by using an instrument of the MDR type for 2 minutes at the temperature of 195° C.
The rheometric units M L and M H are expressed in dN*m (tenths of a Newton per meter) corresponding to the initial force and to the maximum force exerted by an oscillating device on the compound test-piece heated to a given temperature.
The progression of the vulcanization curve initially exhibits a depression (saddle region) where there is the minimum force, corresponding in the raw condition to the plastic state (M L ) and then the curve gradually rises up to a constant maximum value (M H ) corresponding to the vulcanization level where the instrument exerts the maximum force.
The characteristics indicated in Table 1 by the symbols t 30 , t 60 are expressed in seconds and each indicates the time required to reach the percentage (30% and 60%) of the difference between the maximum force and the minimum force.
Table 2 below indicates the characteristics of a test piece consisting of the compound extracted from the second mixer after vulcanization for 30′ (minutes) at the temperature of 151° C.
TABLE 2
Characteristic
Mean value
Variability
Density
(g/cm 3 )
1.196
±0.004
100% modulus (CA1)
MPa)
2.3
±0.2
300% modulus (CA3)
(MPa)
9.8
±0.6
Ultimate tensile strength
(MPa)
>15.0
Ultimate elongation
(%)
>400
Hardness
(IRHD)
73
±2
The density is measured by using the procedure defined in the standard ISO 2781.
The dynamometric characteristics are expressed by the moduli measured along the force/deformation curve traced in a Cartesian diagram having in its ordinate axis the forces expressed in MPa and in its abscissa axis the deformations.
The testing procedures are defined in the standard ISO 37 and the symbols CA1 and CA3 shown in Table 2 indicate the value of the load measured at 100% and 300% deformation of the test piece, respectively.
Using a methodology similar to that explained hitherto for the mixing step, in the method according to the invention reference values with the associated deviations are determined also for the other critical steps in processing of the mixtures.
Thus, for example, the stay (maintenance) times inside the extruder for step 3 downstream from the closed mixer 10 are determined, together with any other operation in successive mixers and the like, depending on the used operating cycle.
On the basis of the data and the information obtained above, a coefficient indicating the weight which non-compliance of a given parameter with the predefined tolerances assumes in the production of a compound or a final mixture with the desired characteristics, is assigned.
This situation is illustrated in the tables shown in FIGS. 4, 5 .
As illustrated, FIG. 4 shows a table divided into a number of sections, the first one of which (on the left) contains the process parameters considered for processing of a given mixture in the discontinuous mixer 10 .
The second section (alongside the first one) shows the nominal values of the aforementioned process parameters, and their variation tolerances with respect to the nominal values and the coefficients (or weights) attributed in the event of non-compliance with the tolerances.
These values relate to the operating steps for processing in the mixer 10 , which are illustrated in the graph of FIG. 3 and are indicated in the first column by the same letters.
The third section (on the right of the preceding one) in FIG. 4, on the other hand, shows the values of the process parameters actually measured during the course of processing of a mixture with the abovementioned recipe, together with the weights attributed depending on whether the predefined tolerances are respected (or not).
The weight which non-compliance with the various tolerances assumes with regard to achieving a desired mixture will obviously depend on each individual case; in Table 4, a scale of values ranging from a minimum of 0 to a maximum of 40 has been chosen.
The weight factors attributed are then added together so as to provide an overall end result which, compared with the reference classification shown in the last right-hand section of FIG. 4, provides the evaluation of the mixture.
Therefore, in this way it is possible to establish immediately, at the outlet from the mixer 10 , whether a batch of material has been processed in accordance with the desired requirements.
In the case of FIG. 4 it can be seen that the total score, i.e. that resulting from the sum of the individual weight factors attributed during the various process operating steps in the mixer 10 , has a value of 45 and, from a comparison with the reference classification, it can be deduced that the processed mixture falls within the third of the four categories envisaged, i.e. the category representing the 2 nd degree of non-compliance.
A similar methodology is adopted for the other mixture processing steps.
For example, FIG. 5 shows a table which relates to the extrusion of the mixture; since this step (indicated by 3 in FIG. 1) is simpler than the preceeding mixing operation, the associated table is also simplified.
In this case, the process parameter to be complied with is the stay time inside the extruder; in the same way as before, therefore a reference classification for this parameter is established, said classification acting as a means of comparison for the actual value measured, in order to determine the quality of the mixture at the outlet.
As shown, in FIG. 5 only three classification categories (instead of four as in the previous case) have been defined for this parameter; once the extrusion phase 3 has been completed, the sheets leaving the calender undergo the remaining working steps illustrated in FIG. 1 .
This is performed continuously (i.e. without interruption) and controlled depending on the progress of production.
Indeed, as illustrated above, with the method according to the invention it is possible to obtain an evaluation, in real time, as to the quality of the semi-finished products obtained from a given batch of starting materials; on the basis of this evaluation it is therefore possible to establish immediately, along the production line, i.e. without having to perform separate laboratory tests on samples taken from the production line, the subsequent use of the semi-finished product.
As a result it is possible to achieve a nearly continuous working cycle, controlling the production with a normal automated system (i.e., a PLC or similar) which functions in accordance with the logic described above; in particular, it will no longer be necessary to interrupt the process to wait for the outcome of the laboratory tests.
For this purpose it is sufficient to provide, at the extrusion outlet, means (such as a punch or the like) for marking the sheets obtained from a given initial batch; in this way any sheet classified as defective or to be discarded (owing to human error or malfunctioning in the mixing or extrusion apparata) may be distinguished from the preceeding or following ones.
Subsequently, along the production line, said sheet will then be separated by means of a cutting operation and will be arranged on a bench together with the sheets which have been attributed the same evaluation.
It should be noted that, in so doing, it is avoided to mix together sheets obtained from batches defect-free and sheets obtained from batches which are defective or which have to be discarded, with the consequent risk of contaminating the semi-finished products that are in a good state and of discarding them as well.
Indeed, in the known art, for monitoring the production laboratory tests are carried out not only on the intermediate mixtures, but also on the (both raw and vulcanized) compound obtained therewith; consequently, if one (or more) of these mixtures (which should be discarded) is mixed with other defect-free mixtures in order to obtain the compound, also the obtained end product has to be discarded, with the corresponding economic loss arising therefrom.
For the sake of completeness of explanation, FIG. 6 shows in the form of a table the characteristics of the raw compounds obtained by using mixtures considered defective and to be discarded in FIGS. 4 and 5, respectively: i.e., a mixture for which mixing was not performed in compliance with the predefined conditions and a mixture which remained in the extruder for too long.
In this latter case, the characteristics of the vulcanized compound (30 minutes at 151° C.) and the behaviour of the tread band during extrusion have also been taken into consideration; the symbols used are the same as those used in the preeceding Tables 1 and 2.
Of course, variations of the invention with respect to that described hitherto are possible.
Firstly it can be pointed out that said invention is not limited only to processing cycles such as that shown in FIG. 1; the latter is in fact a simple cycle during which silicization and silanization of the mixture are performed in the same mixer, but there is nothing to prevent these two steps from being performed in respective mixers, with the mixture being discharged from one mixer and introduced into the other one.
It should also be pointed out that the method according to the invention may also be applied to the processing of compounds, namely to the product obtained by adding the vulcanization components to a mixture.
In other words, the system of determining nominal reference values with the associated tolerances for the process parameters and then evaluating the degree of compliance with said values during production, so as to control the progression thereof, may be applied both to mixtures in general and to the products obtained therefrom, such as for example the compounds.
These and other possible variants in any case fall within the scope of the claims which follow. | A method for processing a rubber mixture or compound for tire manufacturing includes the steps of determining variation tolerances with respect to reference values for process parameters, detecting values of the process parameters, comparing detected values of the process parameters with the reference values and the variation tolerances, attributing an evaluation to a semi-finished product depending on compliance or noncompliance of the detected values with the reference values and the variation tolerances, classifying the semi-finished product on a basis of the attributed evaluation, and establishing successive steps for processing the semi-finished product depending on the classification of the semi-finished product. The processing includes at least a mixing cycle and an extrusion cycle for obtaining the semi-finished product. The cycles are controlled by the process parameters detected during execution of the cycles. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/770,414, filed on Feb. 19, 2013, and entitled “ENHANCING WATER RECOVERY IN SUBTERRANEAN WELLS WITH A CRYOGENIC PUMP,” which is a continuation of U.S. patent application Ser. No. 12/763,650, filed on Apr. 20, 2010, issued as U.S. Pat. No. 8,490,696, and entitled “METHOD AND APPARATUS TO ENHANCE OIL RECOVERY IN WELLS,” which claims the benefit of U.S. Provisional Application No. 61/170,966 filed on Apr. 20, 2009, both of which are incorporated herein in their entirety.
TECHNICAL FIELD
[0002] The present invention provides a method for enhanced oil recovery using cryogenic fluids. In particular, cryogenic fluids are injected into subterranean reservoirs to enhance the recovery of oil.
BACKGROUND OF THE INVENTION
[0003] In recent years, the demand for oil and natural gas has increased. The increase in demand for oil and natural gas is driving the oil and gas industry to produce more oil and natural gas using more cost efficient and effective techniques. Extracting subterranean fluids from depleted oil and gas reservoirs with new means is needed.
[0004] Generally, when extracting oil and natural gas from subterranean reservoirs, the skilled artisan must consider the properties of the reservoir, the types of fluids present in the reservoir, and the physical and chemical properties of fluids of the reservoir. Another important factor in enhancing the total recoverable reserves of hydrocarbons and other fluids form depleted reservoirs is related to the reservoir pressure of the fluids trapped in the reservoir. When a wellbore penetrates a reservoir, the reservoir pressure forces the subterranean fluids out of the reservoir into the wellbore and up ward toward the surface as a function of lower pressure at the surface. As fluids flow into the wellbore, the pressure of the reservoir decreases, or as commonly referred to in the industry the reservoir pressure depletes. As such, over a period of time of extraction, the reservoir pressure becomes insufficient to force hydrocarbon fluids from the reservoir into the well. Therefore, there is a need to maintain and/or increase the reservoir pressure in these depleted reservoirs in order to maximize the percentage of hydrocarbon fluids recovered from the reservoir.
[0005] A reservoir's ability to produce oil is also a function of the reservoir's drive mechanism. A reservoir's drive mechanism refers to the forces in the reservoir that displace hydrocarbons out of the reservoir into the wellbore and up to surface. Reservoir drive mechanisms include gas drive (gas cap or solution gas drive), water drive (bottom water drive or edge water drive), combination drive, and gravity drainage. An example of solution gas drive is when soluble gases in the oil expand and are carried into the well with liquid hydrocarbons. Reservoirs where soluble gases form a significant portion of the drive mechanism typically have the lowest reservoir primary recovery factors for hydrocarbons. Therefore, there is a need for a method to continually and rapidly replenish the reservoir energy depleted by the extracted soluble gases. This can be done with the injection of fluids that can energize the reservoir and still more desirable is injecting a fluid that is soluble in the reservoir fluid at reservoir pressure and temperature conditions.
[0006] Petroleum engineers often refer to the percentage of oil recoverable from a given reservoir versus the oil in place in a reservoir as the “recovery factor.” During primary recovery phase of a wells exploitation, the natural pressure of the reservoir created by the combination of forces like the earths overburden and subsequent compression of the reservoir fluids drives or forces hydrocarbons into the wellbore. However, only about 10 to 30 percent of a reservoir's original hydrocarbons in place are typically produced from the reservoir during the primary recovery phase. After a number of years of producing fluids from reservoirs under primary recovery methods, it becomes necessary to inject fluids from surface into the reservoirs to enhance fluid production from the depleted reservoir. This process is known as Enhanced Oil Recovery (EOR). The purpose of EOR is to increase the recovery of the reservoir fluids.
[0007] In general, Enhanced Oil Recovery is divided into two distinct phases, secondary recovery methods and tertiary recovery methods. Secondary recovery methods generally include injecting water or gas to displace oil and driving the hydrocarbon mixture to a production wellbore which results in the enhanced recovery of 20 to 40 percent of the original oil in place. After a reservoir has been flooded with water or other secondary recovery methods, tertiary recovery methods are used to increase the fluid recovery from the reservoir. However in some cases, tertiary recovery methods may be used immediately after the primary recovery method.
[0008] Generally, tertiary recovery methods include steam, gas injection, and chemical injection. Steam enhanced tertiary recovery involves injecting steam down an injection well to lower the viscosity of the hydrocarbon fluid. That is, heavy viscous oil reserves is made less viscous to improve their ability to flow out of the reservoir into a well. Gas injection tertiary methods employ gases such as natural gas, nitrogen, or carbon dioxide that expand in a reservoir to push additional oil to a production wellbore. In all these gas injection means, the fluids are at temperatures of more than −100° F. Fluids that are at a temperature below −100° F. are commonly referred to as cryogenic fluids. Preferred gases are those that dissolve in the reservoir hydrocarbon, which lower the in-situ hydrocarbons viscosity and improve the hydrocarbons flow rate from the reservoir to the well bore. Chemical injection involves the use of polymers to increase the effectiveness of water floods, or the use of detergent-like surfactants to reduce the surface tension that often prevents oil droplets from moving through a reservoir.
[0009] Generally, carbon dioxide is a common miscible tertiary EOR fluid. Carbon dioxide is the preferred EOR fluid in the current art because it can be delivered to wellbores in a liquid form above cryogenic temperatures. For example, carbon dioxide has a boiling point of −70° F. at ambient pressures, while other gases have a higher boiling point, e.g., methane has a boiling point of −259° F. at ambient pressures. The difference between these boiling points shows that carbon dioxide requires less energy to condense to a liquid phase in comparison to most other fluids that are miscible in hydrocarbon liquids. Nevertheless, over fifty percent of the cost when using carbon dioxide to flood the well is the initial purchase of the carbon dioxide. Further, the use of carbon dioxide in EOR methods has other disadvantages. For example, once carbon dioxide is injected into an injection well, it cannot be recovered and resold. Also, it is a greenhouse gas, the release of which into the atmosphere will likely be regulated. Moreover, it causes formation of carbonic acid in water that can lead to corrosions of pipes and other equipment. What is needed is a tertiary fluid that is soluble in the hydrocarbon fluids, can be commercialized as a part of the reservoir fluid recovery process, and is non-corrosive.
[0010] On the other hand, it is plausible for liquid methane or liquid natural gas, LNG, to be used to flood the reservoir in tertiary recovery methods if the liquefied natural gas supply can be replenished continually. When liquid natural gas (LNG) is used as a cryogenic flood fluid to enhance oil recovery, the LNG may be re-gasified under ground and separated from the tertiary recover of oil upon recovery of the combined fluids at the surface. The recovered LNG can be commercialized and sold as natural gas, using the existing equipment already in place to distribute oil and gas from the recovery sites to the market.
[0011] Further, it is difficult to inject gases into the reservoir, as it requires large high pressure compressors and prime movers at or near the wellbores. It is costly to construct the required compressor injection facilities at each EOR site, and it is even more cost limiting when the EOR site is offshore because the compressors and prime movers would have to be located on the offshore platforms where space is expensive and limited. This present disclosure provides for a solution where these same gases are liquefied as cryogenic liquids prior to injection to the wells, which allows them to be contained in significantly smaller spaces than their gas counterparts because the same volume of the fluid in liquid form contain several orders of magnitude more molecules than when the fluid is in gas form. For example, cryogenic liquefied methane and LNG contains 600 times more methane than an equivalent volume of methane gas. Consequently, a more cost effective method is needed to get large volumes of these cryogenic flood fluids delivered to the EOR sites to be injected into the subterranean oil reservoirs as flood fluids.
[0012] Further, currently, the oil and gas industry has many known reservoirs of natural gas that are stranded because the reservoirs are geographically located far from a commercial markets. As such, to commercialize the natural gas, large facilities are built at these stranded geographical areas to liquefied the natural gas produced at these sites. The LNG is transferred to large cryogenic tankers to commercialize the LNG and bring it to a market. The commercial activities, e.g., sales, of the produced cryogenic fluid, LNG, is limited in the world today because the markets for such LNG requires costly cryogenic facilities to receive and or re-gasify the cryogenic liquids at the destination market. These receiving stations at the destination market, or re-gasification stations, are expensive and require LNG carrying ships to come into ports and near populated areas to discharge their cryogenic cargo. The regasification facilities are often perceived as a potential health hazard; hence, public support for such facilities is difficult to obtain. What is needed are EOR facilities sufficiently far from population centers with facilities and wells equipped to accept the cryogenic fluid cargos as a flood fluid and to serendipitously commercialize the cryogenic flood fluid from production wells once it has served its purpose as a reservoir displacement or flood fluid and is naturally geothermally heated, re-gasified and/or separated from the recovered hydrocarbon produced to surface after the LNG is injected into the subterranean environment and used as the flood fluid.
[0013] The present invention provides a method for injecting large volumes of cryogenic liquids into subterranean reservoirs as very cold fluids, which are subsequently extracted from the reservoir with hydrocarbon fluids as a means of enhanced hydrocarbon recovery. As the geothermal energy warms the cryogenic flood fluid the fluid expands causing an increase in pressure in the reservoir. Additionally, the present invention provides a method for creating large conductivity paths for the cold fluids to enter into the reservoir matrix. Furthermore, this invention teaches methods to inject the cold fluid into wells by means of expanding tubular slip joints in the well. In addition, the present invention discloses methods of utilizing the existing equipment to commercialize LNG from stranded locations without having to build additional structures to re-gasify the delivered LNG in natural gas form.
BRIEF SUMMARY OF THE INVENTION
[0014] The present invention provides methods and apparatus for enhancing the recovery of fluids from subterranean reservoirs using cryogenic flood fluids. In some aspects of the present invention the method for enhancing the recovery of fluids from subterranean reservoirs using a cryogenic flood fluids comprises the steps of providing a source of at least one cryogenic flood fluid, delivering at least one cryogenic flood fluid from the source to at least one wellbore, injecting the cryogenic flood fluid with at least one cryogenic pump through at least one wellbore into at least one subterranean reservoir, warming the cryogenic flood fluid, and transporting reservoir fluids produced from the subterranean reservoir into a storage tank through at least one wellbore. In some cases, the storage tank may be on, near or at the Earth's surface. In other embodiments, the storage tank may be aboard an oil platform, an oil tanker, underground and/or submerged under a body of water. In additional embodiments, the reservoir fluids produced from the subterranean reservoir may feed directly into a pipeline.
[0015] In other aspects of the present invention, the cryogenic flood fluid source is a liquid natural gas plant. In some embodiments, the cryogenic flood fluid source is a liquid air plant. In certain embodiments, the cryogenic flood fluid is liquid natural gas. In specific embodiments, the cryogenic flood fluid is liquid oxygen. In alternate embodiments, the cryogenic flood fluid is liquid nitrogen.
[0016] In some embodiments, the cryogenic flood fluid source is aboard a ship. In alternate embodiments, the cryogenic flood fluid source is provided by a truck in still other embodiments the cryogenic flood fluid source is a pipeline.
[0017] In some aspects of the present invention, the step of injecting the cryogenic flood fluid is performed by at least one cryogenic pump. The cryogenic pumps can be positive displacement pumps fed by low pressure cryogenic centrifugal pumps or a series high rate cryogenic turbo-pumps like the low pressure oxidizer pump and high pressure oxidizer pump used on the Space Shuttle. The high rate attribute of the cryogenic turbo-pumps is useful in rapidly unloading large volumes of LNG from LNG tankers offshore to reduce mooring times of the vessels.
[0018] In some cases, the wellbore is located offshore and the subterranean reservoir is an offshore oil reservoir. In other embodiments, the subterranean reservoir is an offshore gas reservoir. In specific embodiments, the subterranean reservoir is an aquifer. In other embodiments, the subterranean reservoir is a coal bed methane deposit, a shale oil deposit, and/or a shale gas deposit.
[0019] Additionally, the methods of the present invention may include the step of injecting a cryogenic flood fluid comprising a chemical additive. This chemical additive may be a solid, liquid and/or a gas. In some embodiments, the chemical additive is a solid. In some cases, the chemical additive is a polymer. In some cases, the chemical additive may comprise a tetrahalosilane. In specific examples, the tetrahalosilane is silicon tetrachloride.
[0020] Alternatively, the methods of the present invention may include the step of injecting a cryogenic fluid comprising a liquid chemical additive. In some embodiments, the liquid chemical additive is hydrogen peroxide. In yet another embodiment, the chemical additive is a gas.
[0021] In some embodiments, the reservoir fluid produced from the subterranean reservoir comprises a liquid. In some cases, this liquid comprises a liquid hydrocarbon. The liquid produced from the reservoir may comprise water and/or gas. In some cases, the gas comprises a hydrocarbon gas and/or steam.
[0022] In some embodiments, the step of warming the injected cryogenic fluid is performed by an electrical heater. In other embodiments, the warming step is performed by the geothermal energy of the well and reservoir wherein it is injected. The warming step can also be performed by a seawater heat exchanger or a surface combustion fired heat exchanger.
[0023] In additional embodiments, the methods of the present invention further comprises the step of injecting a non-cryogenic flood fluid through at least one wellbore into at least one subterranean reservoir. In particular embodiments, a wellbore has at least one horizontal section.
[0024] The present invention provides for injecting at least one cryogenic flood fluid into a subterranean reservoir. In general, this apparatus has a wellbore extending into a subterranean reservoir, a first conduit that is located within the wellbore, a wellhead coupled to the first conduit, a second conduit is located within the wellbore, and a sealing elastomeric thermal expansion slip joint located near a distal end of the second conduit. In some embodiments, the wellbore extends from the surface into a subterranean reservoir. In some embodiments, the first conduit has a fluid path that extends from a location at or above the earth's surface to at least one subterranean reservoir. In certain embodiments, the wellhead that is coupled to the first conduit is located at or near the earth's surface. Additionally, the second conduit has a fluid path that extends from a location at or above earth's surface to at least one subterranean reservoir and the second conduit coupled to a subterranean reservoir at the earth's surface. In other embodiments, the elastomeric thermal expansion slip joint situated so that it is in contact with the inner diameter of first conduit and the outer diameter of the second conduit.
[0025] 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 that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present 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
[0026] 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:
[0027] FIG. 1 shows schematic of a system that uses a cryogenic fluid to enhance the recovery of oil from a reservoir; and;
[0028] FIG. 2 shows a well apparatus for injecting cryogenic fluids into reservoir.
DETAILED DESCRIPTION OF THE INVENTION
[0029] As used herein, “surface” refers to locations at or above the surface of the Earth, ice, ocean bottom, river bottom, lake bottom, and/or body of water, such as a lake, river, or ocean.
[0030] As used herein, “fluid” refers to substance that continually deforms and/or flows under an applied shear stress. This term includes gases and liquids.
[0031] As used herein, “cryogenic” refers to a liquid that boils, i.e., changes from a liquid to a gas, at temperatures less than about 110 Kelvin (K) at atmospheric pressure, such as hydrogen, helium, nitrogen, oxygen, air, or methane (natural gas).
[0032] FIG. 1 shows a schematic of a system that uses a cryogenic fluid to enhance the recovery of oil from a reservoir. In FIG. 1 , LNG ship 1 transports liquefied natural gas 2 from a LNG fabrication source to offshore oil platform 4 . While FIG. 1 depicts transportation of LNG 2 by ship 1 to offshore platform 4 , it is envisioned that other embodiments include transport of LNG 2 by truck to wellbores located on land. This invention also contemplates the construction of a liquid air plant to produce cryogenic fluids near the EOR site or a natural gas liquefaction plant located near the EOR site. As depicted, LNG 2 is transferred from containers aboard LNG ship 1 to pump 3 located on an offshore platform 4 . In the preferred embodiment, pump 3 is a large cryogenic turbo-pump system, such as the Rocketdyne low pressure and high pressure oxidizer turbo-pumps used on the main engine of the space shuttle. In other embodiments, however, it is envisioned that other suitable cryogenic pumps as known in the art can be used. The liquid natural gas 2 is injected from pump 3 through wellbore 5 . The LNG 2 travels through wellbore 5 into subterranean oil and gas reservoir 6 . Wellbores 7 and 8 are located at different positions in subterranean reservoir 6 . Oil and natural gas are produced through wellbores 7 and 8 . In other embodiments, reservoir 6 can be an aquifer that produces water or a gas reservoir that has a low pressure due to previous depletion.
[0033] In FIG. 1 , wellbores 7 and 8 direct the produced oil and natural gas to a separator 9 located on the surface of offshore platform 4 . Separator 9 is where the oil, gas, and any water are separated. The gas is then transferred through gas pipeline 12 to a site on the shore (not shown). The oil is transferred to oil tank 10 located on offshore platform 4 . From oil tank 10 , pump 13 directs the oil into oil pipeline 14 , which leads the oil from offshore pipeline 4 to a site on the shore (not shown). Any water separated using the separator 9 is transferred to water tank 20 where it can be filtered and then disposed in the sea. In some cases, the recovered water is re-injected into the reservoir 6 using pump 21 . Furthermore, the method can use the injection of sea water to be injected intermittently when LNG is not being injected into a well. In some examples, the recovered water or other water, like sea water, is directed down a wellbore 5 and reused as a flood fluid. In some cases, the oil tank and/or storage tank may be on, near or at the Earth's surface. Additionally, oil tank 10 may be aboard an oil platform, an oil tanker, underground and/or submerged under a body of water. In additional examples, the reservoir fluids produced from the subterranean reservoir may feed directly into a pipeline. As discussed above, the present disclosure allows for the EOR injection fluid to be recovered and sold as natural gas using the already existing structures in place that distribute the oil and gas recovered at platform 4 , or any other recovery sites. As such, the present invention facilitates the commercialization of LNG at stranded locations and eliminates the need to build additional regasification stations.
[0034] In the preferred embodiment, liquid natural gas 2 is injected into subterranean reservoir 6 as a cold liquid. The cold fluid has advantages over previous methods of EOR injection of gases as the cold fluid causes cracking and rubbilizing of the subterranean reservoir thereby exposing a new fluid path for the flood fluids to sweep hydrocarbons from the reservoir. As LNG 2 begins to heat up in the reservoir 6 , a flood bank of liquid natural gas 16 is formed near injection points 15 of well bore 5 . As the LNG 2 is being injected through wellbore 5 , wellbores 7 and 8 draw liquids like oil and gas fluids from the same reservoir 6 . As LNG 2 moves through wellbore 5 , the flood front pushes toward production wellbores 7 and 8 . In other embodiments, other fluids besides LNG like liquid air, nitrogen, and oxygen, can be used as the cryogenic flood fluid. In FIG. 1 , as LNG 2 advances away from the injection wellbore 5 , liquefied gas 2 is warmed by geothermal energy 18 of the earth. Although geothermal energy is used in this particular example, the cryogenic flood fluids may be warmed by other methods including, but not limited to, the various methods used in thermal recovery, in situ combustion, wet combustion and fire flooding. For example, the injected cryogenic fluid, e.g., LNG 2 , can be heated with an electrical heater, a seawater heat exchanger, or a surface combustion fired heat exchanger. This geothermal energy 18 flows into subterranean reservoir 6 and mixes with the fluids of reservoir 6 . During injection, geothermal energy 18 mixes with the reservoir fluids and the injection fluids to form a series of flood banks, exemplified by 16 , 17 , 19 , and 24 of vaporizing cryogenic fluid like natural gas 2 , reservoir fluids, and injected water. As the liquid natural gas is injected into wellbore 5 and fluids are drawn to the surface from the reservoir 6 through wellbores 7 and 8 , another flood bank is formed at 24 . As the flood banks 16 , 17 , 24 , and 19 advance in reservoir 6 , other fluids in reservoir 6 are driven into the production wellbores 7 and 8 , where they are transduced to surface through the wellbores. Prior to the arrival of the actual break through of the injected fluid, a series of flood banks having different fluid phases, and different mixes of fluids comprising injected fluids and reservoir fluids depicted as flood bank 16 , 17 , 24 , and 19 arrive at the production wells 7 and 8 .
[0035] Additionally, FIG. 1 shows two production wells 7 and 8 and one cryogenic flood fluid injection well 5 . A skilled artisan would readily recognize that multiple injection and production wells may be within the spirit and scope of the present invention Likewise, other variations such as horizontal wells may be placed in the reservoir 6 for both injection and production wells.
[0036] Also, the present invention provides the method for stopping and/or restarting the injection of cryogenic fluids, like liquid natural gas 2 , into reservoir 6 . This is done to allow geothermal energy 18 of the earth to heat the cryogenic flood fluids in-situ and to allow for LNG ship 1 to arrive with a fresh supply of LNG 2 . In another aspect of the present invention, liquid natural gas is injected down a different wellbore like 7 when the next cycle of liquid natural gas 2 is injected into reservoir 6 .
[0037] Additionally, the water from tank 20 or sea water may be injected into reservoir 6 and used as an alternative flood fluid in between the injection cycles of cryogenic fluids. This water may be used in alternating injection cycles, alternating between water and cryogenic flood fluid. These waters may be heated prior to injecting into the reservoir to further assist in the thermal cracking of the reservoir to enhance reservoir conductivity and to heat the injected cryogenic fluids. In an additional embodiment, chemical additives, such as solids, liquids and gases may be added to the cryogenic flood fluid and the water injection cycle and injected into reservoir 6 from the flood fluids from tank 22 through an injection pump 23 . The chemical additives may include, but are not limited to polymers, surfactants, corrosion inhibitors, caustics, ammonium carbonate, hydrogen peroxide, sulfuric acid, urea, butanol, N-alkylacrylamides, terpolymers of acrylamide, N-decylacrylamide, and sodium-2-acrylamido-2-methyl-propane sulfonate (NaAMPS), sodium acrylate (NaA), sodium-3-acrylamido-3-methylbutanoate (NaAMB), partially hydrolyzed polymer polyacrylamide, polyacylamide, bentonite clay, polydimethyldiallyl ammonium chloride biopolymers, exopolysaccharide produced by Acinetobacter, Xanthan, Wellan, Pseudozan, silicon tetrahalides (halide refers to a halogen atom such as, fluoride, chloride, bromide, iodide and/or astatide), silicon tetrachloride, silicon tetrafluoride, silicon tetrabromide, and/or silicon tetraiodide.
[0038] FIG. 2 shows a wellbore apparatus used to inject the cryogenic flood fluids. The wellbore apparatus shown in FIG. 2 has wellhead 1 connected at the surface to a casing 2 , which is disposed in well 3 . Casing 2 is set to a depth below subterranean reservoir 6 and has perforations 4 that allow hydraulic communication with reservoir 6 . Located in casing 2 above perforations 4 is polished bore receptacle 5 , which forms a smooth bore through its internal diameter and accepts seal assembly 7 . The seal assembly 7 has outer sealing elements 10 located on its outer diameter such that when seal assembly 7 contracts or expands, the plurality of sealing elements 10 form a moveable sealing means with the inner diameter of polished bore receptacle 5 . That is, there is at least one outer sealing element 10 located at any position of contraction or expansion to form a seal between sealing assembly 7 and polished bore receptacle 5 . Seal assembly 7 is longer than the length of the polished bore receptacle 5 . This allows for seal assembly 7 to contract and expand as tubing 8 is cooled and heated with cryogenic flood fluids and other injection and production fluids thereby forming a moving sealing means with outer sealing elements 10 . Likewise, tubing 8 has sealing elements 9 that form a hydraulic seal between the outer diameter of tubing 8 and the inner diameter of seal assembly 7 . Sealing elements 9 can be hydraulic slip joints that create a moveable sealing means between seal assembly 7 and tubing 8 that allows tubing 8 to contract and expand inside the seal assembly 7 during the injection of fluids. Sealing elements 9 also form moveable sealing means. That is, there is at least one sealing element 9 located at any position of contraction or expansion to form a seal between the inner diameter of sealing assembly 7 and the outer diameter of tubing 8 . As such, the apparatus of FIG. 2 provides great flexibility to accommodate the expansions and contractions in the equipment due to the changes in temperatures of the injection and production fluids.
[0039] 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 present invention provides methods and apparatuses for the enhanced recovery of fluids from subterranean reservoirs using cryogenic fluids. Using the Earth's geothermal energy to warm cryogenic flood fluids injected into subterranean reservoirs, the pressure within the subterranean reservoir is increased. Consequently, the reservoir conductivity is enhanced due to thermal cracking, and improved sweep efficiency of the reservoir by the flood fluids is provided. This rise in pressure due to the injection of the cryogenic fluid increases the reservoir conductivity enhancement and improves sweep efficiency of the flood fluids, which leads to the production of more fluids from to the subterranean reservoirs. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of priority to U.S. Provisional Patent Application No. 61/762,443 filed 8 Feb. 2013 and U.S. Provisional Patent Application No. 61/893,674 filed 21 Oct. 2013; each of which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] The present disclosure is directed generally toward systems and methods of capturing existing customer endorsements at the point of any purchase or transaction and spreading the endorsement through the customer's social media channels to influence the purchase or transaction decisions of that customer's social media connections and the connections of their connections and so on. More specifically, the present disclosure utilizes a customer's influence within social networks to drive additional brand awareness, brand engagement, transactions, and revenue for any organization.
[0003] As social media and online connectivity becomes more and more available, the amount of information users wish to share with their “friends” is ever increasing. Advances in the internet and mobility has made it possible for a user to share their real world experiences through their social media connections in ways as never before imagined.
[0004] There are essentially three layers of the Internet. Layer One (the foundation layer) consists of the backbone network that makes up the Internet and is comprised of the broad interconnection of hardware and networking equipment. Layer Two (the application layer) consists of the many software applications that have been developed by individuals and companies throughout the world to leverage the possibilities of the underlying foundation layer or to make that layer more usable. This includes static websites, dynamic tools, and Web 2.0 applications such as social media channels. Layer Three, creates an opportunity for brand new technologies to be invented that sit on top of the applications in Layer Two and help to integrate those applications and enable them to drive greater value for consumers and organizations. This layer may also integrate offline and online worlds for consumers and organizations—creating a more seamless customer experience. The present disclosure operates at this third layer.
[0005] The expansive and instant reach of the average consumer via their social networks creates a significant, untapped opportunity for organizations of all sizes to leverage the influence of existing customers to drive new customers. The present invention takes advantage of these untapped influences and discloses a hardware and software technology platform that is dedicated to helping organizations and businesses capture these new opportunities.
[0006] The described system technology platform can create significant and measurable value for an organization by providing a vehicle to create broader brand awareness and drive greater brand engagement. The system enables the organization to use social media more effectively as a new conversion channel, allows them to optimize that channel, and then let's them measure the results of that lift in conversion in real-time. The system may be used in both for-profit and non-profit environments.
[0007] The implementer of the system may host the platform or may employ others to host the system. As an implementer of the system a fee for providing increased value to an organization utilizing the service may be charged. This fee can include but not be limited to a performance fee, a percent of sales fee, a flat recurring fee, and/or a licensing fee. Social network providers may also use the system to monetize their user databases and imbedded user base. Social networking providers presently are developing marketing and advertising concepts that directly target their user base to monetize that base. In addition, they are directly targeting organizations to sell them advertising space. And, some do provide organizations with the ability to allow their end users to endorse an organization or a product on an organization's website. However, they don't provide those organizations with an integrated application that engages a user at the point of any transaction (whether online or offline), motivates that user to create an endorsement, facilitates the proliferation of that endorsement via the user's multiple social media networks, measures the ripple effect of the sharing, and provides a set of tools to continually improve and optimize the results. A significant opportunity for them would be to utilize the present system, such that, instead of targeting their user base and targeting organizations separately, they could better allow organizations to engage users at the point of their own conversion and then charge a fee or take a piece of the lift resulting from the incremental awareness, engagement, and purchases or transactions generated by the system. This creates a significant new revenue opportunity for social network providers and is possible utilizing the herein described system.
SUMMARY
[0008] In an embodiment of the present disclosure, the system may be deployed by organizations to engage their customers or users and motivate their customers or users to endorse a purchase or other transaction and to share the purchase or other transaction information (no matter where that purchase or transaction occurs—online, offline or mobile) at or near to the time of purchase or transaction or immediately following purchase or transaction via their social media contacts. A user can share with their connections on social media channels in order to leverage the user's influence within those social networks to drive additional brand awareness, brand engagement, and purchases or transactions. Such purchases or transactions as used herein may be referred to as conversions. A conversion represents any action that is desired by an organization and can include but is not limited to such user actions as a purchase, registration, application completion, lead completion, download, donation, view, click, redirect, renewal, comment, message, email, “Like”, “Follow”, or “Share”.
[0009] In an embodiment, a method, implemented on a machine having at least one processor, a storage device, and a communication platform connected to a network, for influencing a user's social networking contacts' decisions by utilizing social media is disclosed. The method comprising detecting, via the at least one processor, a transaction of the user, interfacing, via the communications platform, with the user's social networking contacts, sharing the user's transaction with the user's social networking contacts, and gathering information related to the sharing.
[0010] In a further embodiment, the transaction is at least one of the following: a donation, an in-person conversion, and an on-line conversion. In another embodiment, the interfacing occurs at the time of the transaction. In another embodiment, the interface is accomplished via at least a point of sale device, a computer, a smartphone, a tablet, a portable communications device, a proprietary device, and a card reader device. In an alternative embodiment, method further comprises issuing a record to the user of the transaction at the time of the transaction that allows the user to share the user's transaction via the communications platform at a time after the transaction.
[0011] In an embodiment, a method, implemented on a machine having at least one processor, a storage device, and a communication platform connected to a network, for engaging a user to share a conversion with a provider, with the user's social networking contacts via a social media network is disclosed. The method comprising detecting, via the at least one processor, the completion of the conversion of the user, launching, via the processor, an application on a user device, interfacing, via the communications platform, with the user's social networking contacts, sharing information about the user's conversion with the user's social networking contacts, and gathering information related to the sharing.
[0012] In another embodiment, the application stores information about the conversion, prompts the user for second information, and communicates third information to the processor. In still another embodiment, the information is a cookie. In another embodiment, the stored information has a built in preset expiration date.
[0013] In another embodiment, the second information relates to a goal set by the user and the user's social network. In another embodiment, the third information is conveyed via the network to a third party and wherein the third information is at least one of the following, a provider identifier, a conversion amount, and a conversion identifier.
[0014] In another embodiment, the goal set by the user is the shared information. In still another embodiment, the method further comprises providing a unique conversion identifier to a social network contact, monitoring if the social network contact selects the unique conversion identifier, directing the social network contact to the provider, and prompting the social network contact to complete a conversion.
[0015] In another embodiment, the unique conversion identifier directs the social network contact to a third party location and information related to the user's conversion is written to a device of the social network contact.
[0016] In still another embodiment, the method further comprising determining if the social network contact completes a second conversion. In another embodiment, social network contact information is conveyed to a third party via the communications platform, and the social network contact information relates to the second conversion.
[0017] In another embodiment, the secondary conversion is associated with the user.
[0018] In an embodiment, a system, for influencing a user's social networking contacts' decisions by utilizing social media is disclosed. The system comprising detecting, via a processor, a transaction of the user, interfacing, via a communications platform, with the user's social networking contacts, sharing the user's transaction with the user's social networking contacts, and gathering information related to the sharing.
[0019] In another embodiment, of the system the transaction is at least one of the following: a donation, an in-person conversion, and an on-line conversion. In another embodiment of the system the interfacing occurs at the time of the transaction. In still another embodiment of the system the interface is accomplished via at least one of the following: a point of sale device, a computer, a smartphone, a tablet, a portable communications device, a proprietary device, and a card reader device.
[0020] In another embodiment, the system comprises issuing a record to the user of the transaction at the time of the transaction that allows the user to share the user's transaction via the communications platform at a time after the transaction.
[0021] In an embodiment, a system, for engaging a user to share a conversion with a provider, with the user's social networking contacts via a social media network is disclosed. The System comprising, detecting, via a processor, the completion of the conversion of the user, launching, via the processor, an application on a user device, interfacing, via a communications platform, with the user's social networking contacts, sharing information about the user's conversion with the user's social networking contacts, and gathering information related to the sharing.
[0022] In another embodiment of the system the application stores information about the conversion, prompts the user for second information, and communicates third information to the processor. In still another embodiment of the system the information is a cookie. In still another embodiment of the system the stored information has a built in preset expiration date. In still another embodiment of the system the second information relates to a goal set by the user and the user's social network.
[0023] In another embodiment of the system the third information is conveyed via the communications platform to a third party wherein the third information is at least one of the following: a provider identifier, a conversion amount, and a conversion identifier. In still another embodiment of the system the goal set by the user is the shared information.
[0024] In another embodiment the system further comprises providing a unique conversion identifier to a social network contact, monitoring if the social network contact selects the unique conversion identifier, directing the social network contact to the provider, prompting the social network contact to complete a conversion. In still another embodiment of the system the unique conversion identifier directs the social network contact to a third party location and information related to the user's conversion is written to a device of the social network contact. In another embodiment the system further comprises determining if the social network contact completes a second conversion. In still another embodiment of the system after the second conversion occurs, a social network contact information is conveyed to a third party via the communications platform, and the social network contact information relates to the second conversion.
[0025] In still another embodiment of the system the secondary conversion is associated with the user. In still another embodiment of the system the interfacing occurs at the time after the transaction.
[0026] In an embodiment a method implemented on a machine having at least one processor, a storage device, and a communication platform connected to a network, for tracking a user's influence over subsequent users is disclosed. The method comprising: detecting, via the at least one processor, an action of the user, interfacing, via the communications platform, with subsequent user's from the user's social networks, distributing, via the communications platform, an application to the subsequent user's, in response to the user's action, tracking the effects of the user's action on the subsequent user's, and gathering information related to the tracking.
[0027] In another embodiment the gathering relates to the ripple effect of the user's action. In another embodiment the action is a selection of content. In another embodiment the action is a conversion. In another embodiment the application is an identifier unique to the user. In another embodiment the information is presented in a report. In still another embodiment the report displays the user's influence and impact on the subsequent users.
[0028] In another embodiment the method further comprising, establishing a campaign with a target goal for the user, providing an incentive to the user to take the action in furtherance of the target goal, rewarding the user for reaching the target goal. In another embodiment the incentive is based on a user's demographics. In still another embodiment the user's action is the selection of content provided by an organization and the organization is able to view a plurality of campaigns in the aggregate or individually.
[0029] In an embodiment a system for tracking a user's influence over subsequent users is disclosed. The system comprising, detecting, via a processor, an action of the user, interfacing, via a communications platform, with subsequent user's from the user's social networks, distributing, via the communications platform, an application to the subsequent user's, in response to the user's action, tracking the effects of the user's action on the subsequent user's, gathering information related to the tracking.
[0030] In another embodiment of the system, the gathering relates to the ripple effect of the user's action. In another embodiment of the system, the action is a selection of content. In still another embodiment of the system, the action is a conversion. In still another embodiment of the system, the application is an identifier unique to the user.
[0031] In another embodiment of the system, the information is presented in a report. In still another embodiment of the system, the report displays the user's influence and impact on the subsequent user's.
[0032] In another embodiment the system further comprising establishing a campaign with a target goal for the user, providing an incentive to the user to take the action in furtherance of the target goal, rewarding the user for reaching the target goal. In another embodiment of the system, the incentive is based on a user's demographics. In another embodiment of the system, the user's action is the selection of content provided by an organization wherein the organization is able to view a plurality of campaigns in the aggregate or individually.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The methods, systems and/or programming described herein are further described in terms of exemplary embodiments. These exemplary embodiments are described in detail with reference to the drawings. These embodiments are non-limiting exemplary embodiments, in which like reference numerals represent similar structures throughout the several views of the drawings, and wherein:
[0034] FIG. 1 depicts the main stages of the sharing system in accordance with an embodiment of the present disclosure;
[0035] FIG. 2 depicts a high level user and data flow in accordance with an embodiment of the present disclosure;
[0036] FIG. 3 depicts various ways to launch or trigger the launching of the software of present system in accordance with an embodiment of the present disclosure;
[0037] FIG. 4 depicts an embodiment of a motivation screen in accordance with an embodiment of the present disclosure;
[0038] FIGS. 5 a - c depicts various embodiments of motivation screens in accordance with an embodiment of the present disclosure;
[0039] FIG. 6 depicts a motivation box showing how many times user's Shared their conversions in accordance with an embodiment of the present disclosure;
[0040] FIG. 7 depicts an alternative motivation box in accordance with an embodiment of the present disclosure;
[0041] FIG. 8 depicts a smart box for motivating a customer in accordance with an embodiment of the present disclosure;
[0042] FIGS. 9 a - b depict thank you boxes intended to motivate in accordance with an embodiment of the present disclosure;
[0043] FIGS. 10 a - b depict a multilayer smart box in accordance with an embodiment of the present disclosure;
[0044] FIG. 11 depicts a summary report in accordance with an embodiment of the present disclosure;
[0045] FIG. 12 depicts a typical user interaction in accordance with an embodiment of the present disclosure;
[0046] FIG. 13 depicts a typical customization page for a user interaction in accordance with an embodiment of the present disclosure;
[0047] FIG. 14 depicts an alternative interaction customization page in accordance with an embodiment of the present disclosure;
[0048] FIG. 15 a - b depict alternative interaction customization pages in accordance with an embodiment of the present disclosure;
[0049] FIG. 16 depicts a typical post by a user of the system on a social networking site in accordance with an embodiment of the present disclosure;
[0050] FIGS. 16-19 depict typical posts by a user of the system on a various social networking sites in accordance with an embodiment of the present disclosure;
[0051] FIG. 20 depicts an example of a Conversion Page in accordance with an embodiment of the present disclosure;
[0052] FIG. 21 depicts an example of a transactional report in accordance with an embodiment of the present disclosure;
[0053] FIG. 22 depicts an example of a donation report in accordance with an embodiment of the present disclosure;
[0054] FIG. 23 depicts an example of a ripple effect report in accordance with an embodiment of the present disclosure;
[0055] FIG. 24 a depicts another example of a ripple effect report in accordance with an embodiment of the present disclosure;
[0056] FIG. 24 b depicts another example of a ripple report in accordance with an embodiment of the present disclosure;
[0057] FIG. 25 depicts an example of a visit (also known as referrals) and revenue report in accordance with an embodiment of the present disclosure;
[0058] FIG. 26 depicts an example of a lift report in accordance with an embodiment of the present disclosure;
[0059] FIG. 27 depicts an example of a program summary report in accordance with an embodiment of the present disclosure;
[0060] FIG. 28 depicts a flow chart of the steps used by a user to set a goal in accordance with an embodiment of the present disclosure;
[0061] FIG. 29 depicts a flow chart of the steps used by a user's connection to set a goal in accordance with an embodiment of the present disclosure;
[0062] FIG. 30 depicts another example of a motivation screen used in accordance with an embodiment of the present disclosure;
[0063] FIG. 31 depicts an exemplary goal setting screen in accordance with an embodiment of the present disclosure;
[0064] FIG. 32 depicts an exemplary social media log in screen in accordance with an embodiment of the present disclosure;
[0065] FIG. 33 depicts an exemplary posting permissions screen accordance with an embodiment of the present disclosure;
[0066] FIG. 34 depicts an example of a posting screen in accordance with an embodiment of the present disclosure;
[0067] FIG. 35 depicts an exemplary personal goal results report in accordance with an embodiment of the present disclosure;
[0068] FIG. 36 depicts an exemplary lead screen in accordance with an embodiment of the present disclosure;
[0069] FIG. 37 depicts an overview of the present system in accordance with an embodiment of the present disclosure;
[0070] FIG. 38 depicts a general computer architecture on which the present teaching can be implemented.
[0071] FIG. 39 depicts an exemplary dialog box of an embodiment of the system that may be automatically presented to a user if the system detects the user is browsing via a mobile device; and
[0072] FIG. 40 depicts another example of a dialog box in an embodiment of the system that can automatically be presented to a user if the system detects the user is browsing via a mobile device.
DETAILED DESCRIPTION
[0073] In the following detailed description, numerous specific details are set forth by way of examples in order to provide a thorough understanding of the relevant teachings. However, it should be apparent to those skilled in the art that the present teachings may be practiced without such details. In other instances, well known methods, procedures, components, and/or circuitry have been described at a relatively high-level, without detail, in order to avoid unnecessarily obscuring aspects of the present teachings.
[0074] As depicted in FIG. 1 , the system and method of the present disclosure is comprised of four unique sequential stages: the motivate stage 100 , the facilitate stage 200 , the accumulate stage 300 , and the demonstrate stage 400 . FIG. 2 depicts a high level depiction of the four stages of a user and data flow of an embodiment of the present disclosure. At stage 1, the motivate stage 100 , the user completes a conversion and may then be prompted to share the experience of the conversion via a social media platform. At stage 2, the facilitate stage 200 , the user completes the information to post their experience of the conversion to their social media pages. At step 3, the accumulate stage 300 , the user's conversion experience is shared with their social network followers, who then become exposed to the organizations the user interacted with. These new user's may also choose to interact with that organization and that information may then be routed through router 310 . Router 310 may send all the incremental conversion information to database 320 for data capture and storage. Once stored in database 320 , the incremental user conversion information may be output as part of the demonstrate stage 400 in report 410 or graphical format.
[0075] FIG. 37 depicts a high level system 3700 in accordance with an embodiment of the present disclosure. Customer 3701 may be an existing customer or a new customer. Customer 3701 interacts with the organization and engages in an online conversion 3702 . Customer 3701 may also make an off line or live interaction or conversion 3703 . During or after either conversion, customer 3701 is engaged by the system technology and/or software via device 3704 . Device 3704 may be a computing device, such as a computer, laptop, tablet computer, it may be a mobile device, an interactive television, a point of sale or credit card device. Device 3704 may also be any other device located at the point of sale, it may be a proprietary device, or a multipurpose device, and it may even be provided in hard copy form, such as a paper sales receipt, with the information to allow the user 3701 to complete the interaction at a later point in time at the same or different location. Any one of the devices 3704 , may allow the user to interact in a number of ways 3705 . Device 3704 may provide an interface to allow the user 3701 to proceed to the motivation stage (Stage 1). These included but are not limited to, a proprietary system code, a bar code, a QR code, an interactive or selectable button provided on any one of the device 3704 .
[0076] Additionally and/or alternatively, the interaction or engagement 3705 is initiated automatically through system code or through another action taken by the customer, such as scanning a bar code, entering an access code, etc. System 3700 may comprise a router, 3711 , a database 3712 , and application server 3713 , all which may be connected on a network. System 3700 may be cloud based 3706 or hosted on one or many servers with various aspects of the system being carried out on one or more servers and carried out over a network.
[0077] In operation, system 3700 engages the customer and motivates (Stage 1) them to share their conversion with their social media connections. This may be accomplished by presenting to the user, motivation screen 3707 . After viewing motivation screen 3707 and determining that he or she wishes to share their conversion the system 3700 , facilitates (Stage 2) the sharing process for the customer by providing access to facilitate screen 3708 , which allows user 3701 to format their share with their social media connections. User 3701 shares via various social media outlets and that information is posted to the chosen social media channels with a unique, dynamically generated link via web page 3709 . At 3710 , the user's post is seen by customer 3701 's social media connections. This post may contain information to help an interested connection convert such as but not limited to an address, phone number, or coupon. An interested connection may go directly to the organization's location to convert or they may click on a unique link presented in post 3709 and be routed via router 3711 to learn more about the customer's conversion and how to convert themselves. If the connection is using a mobile device, they may also be engaged and asked whether they want to learn more or convert by calling a unique tracking phone number dynamically generated by the system. Database 3712 captures the connection's interactions and accumulates (Stage 3) conversion information on every interaction all under the control of application server 3713 . Reports of all the conversions and interactions, can be displayed via reporting dashboard 3714 . Reporting dashboard 3714 displays the captured data in a form that is relevant to organizations in order to demonstrate (Stage 4) the effectiveness and results of the system 3700 's performance. When connections are routed via 3711 back to learn more about the user's conversion and how to convert themselves, they may first go to a Conversion Page 3716 which is intended to facilitate getting the connection to the appropriate location and help to drive a range of conversions.
Stage 1—Motivate
[0078] In an embodiment, the “Motivate” stage 100 is designed to engage with the customer immediately during or after a “conversion” and inspire or motivate that customer or user to share the fact that they just made a conversion with their social media connections.
[0079] As seen in FIG. 3 and FIG. 37 , conversion's can occur on any interface ( 300 a - 300 n ) a customer sees upon completing the desired user action (either online or offline) including but not limited to:
[0080] Point of Sale Devices ( 300 a )
[0081] Computers ( 300 b )
[0082] Mobile Phones ( 300 c )
[0083] Proprietary Devices ( 300 d )
[0084] Other Mobile devices ( 300 e - 300 n )
[0085] Tablets
[0086] Cash Registers
[0087] Kiosks
[0088] Product Terminals
[0089] Credit Card Swipe Devices
[0090] Televisions
[0091] Interactive/Web-enabled TVs or similar home viewing devices
[0092] TV shows
[0093] Interactive TV shows
[0094] Webisodes
[0095] Podcasts
[0096] Websites
[0097] Microsites
[0098] Web pages
[0099] Web applications
[0100] Mobile applications
[0101] Mobile wallet devices
[0102] Videos
[0103] Streaming media
[0104] Paper receipts
[0105] Paper invoices
[0106] Interfaces may also happen at or near the time of conversion or at some later point in time.
The User Experience in the Motivate Stage
[0107] At the point of conversion, the technology platform of the present disclosure may engage the customer and motivate or inspire them to share the fact that they just made the conversion. In an embodiment, the computer code or software used to engage with the customer after a conversion is stored remotely in servers 330 and accessed through a Software As A Service (SAAS) model. Alternatively and/or additionally, the software may be stored in several servers across several platforms. It may be cloud based and stored on leased or rented resources or may be stored or resident on proprietary devices. In an interactive environment, the application can be deployed automatically at the point of conversion or can be requested by the seller or organization for select customers based on specific criteria.
[0108] In an embodiment, a part of the software (client-side code) 340 may reside at the point of conversion, and may interact with the provider's servers as required. The application may self launch, triggering the full platform.
[0109] In an embodiment, when it is not possible to embed software or code at a customer location, i.e., a non-interactive environment, the system and method may still inspire the customer (e.g., motivational text or monetary or other reward) to take an action that will then deploy the system or method. (e.g., scan a barcode or QR code, send a text message, make a mobile call, scan an RFID device, launch a mobile app) at a later time. The inspirational method may be anything that will cause the customer to follow up on completing the transaction with the present system and method.
[0110] In an embodiment, the user interacts directly with the software that is integrated into the existing conversion experience as part of the motivate stage 100 . FIG. 4 is an example of a customer being engaged during motivate stage 100 in an embodiment of the present invention. As seen in FIG. 4 , the user may have just made a purchase or donation on a Website. Following the purchase, the customer is engaged by the motivation stage software and inspired by motivation box 410 to share their purchase or contribution with their social media connections. In this example, the customer engagement begins with JavaScript code 340 (however, this approach is not limited to JavaScript code as a wide variety of software technologies, such as Flash, HTML5, Video, or any other software or programming technique, can be used to provide this client-side functionality) being deployed by the organization on the organization's confirmation page (shown in the background of motivation box 410 ). When the customer reaches the confirmation page of the web site it is interacting with, JavaScript code 340 begins the interaction with the core platform and launches the motivation box 410 . As seen in FIG. 4 , a message 420 is used to motivate the user to move to the next stage of the process. In addition to message 420 or any other information, the user may be presented with buttons 430 to select a social media site on which to share their conversion. The number and type of social media channel can be added and removed from the system as the social media landscape evolves. The user may elect to share with their connections without any additional prompting or specific messaging, content, data, measurements, incentives, or other tools or techniques may be used to increase a user's desire to share.
[0111] FIGS. 5 a - 5 c show various embodiments of motivation box 410 all of which disclose a message 420 and buttons 430 . FIG. 5 b disclose a motivation box 410 with just the top two social channels for selection, while FIG. 5 c highlights two top channels but including others as well.
[0112] FIG. 6 discloses another embodiment of a motivation box showing how many times user's Shared their conversion, “Shares to Date” 610 , and the amount “Raised from Shares” 620 . In an embodiment of the present disclosure, these numbers/totals are updated in real-time for the user or may be periodically updated. In an embodiment, the motivational box may be personalized to contain personalized information by using parameters, such as the user's name, the product type, the quantity, the purchase price, the quantity remaining, a coupon, a discount code, a reward, a unique message, the name of the organization or business. Personalization may occur via the parameters within the client-side code that are passed into the platform.
[0113] FIG. 7 discloses an embodiment that utilizes another type of motivation box 710 to engage a user during the Motivate Stage. In this embodiment, the motivational box is displayed in a small gray banner on the right-hand side of the page rather than on top or overlaid on the underlying confirmation page. It is to be understood, that the motivational box may be presented in several ways without departing from the spirit of the invention.
[0114] For example, the customer engagements in FIGS. 4-7 may begin with the use of an inline frame or iFrame, a customer engagement based on the present disclosure can occur through a wide range of software technologies including but not limited to iFrames, pop-ups, lightboxes, overlays, links, video, or Flash depending on the type of application (i.e., mobile, tablet, desktop, laptop).
[0115] In an embodiment, the look and feel of the motivation box is completely customizable by the organization. Customization includes, but is not limited to size, placement, colors, and content. Additionally, and/or alternatively, all elements within the experience can be changed automatically by an administrator within the organization through a password-protected or other secure interface into the platform.
[0116] In an embodiment of the present disclosure, a key advantage and differentiator of the present platform is the fact that it may provide options regarding the type of technology (e.g., iFrames, pop-ups, lightboxes, overlays, links, video, Flash) used in the Motivate stage. Many existing social networks (e.g., Facebook™) often use pop-ups. However, there is a disadvantage to this approach. Most consumers and users have pop-up blockers within their browsers that either eliminate pop-ups or greatly reduce their effectiveness. As a result, the pop-ups cannot automatically engage most users without being blocked. So, if the customer does not first engage the social networking site via its icon, that is typically positioned as a small badge on the page, the social network can not launch its pop-up. The fact that the customer must take an action to engage the technology creates a significant hurdle that will drive a lower overall engagement rate. The present disclosure is able to avoid this problem by using other options to display the motivation box, such as the use of iFrames.
[0117] In an embodiment, a Smart Box may be used to capture additional information about the user. FIG. 8 depicts a single layer smart box 810 . The objective of smart box interface is to allow the platform to capture more information from the user or customer to allow the latter stages of the process to have more impact. The Smart box interface asks the customer to complete a series of targeted questions, captures the responses within a database and utilizes those answers to personalize the content and experience in the remaining stages. FIG. 8 is an example of a single layer smart box, i.e., where all the information is gathered in a single frame. This interaction during the motivational stage supplies the system with more data to use for the latter stages. As seen, in FIG. 8 , the single layer smart box 810 allows the user to input all the requested information in one box. However, the interactions may be spread over several screens and are not limited to any one set of data.
[0118] In an embodiment, a very important field of information that will be captured within the Smart Box is “Goal”. The goal amount 820 is the amount the customer hopes to raise, sell or achieve through his or her social media connections. This sort of goal setting is important because it motivates additional connections who are then more likely to purchase or donate in order to help a friend or colleague reach a predefined organization or personal goal. This feature of the present disclosure is called Goal Setting.
[0119] FIGS. 9 a and 9 b depict additional single layer smartboxes. As seen in FIG. 9 a , single layer smart box 900 contains personalized content 910 passed by the organization into the platform using the parameters provided within the technology. As with Smart Box 810 , smart box 900 collects all the information at once. Smart Box 920 seen in FIG. 9 b while, still single layer smart box, only collect a single piece of information, in this example, goal 930 . It is to be understood that as much or as little information as the organization wishes to seek can be presented in a single or multi-layer smart box.
[0120] FIGS. 10 a - b depict an embodiment of a multi-layer smart box in accordance with the present disclosure. The multi-layer smart box may collect the same or different information as the single layer smart box, but does so across multiple boxes, screens, frames, or windows. FIG. 10 a discloses a first smart box 1000 a user might encounter during the motivation stage 100 and FIG. 10 b discloses a second smart box 1010 , the user encounters as part of the same transaction. It is to be understood, that the number of multilayer smart boxes used is not limited to two, but to how much information needs to be collected. Single or multiple pieces of information may be collected on each screen through each box. For example, smart box 1000 may be the opening screen and smart box 1010 may be the next or last screen. As seen, in FIG. 10 b , smart box 1010 collects a single piece of information 1020 , but other information might also be collected in this smart box 1010 as well.
A/B and Multivariate Testing—Motivation Stage
[0121] A feature of the present disclosure allows the organization to determine which is the most effective way to entice donors/customer into sharing his or her social networking contacts and accordingly, to increase exposure and drive increased sales and or contributions. In an embodiment of the present disclosure, various forms of testing (e.g., A/B, multivariate) may be employed to test a variety of creative concepts, content, placement, and rewards to determine which maximizes user engagement. The system of the present disclosure is designed to dynamically alternate various versions of the motivational box 410 in real-time to measure which version drives the greatest results so that an organization can use the version most likely to generate additional conversions.
Use of Parameters—Motivation Stage
[0122] The present disclosure enables a user organization to pass organization-defined parameters into the platform in stages. In Stage 1, those parameters can be used to customize the content within the motivational box. As an example, if the customer just purchased a product or made a donation for $100, the experience in FIG. 6 can be customized to say something like “Thank you for your $100 donation.” The objective of customizing the user engagement is to drive greater customer interaction.
Measuring the Motivation Stage
[0123] In order to be able to measure the specific interaction with the software in Stage 1, the motivation stage 100 , the present disclosure can be configured to generate a Stage 1 results report. FIG. 11 is an example of a “Stage 1 Summary Report” to help the organization understand a customer's interaction with the motivation box in accordance with an embodiment of the present disclosure. This data will also help the organization optimize this stage for greater conversion.
Facilitate Stage
[0124] The second stage of the system if the “Facilitate” stage 200 . In this stage, once the customer chooses to interact with the motivation box, the system is designed to guide them through the process of sharing information with their social media connections.
[0125] FIG. 12 depicts is an example of a customer choosing to interact with the motivation box 410 by choosing to share on Facebook by selecting the Facebook button 1210 . This moves the customer from Stage 1 (the Motivate Stage 100 ) of the platform to Stage 2 (the Facilitate Stage 200 ).
[0126] Once the customer selects a social media channel by clicking on Facebook button 1210 , the interaction with that channel begins. If the customer is not already logged into the chosen channel, they will be prompted to do so. If they are already logged in, they will begin to develop the content that they will post to their “wall” on the chosen social media channel. Although other avenues of sharing data with a social network can be used without departing from the spirit of the disclosure. It is important to note that all of the major social media channels provide such an interface. This configuration essentially allows a way to log into the social media channel via another website, post something to the user's wall or other information sharing platform on the social media channel, and then return to the original website. The present disclosure leverages and takes advantage of these interfaces.
[0127] FIG. 13 depicts a user experience in the Facilitate Stage 200 in accordance with the present disclosure. Such an interface (or a similar interface) is provided by most major social media channels. Slight variations, with the addition of more or less interactive fields is possible. While the parameters (e.g., character limitations) of each interface are different depending on the social media platform, the present system works within these rules to maximize the potential impact of the user's post. In FIG. 13 , the initial content in box 1301 is provided to the user in order to allow them to customize the introduction of the post or comment. Symbol, image, or logo 1302 is chosen by the organization using the system and is preloaded and stored within the system platform and then dynamically populated in real-time into the post. Symbol, image, or logo 1302 is not customizable by the user. However, it is completely customizable by the organization through a protected interface into the system platform. Title 1303 , may be the name of the organization or any other name, title, promotional name, abbreviation, etc. and is also selected by the organization and completely customizable by the organization through the interface to the system platform. The title 1303 is stored within the system platform and dynamically inserted in real-time. The title 1303 is not customizable by the user. Link 1304 is a hyper link or any other address for routing a user to a specific location and is dynamically generated by the system technology platform and pre-populated into the post in real-time. Link 1304 is not customizable by the user or the organization. Link 1304 is critical to the routing and reporting functionality in Stages 3 (Accumulate 300 ) and 4 (Demonstrate 400 ) of the System technology platform. It is a link generated by the system platform that uniquely identifies the organization and the user. This link may be shown as a link or it may be shown as text with a hyperlink to this link. Content 1305 is selected and customizable by the organization. It is pre-populated by the organization into the system platform through the protected interface and dynamically served into the post in real-time. It is not customizable by the user. Button 1306 is a share button. Once the user is satisfied with the post, they hit button 1306 , which may be provided by the social network, and the user's wall is then updated with the post for all of their social media connections to see.
[0128] FIG. 14 is another example of a facilitate box typically found on social media site Twitter. Similar to FIG. 13 , the user can populate a message in content box 1401 , the social media's logo is found at 1402 and the share button 1403 is used to finalize the post once complete.
[0129] FIGS. 15 a and 15 b are additional examples of facilitate boxes that may be found on such social network sites as Linkedin and Google+, receptively.
A/B and Multivariate Testing—Facilitate Stage
[0130] As noted, in an embodiment of the present disclosure, various forms of testing (e.g., A/B, multivariate) can be used in the facilitate stage 200 (Stage 2) to test variations of the content to determine which maximizes the results within the accumulate stage 300 (Stage 3). In an embodiment, the system is designed to dynamically alternate various versions of the content in real-time and measure which version drives the greatest results so that the organization can use the most effective version.
Use of Parameters—Facilitate Stage
[0131] In an embodiment, an organization can capture parameters from the motivation stage 100 which can then be passed along and added to the content within the facilitate stage 200 (e.g., names, product information, donation amounts, goals). As a result, that information can be posted to the customer's social media wall. This in turn causes further personalization of a post and drives greater or higher conversion rates.
Accumulate Stage
[0132] The third stage of the system is the accumulate stage 300 . During the accumulate stage 300 , the system is designed to maximize the number of social media connections who select the link 1304 and ultimately turn into incremental conversions. Maximizing the accumulate stage 300 is the primary driver for the system. As understood, the goal of the system technology platform is to drive a lift in conversions (i.e., brand awareness, brand engagement, purchases, donations, registrations). In an embodiment of the present system, the accumulate stage 300 starts with a customer's social media connections seeing the customer's post from the facilitate stage 200 . FIGS. 16-19 are examples of social media post experiences by a customer's social media contacts on popular social media sites.
[0133] In the accumulate stage 300 , an objective is to motivate and/or inspire the maximum number of a user's connections to click on the unique link 1304 in order to increase conversions. When they click on a link, they can be taken to learn more about the organization or product, or directly to convert. Or, if clicking on the link from a mobile device, they can be first prompted with a number to call or a text message they can send in order to learn more or convert. All of these actions can be tracked within the system. FIGS. 39-40 are examples of the how the system can detect in real time whether a connection is using a mobile phone to browse. If so, the system can automatically serve up a dialog box that will enable the connection to leverage the benefits of having a phone (e.g., calling, text messaging). So, this would create a better user experience for the connection and drive them to take action as easily and quickly as possible.
[0134] Next, the goal is to motivate and inspire those referrals to convert (perform the organization's desired user actions) at the highest possible rate.
A/B and Multivariate Testing—Accumulate Stage
[0135] In an embodiment, various forms of testing (e.g., A/B, multivariate) can be used during the accumulate stage 300 to test variations in landing pages, i.e., the pages that a user's social media contacts arrive at after clicking on link 1304 , to determine which landing page maximizes the conversion rate. Social media connections that click on the dynamically generated link 1304 during the accumulate stage 300 are routed through the system router and then forwarded to the appropriate landing page as determined by the organization. As part of the platform, the organization is able to predetermine a series of landing pages and elect what percentage of traffic should be routed to each page. This allows the organization to test multiple variations of pages and identify, in real-time, which page delivers the highest rate of conversion.
Example
[0136]
[0000] Route Landing Page Percentage of Traffic Conversion Rate A www.xxxx1.com 25% 10.25% B www.xxxx2.com 25% 29.75% C www.xxxx3.com 25% 40.00% D www.xxxx4.com 25% 20.00%
The organization can also test whether mobile users would convert at a higher rate if they were to click on the link and be directed to a landing page or if they were prompted to call a phone number or prompted to use text messaging.
Conversion Page
[0137] In an embodiment, as part of the accumulate stage 300 , there is an optional conversion optimization feature called a “Conversion Page”. FIG. 20 depicts a typical Conversion Page in accordance with the present disclosure. As seen in FIG. 20 , the user's social media contacts (User B) are directed to Conversion Page 2000 when they click on link 1304 . Conversion Page 2000 contains several options for a User B (a second level user) to choose from. In this example, User B can choose to contribute 2001 to the organization, to contribute later 2002 , to follow on various social media platforms 2003 , or to obtain additional information 2004 . It is to be understood, that the Conversion Page 2000 can be configured with more or less or different options. As seen in FIG. 20 , Conversion Page 2000 is shown with respect to a charitable organization, however, it is not so limited. Conversion Page 2000 can be from a commercial vendor, a political organization or supplier wishing to sell additional goods or services, and my offer such additional choices as to purchase a specific item, see a selection of all items, etc.
[0138] In an embodiment, Conversion page 2000 may reside between the system router and the organization's website, although other system configurations are possible. When the Conversion Page 2000 feature is enabled, a user or second level user that clicks on a system link 1304 within the social media networks is routed to the Conversion Page 2000 page which acts to quickly and effectively route them to their desired location and/or quickly drive a range of conversions. Conversion Page 2000 is database-driven in real-time. In an embodiment, and as a result, it is completely customizable by an organization and can have an unlimited number of desired user actions. In addition to driving users to a desired location more quickly, Conversion Page 2000 allows the organization to drive and measure a broader range of conversions. The system technology platform can measure every interaction with Conversion Page 2000 —providing organizations with more data to understand their prospective customers and the desired user actions of those prospective customers.
Tracking Through the Use of Unique Links and Cookies
[0139] In order for the system platform to measure conversions, a unique link is created and assigned, based on the original customer who shares via the system platform during the facilitate stage 200 . The link 1304 in FIG. 13 is an example of the unique link created by the system. This link may be shown to the user as a separate link as depicted in FIG. 13 or the link may be a text hyperlink within the text show in FIG. 13 . Either way, this link enables the system to uniquely identify both the organization and the customer. In an embodiment, the system may apply a first party cookie when a customer's connection (User B or second level user) clicks on the dynamically generated unique link 1304 and gets routed through the system router. When User B later converts on the organization's website, the system platform, using the cookie, is able to determine whether that conversion came through the system link 1304 and the primary user A that was responsible for the referral. In an embodiment, the cookie, or similar informational code, can be set to last for a predefined period of time (e.g., 30 days). In such a configuration, if User B comes through the system link 1304 and does not convert, but comes back to the organization's website within that predefined period and then converts, the system platform can still identify that as a conversion that resulted from the system technology and the system link 1304 .
Demonstrate Stage
[0140] The demonstrate stage 400 or fourth stage of the system platform is designed to provide organizations and customers with all of the real-time and historical results data collected by the system platform.
[0141] The system may include a reporting system that may include at least the following elements:
[0142] Dashboard—the dashboard may provide a quick snapshot of results. This enables an organization to easily understand the results being generated and driven by the system technology. FIG. 21 is an example of a possible system dashboard 2100 .
[0143] Reports section 2110 can provide the organizations and its customers with a deeper view into the data. Reports can be fixed (standardized) in the system or be custom designed by an organization to fits its particular needs. As seen in FIG. 21 , reports can include the number of transactions, 2115 , from a particular community 2120 , the amount of revenue 2125 generated from each sharing interaction and the number of transactions by channel 2130 or transactions per social media outlet. Once a custom report is created, there will be an option to save them in the system for future use and/or have them automatically run on a periodic basis as determined by the organization. Once run, reports can be printed or the data can be exported for use within other software packages (e.g., Excel, Access). In an embodiment, the reports provide the ability to sort and manipulate the data in any fashion the user needs. In an embodiment, some typical reports can include:
[0144] A Conversion Detail report as seen in FIG. 22 . Report 2200 provides the details of each conversion driven through the System platform and provides the details of donations made to a particular organization. Donation tab 2210 details the specific donations or amounts spent per conversion including name, date and amount. Ripple Effect tab 2220 may be used to show the ripple effect of a particular users sharing activities. Visits and revenue tab 2225 may be used to show the number of visits made to the site and the revenue generate. Lift reports tab 2230 is used to display lift reports and Summary tab 2235 provides a program summary. As will be appreciated by those skilled in the art, the number and types of tabs available via the reports page is not limited to those shown, but can be configurable based on the information sought.
[0145] The Ripple Effect (also known as Leaderboard Reports) report provides the ability for the organization or the customer to view an individual's influence and impact across various social media outlets. In an embodiment for example, if a customer purchases something for $100 and then asks their social network connections, via the system technology platform, to join them and make a purchase, the customer and the organization will both be able to see who took that action and how many purchases resulted. The customer will be able to see the results generated by their own personal influence. This will include the ripple effect associated with their influence and then the influence of their connections. In an embodiment, the customer and organization will be able to see the results from their connections (wave 1 or ripple 1), then from the connections of their connections (wave 2 or ripple 2), then from the connections of the connections of their connections (wave 3 or ripple 3), and so on.
[0146] This Ripple effect view provides for a powerful new way to look at the data and understand the influence of individuals and the ripple effect of a message across social connections. Such positive reinforcement serves to further motive a user into utilizing future sharing opportunities. The ripple effect report allows an organization to rank the results by the customer influencing the most conversions. As a result, it may allow the organization to reward that user, if desired. Such rewards may include recognition, coupons, point of sale discounts, rewards program incentives, products, services, etc. In an embodiment, the report may also provide a customer's results relative to a goal that customer may have set during the motivation stage 100 .
[0147] FIG. 23 is an example of one type of Ripple Effect Report 2300 or Leaderboard Report. Ripple effect report 2300 provides several views 1-3 of the proliferation of the endorsement and ripple impact of a particular customer or donor. Level column 2310 indicates the level of connection between the original user and the new donor. As seen in level column 2310 indicates a direct connection (Level One, Wave One, Ripple One), a secondary connection (Level Two, Wave Two, Ripple Two—i.e., a connection of a connection), and level three (Level Three, Wave Three, Ripple Three—i.e., a connection of a connection of a connection). Name column 2315 and 2316 include the new user's name, confirmation column 2320 indicates the unique transaction ID (also known by such names as Confirmation Number, Order ID, Transaction Number, etc.) assigned by the organization to that user's conversion, donation column 2325 includes the user's donation or purchase amount, ripple column 2330 indicates how much that user's social media contacts have generated as a result of, in this case, the donations of their connections and goal column 2335 is the goal set by the user. FIGS. 24 a and 24 b are alternative examples of a Ripple Effect Reports. As seen in FIG. 24 a , the information available in report form is customizable and completely configurable. Ripple report, 2400 b provides an additional/alternative view of ripple report information. As graphed in Report 2400 b the total amount of each level of connection can be graphed to display a simpler view of a user's impact via social networking. Each bar shows the results for each level of connection (also referred to as Wave, Ripple, Level, etc.). If the report user clicks on a bar, a report showing the data that makes up that bar is presented to the user.
[0148] If a user wishes to review a Visits and Revenue Report from the reports page 2200 , they can link through tab 2225 . The visits and revenue report provides a summary of the total number of visitors within a particular timeframe and the conversions and resulting revenue that occurred from that transaction. (Assuming it is a revenue-based conversion. It should be noted, however, that in an embodiment, the conversions do not necessarily need to be revenue-based and could for example, the number of surveys completed or the number of downloads of an items or the number of comments on a topic. A conversion is whatever is the organization's desired user action). FIG. 25 is a typical visits and revenue report 2500 . This displays the number of visits 2510 by others, generated as a result of a user's sharing and the actual number of conversions 2515 that occur as a result of those visits and the respective revenue generated 2520 as a result. As noted above, revenue is not the only thing traceable, and this information could include any desired user action.
[0149] FIG. 26 shows a lift report that might be generated if a user were to click on the lift tab 2230 . This report shows the actual “lift” in conversions and revenue (in the case of a revenue-based conversion). This enables the organization to quickly and easily understand the actual business impact of the system technology. As seen in Lift report 2600 the user is able to see all of the organization's conversion—whether generated through the system or not. The user is then able to see separately all conversion not generated through the system and all conversions generated through the system. As a result of having that data, the system is able to determine the incremental lift attributable to the system.
[0150] FIG. 27 depicts a program summary report 2700 in accordance with an embodiment of the present disclosure. Program summary report 2700 can provide an organization with a quick but detailed view of the results across every stage of the system (Stages 100 , 200 , 300 and 400 ) over a chosen period of time. The information in section 2710 shows, of the number of users engaged by the system at the point of conversion, how many were willing to share with their social media connections. It also shows which channels they shared on and what the total share rate was. The system will also be able to show how much awareness was generated as a result of the sharing—whether a connection responds or not. The information in section 2720 shows how many connections responded as a result of the sharing and which social media channels provided the greatest response rates. Section 2730 shows the revenue impact (if a revenue-based program) and conversion transaction impact. This can include the total revenue and transactions without the system and the total incremental revenue and transactions as a result of the system.
Goal Setting
[0151] Goal Setting is a feature of the present system designed to drive greater results. Goal Setting enables the customer to set a goal and share that goal with their social media connections. It has been determined that a connection (User B) is more likely to take action in order to help a customer (User A) achieve their desired target. FIG. 28 depicts an example in an embodiment of how goal setting works within an embodiment of the platform. At step 2800 User A goes to an organization's website (or any conversion point) and makes a donation/payment. At step 2801 once User A reaches the Thank You/Confirmation page the system imbedded (client-side) code does the following: at 2802 it writes a third party cookie (cookie A) on User A's computer (with a preset expiration date, such as 30 days). At step 2803 the imbedded code sends the following data to System server: System customer ID; dollar amount; unique transaction ID; and other information, such as, but not limited to, name or email, promo code, etc. At step 2804 , the system motivation box with the organization's customized message to motivate the user to set a personal collection goal and share their conversion on a social network is produced. At step 2805 , user A, sets a personal goal in the Personal Goal Window by selecting a personal goal amount. At 2806 User A selects a social network. At 2807 , if User A is not logged into the selected social media site, the user is prompted with a social media login screen at step 2808 . If User A is already logged into their selected social media site, he or she progresses to step 2809 where he or she is prompted with a social media permission window. A social media permission window as seen in FIG. 33 allows the system to post on the User's behalf on the social media site. This permission to post typically expires in a preset period of time, or the user can go into the user's settings and remove the system permission anytime.
[0152] At step 2810 the social media site presents a window to User A allowing user A to enter the text of the message to be shared (see FIGS. 13-15 ). Once the message is complete and User A is finished with his or her post, the personal goal amount set in step 2805 is sent to the system server at step 2811 and User A's post is made to the user's social media “wall” at step 2812 . At step 2813 , the personal goal window closes and at step 2814 , the user is presented with the organization's Thank You/Confirmation page.
[0153] FIG. 29 depicts a flow chart of how a secondary user, User B, responds to User A's post. At step 2900 , User B sees User A's post on their social media site and selects the embedded link in the post. This link is a unique to User A and is typically, a dynamically generated bit.ly redirect URL that goes to a hidden page generated by the system of the present disclosure. At step 2901 , user B is directed to the hidden page on the system. A third party cookie (cookie B) is written to User B's system with an expiration date (typically, 30 days, but could be anything). At step 2902 , the system platform records in a database that User B clicked on User A's unique link. At 2903 , the hidden system page redirects User B to the organization's website. The redirection and placing of the cookie all happen without User B's knowledge. At 2904 User B is prompted to makes a donation or purchase from the organization's web site. At 2905 , the system determines if User B makes a purchase and or a donation. If yes, then at 2907 the organization presents a thank you and/or a conformation page. During the conformation of step 2907 , the system 2908 , reads cookie B and gathers data at 2909 to send to the system sever on user B. At 2910 , User B's conversion is recorded and credited to User A's sharing and User A's unique link. At 2911 , the system code displays the motivation box again with the organization's customizable message to allow User B to share on his or her social networks. At 2912 , a message is posted on User A's social media “wall” with the donation amount that was made and an e-mail with a link to a Goal Summary Report is sent to User A. The Goal Summary Report can have user names or just a unique transaction ID. If at step 2905 , User B leaves the organization's site without making a conversion, step 2913 , but returns at a later time before cookie B expires, at step 2914 , then User A will still get credit for the conversion based on the original posting.
[0154] FIGS. 30-35 are views in accordance with an embodiment of the present disclosure. FIG. 30 is an example of a motivation box that may appear at step 2804 of FIG. 28 . FIG. 31 is an example of a Personal Goal Setting Screen that a user may see at step 2805 after agreeing to share their conversion. FIG. 32 is an example of a social media login page a user may encounter after agreeing to share their conversion on their social media sites. (See Step 2808 ). FIG. 33 is a typical social media permission window that a user may see at step 2809 . The permission window allows the system to post on the user's behalf to the social media sites. FIG. 34 is an example of a typical post window for a social media wall (Step 2812 ). FIG. 35 is a Personal Goal Setting Report that shows a user a summary of all the subsequent conversions and the ripple effect resulting from the posting of their goal.
Mobile Device Features—Phone Number, Lead/Pledge Form
[0155] The system contains several features that enable more interaction with users on mobile devices.
[0156] The first mobile feature ( FIG. 39-FIG . 40 ) enables connections, using a mobile phone and clicking on the user's unique link posted on the social media channels (Stage 3), to be prompted to call a phone number. The system automatically determines whether a user is engaged with the system via a mobile phone device. And, if this feature is enabled, the system or phone will prompt the user with a dialogue box asking them if they'd like to use their phone to call. If not, the user is taken through the standard process. If yes, the user is directed to a call center.
[0157] The second mobile feature is the Lead/Pledge Form. This is a feature of the system platform is designed to capture preliminary conversion information from a customer's connections who are unable or unwilling to go through a full conversion process at the time of the original engagement. This could occur if a user is engaged with the system through a mobile device with a smaller screen that makes it more difficult to complete a transaction. Or, this could occur if a user is engaged with the system while traveling or with limited time and, as a result, wouldn't have access to credit card information or wouldn't have the time required to complete a transaction. While the Lead/Pledge Form can be used by any User B (as long as this feature is enabled by the organization), the Lead/Pledge Form capability becomes very important as more and more consumers interact with social networks via mobile devices. The Lead/Pledge Form is mobile friendly and allows an individual to quickly provide information that can be followed-up on by the organization at a time that is more convenient for the User B. User B lands on a typical Conversion Page after clinking on the unique system link located on User A's social media wall. FIG. 20 is a typical Conversion Page in accordance with an embodiment of the invention. As seen, a secondary user, such as user B is presented with several options to chose from. If user B decides to contribute later and selects the contribute later box 2002 , then, the Lead/Pledge Form 3600 as seen in FIG. 36 is presented. The Lead/Pledge Form can be customized in any way the organization chooses. FIG. 36 illustrates some information gathering options, such as personal information 3601 , pledge amount 3602 , contact information 3603 , but is not limited to only the fields shown. Other possible fields include, best way to contact, alternative numbers, e-mail addresses, send reminder option, etc.
[0158] In an embodiment, incentives in the form of points, dollars, discounts, coupons, badges, promotion codes, bit coins, rewards, or recognition may be used to increase user engagement and drive greater results throughout all four stages of the system platform.
[0159] User incentives to drive user engagement provide the capability for organizations of all types and sizes to reward consumers for sharing with their connections across social media. The platform will track actions, impact, or points that consumers earn for various levels of social sharing activity and, based on the actions, impact or points earned, organizations can award the users having the greatest results. This may be referred to as social gamification.
[0160] Incentives can be used as a way to motivate user engagement within any channels, platforms, interfaces or devices outlined above.
[0161] Users can also be motivated with incentives for spreading “content” across their social media connections including things such as but not limited to messages, videos, photos, images, links, or files.
[0162] In an embodiment, organizations or third-party providers can load content into the system or the content can be resident on a different system or hosted on a remote system or a third-party network and coupled to the present system via a network. The content may including but is not limited to messages, videos, photos, images, links or files. Content providers/selectors (i.e., organizations) will describe the benefits of the content and the reasons why users should be interested in sharing that content with their social media connections. The organizations will also be able to describe a reward that a certain number of users will get if they are able to spread the word about the content further than other users. In an embodiment, organizations can provide a start date and an end date for each “contest” or “campaign”.
[0163] Users are able to browse, search and select content within the system that they wish to share due to their interest in either the content or the reward or both. The system then engages the user to share, facilitates the sharing process, tracks and tabulates the points that each user accumulates for spreading the content across social media, creates leaderboard reports so that users and organizations can view the current leaders for each campaign, and provides the organizations with a list of the winners for each campaign.
[0164] In an embodiment, in order to track how far a specific user is able to spread content across social media in terms of measurements such as the number of shares, the awareness generated, the engagement driven, the incremental views and/or visits and/or conversions, users may be required to “Sign In” or “Create an Account”. In an embodiment, there are 2 classes of users, Individuals and Organizations.
[0165] In an embodiment, the content and incentives may be targeted to users based on demographics—including geography. As an example, in an embodiment, all campaigns are national by default, but the system may comprise a check box for organizations to use for local targeting such as local region or zip code. If checked, certain content may only display to users within a specific targeted geography. In an embodiment, the system may utilize an IP location, zip code location, GPS location, or other form to target specific users in specific areas. In an embodiment, the geography feature can be implemented to add a target region to select geography: Country>State>City>Zip Code->use IP address or GPS to determine the location of user, and serve only matching offers. For local region the system may determine device IP location (zip code) or a GPS for mobile, return offers that are within a radius within 20 miles of that location. In an embodiment, organizations are able to view all of their campaigns and the performance of each in aggregate or individually.
[0166] In an embodiment, as users seek to earn incentives, organizations can track, gather and report information related to the user's ripple through the social networking contact. As discussed with respect to user's conversions above, a user's spread of content creates a quantifiable ripple effect as the user's second, third, forth, etc, tier contacts continue to spread that content. This provides the organization with feedback regarding the content most likely to convey the desired message.
[0167] FIG. 38 provides a functional block diagram illustration of a computer hardware platform, which includes user interface elements. The computer may be a general purpose computer or a special purpose computer. This system may be cloud based or distributed. Computer 3880 can be used to implement any components of the system sharing architecture as described herein. For example, the motivation stage 100 , facilitate stage 200 , and reporting stage 300 can all be implemented on a computer such as computer 3880 , via its hardware, software program, firmware, or a combination thereof. Although only one such computer is shown, for convenience, the computer functions relating to conversions, motivating users, facilitating users, generating unique links, generating reports, may be implemented in a distributed fashion on a number of similar platforms, to distribute the processing load.
[0168] The computer 3880 , for example, includes COM ports 3850 connected to and from a network connected thereto to facilitate data communications. The computer 3880 also includes a central processing unit (CPU) 3820 , in the form of one or more processors, for executing program instructions. The exemplary computer platform includes an internal communication bus 3810 , program storage and data storage of different forms, e.g., disk 3870 , read only memory (ROM) 3830 , or random access memory (RAM) 3840 , for various data files to be processed and/or communicated by the computer, as well as possibly program instructions to be executed by the CPU. The computer 3800 also includes an I/O component 3860 , supporting input/output flows between the computer and other components therein such as user interface elements 3880 . The computer 3800 may also receive programming and data via network communications.
[0169] FIG. 39 depicts an exemplary dialog box of an embodiment of the present system, wherein the platform may detect in real time whether someone in Stage 3 of the system is using a mobile phone device to browse. If so, the system or phone can display a dialog box that will enable the user to leverage the benefits of having a mobile device. This allows for a better user experience for the user and allows for greater results for the organization. In the example depicted in FIG. 39 , the dialog box 3900 provides the user with the ability to make a phone call in order to purchase the product rather than selecting or clicking on a link and visiting a website or going to a store.
[0170] Similarly, FIG. 40 depicts an exemplary dialog box of an embodiment of the present system, wherein the system is able to detect in real time whether someone is using a mobile phone device to browse. If so, the system may serve up a dialog box 4000 that will enable the user to leverage the benefits of having a mobile device. This too creates a better user experience for the customer and can lead to better overall results for the organization. In dialog box 4000 , the user is provided with the ability to use text messaging to make a donation (or make any conversion) and have that charged to the user's phone bill (if it is a revenue-based conversion) rather than having to click on a link or make a call to continue through the process.
[0171] Hence, aspects of the methods of utilizing a user's social media connections to increase visibility of an organization may be embodied in programming. Program aspects of the technology may be thought of as “products” or “articles of manufacture” typically in the form of executable code and/or associated data that is carried on or embodied in a type of machine readable medium. Tangible non-transitory “storage” type media include any or all of the memory or other storage for the computers, processors or the like, or associated modules thereof, such as various semiconductor memories, tape drives, disk drives and the like, which may provide storage at any time for the software programming.
[0172] All or portions of the software may at times be communicated through a network such as the Internet or various other telecommunication networks. Such communications, for example, may enable loading of the software from one computer or processor into another, for example, from a application server or host computer of a search engine operator or social network provider into the hardware platform(s) of a computing environment or other system implementing a computing environment or similar functionalities in connection with social networking behaviors. Thus, another type of media that may bear the software elements includes optical, electrical and electromagnetic waves, such as used across physical interfaces between local devices, through wired and optical landline networks and over various air-links. The physical elements that carry such waves, such as wired or wireless links, optical links or the like, also may be considered as media bearing the software. As used herein, unless restricted to tangible “storage” media, terms such as computer or machine “readable medium” refer to any medium that participates in providing instructions to a processor for execution.
[0173] Hence, a machine readable medium may take many forms, including but not limited to, a tangible storage medium, a carrier wave medium or physical transmission medium. Non-volatile storage media include, for example, optical or magnetic disks, such as any of the storage devices in any computer(s) or the like, which may be used to implement the system or any of its components as shown in the drawings. Volatile storage media include dynamic memory, such as a main memory of such a computer platform. Tangible transmission media include coaxial cables; copper wire and fiber optics, including the wires that form a bus within a computer system. Carrier-wave transmission media can take the form of electric or electromagnetic signals, or acoustic or light waves such as those generated during radio frequency (RF) and infrared (IR) data communications. Common forms of computer-readable media therefore include for example: a floppy disk, a flexible disk, hard disk, magnetic tape, any other magnetic medium, a CD-ROM, DVD or DVD-ROM, any other optical medium, punch cards paper tape, any other physical storage medium with patterns of holes, a RAM, a PROM and EPROM, a FLASH-EPROM, any other memory chip or cartridge, a carrier wave transporting data or instructions, cables or links transporting such a carrier wave, or any other medium from which a computer can read programming code and/or data. Many of these forms of computer readable media may be involved in carrying one or more sequences of one or more instructions to a processor for execution.
[0174] Those skilled in the art will recognize that the present teachings are amenable to a variety of modifications and/or enhancements. For example, although the implementation of various components described above may be embodied in a hardware device, it can also be implemented as a software only solution—e.g., an installation on an existing server. In addition, the system and its components as disclosed herein can be implemented as a firmware, firmware/software combination, firmware/hardware combination, or a hardware/firmware/software combination.
[0175] While the foregoing has described what are considered to be the best mode and/or other examples, it is understood that various modifications may be made therein and that the subject matter disclosed herein may be implemented in various forms and examples, and that the teachings may be applied in numerous applications, only some of which have been described herein. It is intended by the following claims to claim any and all applications, modifications and variations that fall within the true scope of the present teachings. | Systems and methods directed generally towards capturing, tracking, and incentivizing customer endorsements at a point of interaction or transaction and monitoring and facilitating the spreading of that endorsement through the customer's social media channels in an effort to influence the purchase or transaction decisions of that customer's social media connections and the connections of their connections and so on. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a choke coil in which a magnet for applying a magnetic bias is placed in a gap in a core that forms a closed magnetic circuit.
[0003] 2. Description of the Related Art
[0004] The capability of maintaining stable characteristics for higher current than ever before is being required of choke coils incorporated in power supply circuits of audio-video equipment, office automation equipment and factory automation equipment because of reduction of voltage for saving power consumption or the increase in power consumption resulting from increased multifunctionality.
[0005] To meet the demand, a choke coil has been developed in which a magnet that applies magnetic fluxes that are opposite in direction to magnetic fluxes of a core is placed in a gap in the core to improve direct-current superposition characteristics of the choke coil.
[0006] Conventional choke coils in which a magnet of this type is provided in general have a structure in which one magnet having an area required for applying a desired magnetic bias is placed in a gap in the core. The magnet is a disc magnet 50 as illustrated in FIG. 9A or a rectangular magnet 51 as illustrated in FIG. 9B .
[0007] However, when the magnetic field from the core of the conventional choke coils described above radically changes, eddy currents are created in the magnets 50 and 51 due to electromagnetic induction, which then cause Joule heat to heat the magnets 50 and 51 , increasing the temperature of the choke coil. Consequently, desired magnetic characteristics cannot be achieved or the heat can adversely affect a neighboring device.
[0008] The present invention has been made in light of the circumstances described above and an object of the present invention is to provide a choke coil capable of applying an optimum magnetic bias without causing degradation of magnetic characteristics and any adverse effect on a neighboring device which would be caused by a temperature rise, therefore capable of adequately accommodating higher current.
SUMMARY OF THE INVENTION
[0009] To solve the problem, the invention in a first aspect of the invention provides a choke coil including a choke coil including a toroid coil and a core in which a first core inserted in the center of the coil and a second core disposed at an outer periphery of the coil form a closed magnetic circuit. A gap is formed in the first core. A magnet array applying a magnetic bias is placed in the gap. The magnet array is formed by a plurality of submagnets separated in a plane perpendicular to a direction in which a magnetic flux from the first core interlinks.
[0010] Modes of the coil include a coil constructed by wire wrapped around a bobbin, a single-wire coil, an edgewise coil, and coils of various other types.
[0011] The core may be formed by first cores inserted in the center of the coil and second cores disposed at the outer periphery of the coil into the shape of one rectangle or the shape of two stacked rectangles as a whole.
[0012] The invention in a second aspect of the invention provides a choke coil of the first aspect of the invention, wherein a tabular member made of resin or ferrite is provided in the gap, the tabular member has a plurality of holes passing from a top surface to a bottom surface of the tabular member, and the submagnets are inserted in the holes.
[0013] The invention in a third aspect of the invention is a choke coil according to the first or second aspect of the invention, wherein a plurality of recesses are formed in a surface of the first core, the surface facing the gap in the first core, and ends of the submagnets are inserted in the recesses.
[0014] The invention in a fourth aspect of the invention provides a choke coil according to any one of the first to third aspects of the invention, wherein the plurality of submagnets are located off the center of a magnetic path of the first core.
ADVANTAGEOUS EFFECTS OF THE INVENTION
[0015] The invention according to any of the first to fourth aspects of the invention reduces or inhibits generation of eddy currents in each of the submagnets even when a magnetic field from the first core has radically changed, as compared with a conventional single magnet because a plurality of submagnets that have areas into which an area required for applying a desired magnetic bias is divided are placed in a gap in the first core. As a result, the total amount of heat produced in the submagnets can be reduced to prevent harmful temperature rise in the choke coil and loss due to the eddy currents can also be reduced.
[0016] It is preferable that the plurality of submagnets be placed in such a manner that the magnetic force is evenly distributed. In practice, however, the magnetic attractive force between the submagnets makes it difficult to accurately space the plurality of submagnets in the plane because each of the submagnets has a specific magnetic force.
[0017] In that respect, the invention in the second aspect of the invention enables the submagnets to be readily evenly spaced because the resin or ferrite tabular member in which a plurality of holes are made is provided in the gap and the submagnets are inserted in the holes in the tabular member.
[0018] In addition, since the tabular member after the submagnets have been inserted in the holes is fitted into the gap in the first core to accomplish the placement of the submagnets, the number of man-hours needed to manufacture the choke coil can be reduced. Moreover, more holes than the number of the submagnets may be made in the tabular member to enable the magnetic bias to be flexibly adjusted later by appropriately changing the locations and/or the number of the submagnets.
[0019] Alternatively, placement of the submagnets can be facilitated by forming a plurality of recesses in a surface that faces the gap in the first core and inserting ends of the submagnets into the recesses as in the invention according to the third aspect of the invention.
[0020] Furthermore, the invention in the fourth aspect of the invention can reduce magnetic fluxes interlinking with the submagnets to further inhibit generation of eddy currents themselves which produce heat, because the submagnets are not placed in the center of the magnetic path in the first core where magnetic fluxes are more likely to concentrate but instead are located off the center of the magnetic path.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1A is a plan view of one embodiment of a choke coil according to the present invention;
[0022] FIG. 1B is a front elevation view of the choke coil; and FIG. 1C is a longitudinal sectional view of the choke coil;
[0023] FIG. 2A is a plan view illustrating the shape of a core of the choke coil; FIG. 2B is a front elevation view of the core;
[0024] FIGS. 3A , 3 B and 3 C are diagrams illustrating a shape of a tabular member and a mode of use of the tabular member;
[0025] FIGS. 4A , 4 B and 4 C are diagrams illustrating another shape of the tabular member of the choke coil and another mode of use of the tabular member;
[0026] FIG. 5 is a front elevation view illustrating submagnets positioned with the core of the choke coil;
[0027] FIG. 6A is a plan view illustrating a first practical example of the present invention;
[0028] FIG. 6B is a plan view illustrating a comparative example;
[0029] FIG. 7A is a plan view illustrating a second practical example of the present invention;
[0030] FIG. 7B is a plan view illustrating a comparative example;
[0031] FIG. 8A is a plan view illustrating a third practical example of the present invention;
[0032] FIG. 8B is a plan view illustrating a fourth practical example of the present invention as a comparative example; and
[0033] FIGS. 9A and 9B are plan views illustrating shapes of a magnet used in a conventional choke coil.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] FIGS. 1 to 5 illustrate an embodiment of a choke coil according to the present invention and a variation thereof. Reference numeral 1 in the drawings denotes a ferrite core.
[0035] The ferrite core 1 is formed by a pair of butterfly cores 2 , 2 , each of which has the shape of a letter E viewed from the front, into the shape of two stacked rectangles as a whole as viewed from the front.
[0036] As illustrated in FIGS. 2A and 2C , each of the butterfly cores 2 includes a tabular portion 3 , substantially plate-like outer legs 4 provided vertically at both ends of the length of the tabular portion 3 , and a cylindrical center leg 5 vertically provided in the center between the outer legs 4 , all of which are formed into a unitary structure. The center leg 5 is shorter in height than the outer legs 4 . The tabular portion 3 is formed in the shape of a pair of sectors (fan shapes) having a width that gradually increases from the center leg 5 toward the outer legs 4 at both sides. The outer and inner peripheral surfaces of the outer legs 4 at the both ends are formed in the shape of arc surfaces centered on the axis line of the center leg 5 .
[0037] The end surfaces of the outer legs 4 are joined together with a coil 6 having a substantially cylindrical appearance between them while the tabular portions 3 are located at the edges of the coil 6 and the center legs 5 are inserted in the coil, so that the pair of butterfly cores 2 are formed into a unitary structure. As a result, the center legs 5 (a first core) inserted in the center of the coil 6 of the pair of butterfly cores 2 and the outer legs 4 and the tabular portions 3 (a second core) that surround the outer periphery of the coil 6 form the ferrite core 1 having substantially the shape of two stacked rectangles, which forms a closed magnetic circuit, and a gap G is formed between both center legs 5 .
[0038] A tabular member 8 in which a plurality of submagnets 7 are inserted is interposed in the gap G.
[0039] The tabular member 8 is made of resin or ferrite into the shape of a disc as illustrated in FIG. 3A . A plurality of (four in the figure) circular holes 8 a passing from the upper surface to the bottom surface are bored in positions symmetrically to each other with respect to the center of the tabular member 8 . A submagnet 7 is inserted in each of the holes 8 a as illustrated in FIG. 3B .
[0040] Each of the submagnets 7 is a neodymium magnet or a samarium-cobalt magnet formed into the shape of a disc so that the area of each submagnet 7 is a quarter (quadrisection) of the area needed to apply a desired magnetic bias. The submagnets 7 are spaced apart from each other in a plane perpendicular to the direction in which magnetic fluxes from the center leg 5 of the ferrite core 1 interlink. In this arrangement, the four submagnets 7 are located off the center of the magnetic path of the center leg 5 in the ferrite core 1 .
[0041] FIG. 4A illustrates a modification of the tabular member. The tabular member 9 is also made of resin or ferrite into the shape of a disc. However, a plurality of square holes 9 a (12 holes in a matrix of 3 columns and 4 rows in the figure) passing from the top surface to the bottom surface are bored in the tabular member 9 . A square-plate submagnet 7 is inserted into each hole 9 a as illustrated in FIG. 4B .
[0042] In the choke coil configured as described above, since the submagnets 7 each having a quarter or quadrisection (twelve equal areas in the modification of FIGS. 4A-4C ) of the area needed to apply a desired magnetic bias are placed in the gap G formed between the center legs 5 of a pair of butterfly cores 2 , generation of eddy currents in each submagnet 7 is reduced or inhibited as compared with a conventional magnet that uses a single magnet, even when a magnetic field from the center legs 5 of the ferrite core 1 has radically changed.
[0043] Consequently, the total amount of heat produced in the four submagnets 7 (twelve submagnets 7 in the modification of FIGS. 4A-4C ) can be reduced to prevent a harmful temperature rise in the choke coil and loss due to the eddy currents can be minimized. In addition, the ferrite core 1 in which the opposed butterfly cores 2 are placed has excellent core loss characteristics and direct-current superposition characteristics. Therefore, by combining the ferrite core with the submagnets 7 which apply the magnetic bias, a choke coil that is smaller in size, lighter in weight, and more economical than conventional ones can be implemented.
[0044] Moreover, since resin or ferrite tabular member 8 or 9 in which four holes 8 a or twelve holes 9 a are made is provided in the gap G and the submagnets 7 are inserted in the holes 8 a , 9 a in the tabular member 8 , 9 , the submagnets 7 can be readily evenly disposed.
[0045] Furthermore, since the tabular members 8 , 9 after the submagnets 7 have been inserted in the holes 8 a , 9 a is fitted into the gap G between the center legs 5 to accomplish the placement of the submagnets 7 , the number of man-hours needed for manufacturing can be reduced.
[0046] In addition, making more holes 8 a , 9 a in the tabular member 8 , 9 than the number of submagnets 7 required as illustrated in FIGS. 3C and 4C enables the magnetic bias to be adjusted by appropriately changing the locations and/or number of the submagnets 7 .
[0047] Furthermore, since the submagnets 7 are not located in the center of the magnetic path from the center leg 5 where magnetic fluxes are more likely to concentrate but instead are located off the center of the magnetic path as illustrated in FIGS. 3A to 3C , magnetic fluxes that interlink with the submagnets 7 can be reduced to further inhibit generation of eddy currents themselves which would produce heat.
[0048] While the tabular member 8 , 9 in which a plurality of submagnets 7 are inserted in holes 8 a , 9 a is placed in the gap G between the center legs 5 in the embodiment described above, the present invention is not limited to this. For example, as illustrated in FIG. 5 , a plurality of recesses 5 a may be formed in the surface of the center leg 5 that faces the gap G and then one end of each submagnet 7 may be inserted in each recess 5 a to position and place the submagnets.
[0049] While the tabular member 8 , 9 may be made of any of resin and ferrite, the tabular member 8 , 9 made of ferrite can further increase heat dissipation by heat conduction, and improve magnetic bias characteristics.
PRACTICAL EXAMPLES
[0050] First, an experiment for comparison of the amounts of heat produced in magnets was conducted on a choke coil of a first practical example with sixteen rectangular-plate submagnets 7 illustrated in FIG. 6A according to the present invention and on a conventional choke coil with a single rectangular-plate magnet 51 illustrated in FIG. 6B .
[0051] In this experiment, butterfly cores 2 of the same shape were used as the ferrite cores 1 and the sum of the areas of the submagnets 7 was equal to the area of the magnet 51 .
[0052] Table 1 shows the results of the experiment on the choke coils illustrated in FIGS. 6A and 6B . The results in Table 1 demonstrate that the amount of heat produced in the submagnets 7 in the first practical example of the invention is approximately 1/14 of that of the conventional magnet 51 .
[0000]
TABLE 1
First practical
example
Conventional form
Submagnets
Single magnet
Amount of heat
1.2 [W]
17 [W]
produced in
magnet(s)
[0053] Then, using butterfly cores 2 similar to the ones used in the example, an experiment for comparing the amounts of heat produced in magnets was conducted on a choke coil of a second practical example with four disc-like submagnets 7 illustrated in FIG. 7A according to the present invention and on a conventional choke coil with a single disc-like magnet 50 illustrated in FIG. 7B . Again, the sum of the areas of the submagnets 7 was equal to the area of the magnet 50 .
[0054] The results of the experiment on the choke coils in FIGS. 7A and 7B demonstrate that the amount of heat produced in the submagnets 7 in the second practical example is approximately ⅓ of that of the conventional magnet 50 .
[0000]
TABLE 2
Second practical
example
Submagnets in
Conventional form
adjusted locations
Single magnet
Amount of heat
3.7 [W]
12 [W]
produced in
magnet(s)
[0055] Then, an experiment for comparing the amounts of heat produced in magnets was conducted on a choke coil of a third practical example according to the present invention in which 12 rectangular-plate submagnets 7 illustrated in FIG. 8A were located off the center of the magnetic path from the center leg 5 and on a choke coil of a fourth practical example according to the present invention in which the same number of submagnets of the same shape as those of the third practical example were placed in and around the center of the magnetic path from the center leg 5 as illustrated in FIG. 8B .
[0056] The results of the experiment on the choke coils in FIGS. 8A and 8B shown in Table 3 demonstrate that the amounts of heat produced in both of the choke coils are smaller than the amounts of heat in the conventional choke coils and that the amount of heat produced in the choke coil of the third practical example illustrated in FIG. 8A in which the submagnets 7 are located off the center of the magnetic path from the center leg 5 is smaller than that in the choke coil of the fourth practical example.
[0000]
TABLE 3
Third practical
example
Fourth practical
No magnet in
example
center of magnetic
Magnets in center
path
of magnetic path
Amount of heat
2.62 [W]
2.74 [W]
produced in
magnet(s) | The present invention provides a choke coil capable of applying an optimum magnetic bias without causing degradation of magnetic characteristics and any adverse effect on a neighboring device which would be caused by a temperature rise, therefore capable of adequately accommodating higher current. A choke coil according to the present invention includes a toroid coil 6 and a core 1 in which a first core 5 inserted in the center of the coil and a second core 3, 4 disposed at an outer periphery of the coil form a closed magnetic circuit. A gap G is formed in the first core 5 . A magnet array applying a magnetic bias is placed in the gap G. The magnet array is formed by a plurality of submagnets 7 separated in a plane perpendicular to a direction in which a magnetic flux from the first core 5 interlinks. | 7 |
FIELD OF THE INVENTION
The present invention relates to the field of electronic commerce. More particularly, the present invention provides a system and methods through which valid license plates or other similar identifiers can be traded by private parties.
BACKGROUND OF THE INVENTION
Vehicle owners in the United States are required to register their vehicle with a Motor Vehicles Department or other state or federal agency. In the case of street-based motor vehicles, such as passenger cars, motorcycles, and most commercial vehicles, such registration is evidenced by attaching a state-issued identifier, typically in the form of a license plate, to the vehicle.
As states grapple with ever-increasing pressure to cap tax levels while at the same time providing the same or higher levels of service to residents, many are looking at alternative forms of fundraising. One source of funds which many states have begun to utilize is charging additional fees to provide residents with customized license plates. Customized license plates, also referred to as vanity plates, permit registrants to put their name, a company name, an expression, or other combination of letters, numbers, or other characters on the license plate rather than a state-generated combination of characters.
SUMMARY OF THE INVENTION
The down side to customized license plates is that only one plate will be issued in a given state with a particular name, expression, or character combination, such as, but not limited to, “I SKI”. Although variations on the basic character combination may be issued, such as “ISKI”, “I SK1”, “I-SKI” for the previous example, most residents typically prefer the more recognizable term. In addition, once the variations have been issued, others wanting to purchase customized license plates with the same or similar combination of characters will not be able to obtain such customized license plates.
Accordingly, the present invention is directed to a license plate trading system and method that substantially obviates one or more of the problems due to limitations and disadvantages of the related art. Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings. The terms license plate and license plates are used interchangeably herein, and reference to a single license plate or multiple license plates should not be construed as limiting the invention to that number of license plates.
One aspect of the present invention is the creation of a marketplace through which a state resident to whom a license plate has been issued, referred to herein as the “owner” or “seller”, can trade a license plate or license plates with a person who is authorized to receive the license plate or license plates, referred to herein as the “prospective buyer” or “buyer”. A preferred license plate trading method includes receiving information about a license plate from a seller; storing the license plate information in a database; presenting license plate information to at least one prospective buyer; recording at least one prospective buyer's desire to purchase the license plate; notifying the seller and the buyer when the transaction can be finalized; receiving payment from the buyer; and, receiving confirmation that the license plate has been transferred to the buyer. License plate information received from a seller can include, but is not limited to, the state or federal agency issuing the license plate, the characters appearing on the license plate, one or more renderings or photographs of the license plate, a minimum price at which the seller is willing to transfer his or her rights to the license plate, and comments from the seller.
Prospective buyers can browse a list of available license plates or search the database for license plates of interest. In a preferred embodiment, prospective buyers searching based on the characters appearing on the license plate can request that the search results contain only exact matches, or prospective buyers can indicate that permutations may be acceptable. Where a prospective buyer indicates that permutations are acceptable, the prospective buyer can select from individual permutations as well as groups of permutations. Examples of such permutations may include, but are not limited to, removing spaces or other non-alphanumeric characters from the license plate characters; substituting the number 1 for the letter I; substituting the number 2 for the words “To”, “Too”, and “Two”; substituting the letter “B” for the word “be”; substituting the letter “C” for the words “Sea” and “See”; removing one or more characters; and substituting “WE” for “I”. Thus, a prospective buyer may search for “I SKI”, and the present invention may return “1 SK1”, “I SK1”, “-ISKI-”, “I-SKI”, “ISKI”, “WE SKI”, “WESKI” and the like.
In a preferred embodiment, the price at which a license plate will be sold is determined by an auction which runs for a period of time specified by the seller. In an alternative embodiment, the auction may run until a minimum price selected by the seller is met. In both embodiments, the minimum price at which a seller is willing to sell the license plate is preferably not disclosed to the prospective buyer as this typically encourages higher bids. However, a seller may elect to provide prospective buyers with the minimum sale price if the seller so chooses. In still another embodiment, license plates may be sold using traditional, fixed selling price transactions.
In a preferred embodiment, when a prospective buyer places a bid on a license plate, the prospective buyer supplies credit card or other payment information to the present invention. Where the prospective buyer provides credit card or similar information, a hold may be placed on the credit card for an amount proportionate to the prospective buyer's maximum bid. The amount placed on hold may also include transaction fees which will be assessed to the prospective buyer. Where the prospective buyer has provided a checking account number or similar information as a means of payment, the present invention may verify that sufficient funds are available to meet the maximum bid, including any fees. With accounts that do not support placing holds on the funds, such as traditional checking accounts, the present invention may periodically verify fund availability until the auction is complete or until the prospective buyer is no longer the winning bidder. If the prospective buyer's payment means cannot support the amount bid, as may occur where the funds are withdrawn from a checking account, the prospective buyer's bid may be cancelled.
At the end of the auction or when the transaction is otherwise complete, the buyer and seller are preferably notified of the final selling price, including any processing fees assessed as part of the transaction processing service of the present invention. The parties are also preferably provided with any documentation necessary to facilitate the license plate transfer. Such documentation may include, but is not limited to, state or federal agency specific instructions for effecting the transaction.
The buyer's payment is preferably processed and held in escrow until confirmation is received that the license plates have been properly transferred to the buyer. The seller is given a fixed period of time, such as ten business days, within which to surrender the license plates to the issuing state or federal agency or otherwise legally transfer the plates to the buyer.
In a preferred embodiment, confirmation of effective license plate transfer is provided by the state or federal agency issuing the license plates. Where a state or federal agency provides license plate transfer confirmation, the present invention may refund at least a portion of the buyer's payment if confirmation is not received within a given period of time, such as ten business days.
In an alternative embodiment, confirmation may be provided by the buyer. Where buyer confirmation is used, the present invention may provide payment to the seller if the buyer has not confirmed transfer within a given period of time after the license plates were to have been transferred, such as twenty business days after transaction completion. Such time should be long enough to allow the buyer to lodge a complaint in the event the license plates are not transferred in a timely manner so that the buyer can be refunded.
The license plate trading system of the present invention preferably includes a license plate information collection means; a database, used to store the license plate information collected from the license plate information collection means; a license plate information searching means; a license plate information display means; a buyer payment processing means; a license plate transfer confirmation means; and, a seller payment processing means. In a preferred embodiment, the license plate information collection, license plate information searching, and license plate information display means are each implemented through a World Wide Web based interface.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
In the drawings:
FIG. 1 is a block diagram illustrating a preferred network architecture to support the present invention.
FIG. 2 is a flow chart illustrating a preferred transaction process.
FIG. 3 is a flow chart illustrating a license plate transfer process.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
FIG. 1 is a block diagram illustrating a preferred network architecture for supporting the present invention, and FIG. 2 is a flow chart illustrating a preferred transaction process. Although the network architecture and transaction process of FIGS. 1 and 2 are presently preferred, it should be apparent to one skilled in the art that alternative network architectures and transaction processes may be used without departing from the spirit or the scope of the invention.
As illustrated in FIG. 1 , a preferred implementation of the present invention includes a redundant server architecture, represented as Internet Connections 135 , Routers 140 , Hub/Load Balancers 150 , Servers 160 , and Databases 170 . Although FIG. 1 illustrates redundancy implemented as two hardware devices or internet connections, those skilled in the art should recognize that additional hardware devices and/or internet connections can be added without departing from the spirit or the scope of the present invention. Furthermore, it should be understood that although redundancy is preferred, redundancy is not necessary.
In the preferred embodiment of FIG. 1 , the present invention is connected to Internet 130 through multi-homed Internet Connections 135 . In a multi-homed connection, each of Internet Connections 135 is preferably provided via a different Internet Service Provider, and connectivity is preferably provided through separate transmission means, such as different physical cables, different satellite links, or other wired or wireless connectivity means.
Routers 140 connect Hub/Load Balancers 150 to the redundant Internet Connections 135 . Hub/Load Balancers 150 allow Servers 160 to communicate with Internet 130 . Hub/Load Balancers 150 also distribute incoming communications among Servers 160 so that each of Servers 160 can be utilized without overwhelming any of Servers 160 .
Servers 160 are preferably Intel-based servers running the Windows 2000 Server operating system distributed by the Microsoft Corporation of Redmond, Wash.; one of the many LINUX operating system variants available; or another such operating system. Servers 160 preferably have World Wide Web server software installed thereon, such as Internet Information Server (IIS) distributed by the Microsoft Corporation of Redmond, Wash., or the Apache HTTP Server distributed by the Apache Software Foundation of Forest Hill, Md. Such World Wide Web server software can allow Servers 160 to provide external users with an interface to at least portions of Databases 170 . Databases 170 preferably comprise both a software and a hardware element. The software element of Databases 170 is preferably implemented through software such as, but not limited to, SQL Server, distributed by Microsoft Corporation of Redmond, Wash.; MySQL, distributed by MySQL AB of Uppsala, Sweden; and Oracle 9i Database, distributed by Oracle Corporation of Redwood Shores, Calif. Although the hardware aspects of Databases 170 are illustrated as two separate database servers in FIG. 1 , it should be appreciated by those skilled in the art that additional or alternative redundancy schemes may be used, such as, but not limited to, implementing Databases 170 as a Redundant Array of Inexpensive Disks (RAID) array with hot-swappable drives. Such techniques are well known in the art.
A license plate owner can use Seller Computer 110 to connect to Internet 130 , and through that connection the license plate owner can communicate with the present invention. A license plate owner can utilize the World Wide Web server installed on Servers 160 to enter license plate information into Databases 170 . Such information may include, but is not limited to, the state or federal agency issuing the license plate, the characters appearing on the license plate, the condition of the license plate, one or more renderings or photographs of the license plate, a minimum price at which the seller is willing to transfer his or her rights to the license plate, and comments from the seller.
A prospective buyer can utilize Buyer Computer 100 , Buyer Personal Desktop Assistant (PDA) 105 , or other such computer to connect to Internet 130 , and through that connection the prospective buyer can communicate with the present invention. The prospective buyer can utilize the World Wide Web server installed on Servers 160 to browse the license plate information stored in Databases 170 , search the license plate information stored in Databases 170 , place a bid on or purchase a license plate, enter comments about a recently executed transaction, and other such functions.
Transfer of rights in a license plate can be accomplished in a variety of ways, as dictated by the state or federal agency issuing the license plate. By way of example, without intending to limit the present invention, FIG. 3 illustrates a process through which license plates can be transferred in New York state. In New York state, license plate transfers begin with the license plate being placed in storage with the Department of Motor Vehicles (DMV) (Block 300 ). The DMV provides a storage receipt to the license plate owner and the DMV's records are updated to reflect the fact that the license plates are no longer being used (Block 310 ). The seller sends the buyer a copy of the storage receipt (Block 320 ), along with a letter transferring the seller's rights in the license plates to the buyer and a copy of the seller's driver license (Block 330 ). The buyer provides the seller's documentation to the DMV, along with a copy of the buyer's vehicle registration (Block 340 ). The DMV may assess a fee to the buyer, with the amount of such a fee based on whether the buyer wishes to have a new plate issued, the format of the new plate, and other such factors (Block 350 ). Once the DMV has completed the transaction, including, but not limited to, recording the transfer of rights in the license plate and issuing a new license plate if the buyer requested one, the buyer is provided with authorization to retrieve the license plate (Block 360 ). The buyer can then retrieve the license plate from the DMV (Block 370 ).
By way of further example, without intending to limit the present invention, in Washington State, West Virginia, Connecticut, Florida, and Massachusetts, transfer may occur by the seller signing and having notarized a release of interest in the license plate. The notarized release of interest can be brought to a County Auditor's office, a Department of Motor Vehicles, or other such county or state office along with the license plate and, for a minor state fee, the license plates can be transferred to the prospective buyer. In most cases, if the seller is keeping the vehicle to which the license plate was registered, the seller must also apply for a new license plate and pay the appropriate fee.
To effectuate license plate transfers, the present invention may generate the paperwork and/or instructions for the seller and the prospective buyer to follow. The paperwork and/or instructions may also include a computer readable identification code, such as, but not limited to, a bar code, or similar human readable identification code. In a preferred embodiment, an operator at the state or federal agency receiving the license plate from the license plate owner will enter the license plate owner's identification code into Computer System 120 . Computer System 120 will then preferably transmit information via Internet 130 to Server 160 confirming that the license plate has been received. When the prospective buyer picks up the license plate, an operator at the state or federal agency can enter the prospective buyer's identification code into Computer System 120 . Computer System 120 will preferably transmit information via Internet 130 to Server 160 confirming that the license plate has been properly transferred to the prospective buyer.
FIG. 2 is a flow chart illustrating a preferred transaction process. Although the process of FIG. 2 is presently preferred, those skilled in the art should appreciate that alternative processes may be substituted therefor without departing from the spirit or the scope of the present invention.
The process of FIG. 2 preferably begins with a license plate owner, or seller, registering with the present invention (Block 205 ). Registration can include, but is not limited to, selecting a user name and password, entering the seller's mailing address and/or physical address, and entering the bank account or credit card account to which payment should be made in the event of any license plate sales.
Once registered, a seller can list one or more license plates for sale with the present invention (Block 210 ). Such listing may include, but is not limited to, selecting the type of sales transaction to be used (i.e. auction, standard sale, etc.), entering a minimum price at which the seller is willing to transfer his or her rights to the license plate, the length of time the license plate is to be listed, the state or federal agency issuing the license plate, the characters appearing on the license plate, one or more renderings or photographs of the license plate, and comments from the seller.
Prospective buyers can browse and/or search the database of license plates available through the present invention (Block 220 ). If a prospective buyer is interested in a license plate (Block 215 ), the prospective buyer can enter a bid or purchase the license plate (Block 225 ), as appropriate given the seller's chosen transaction type. In the embodiment illustrated in FIG. 2 , prospective buyers can enter payment information at the time the bid is entered or the license plate is purchased. In an alternative embodiment, prospective buyers can register with the present invention in advance, wherein such registration can include storing payment information with the present invention.
If the seller has elected an auction-based transaction, and another bid has been entered for the license plate (Block 230 ), the prospective buyer's bid is compared against the current high bidder (Block 235 ). If the prospective buyer's bid is higher than the current high bidder, or if no other bids have been received, the prospective buyer becomes the current high bidder.
Where the prospective buyer has provided credit card or similar payment information to the present invention, a hold may be placed on the credit card for an amount proportionate to the prospective buyer's maximum bid (Block 240 ). Where the prospective buyer has provided a checking account number or similar information as a means of payment, the present invention may verify that sufficient funds are available to meet the maximum bid, including any fees. With accounts that do not support placing holds on the funds, such as traditional checking accounts, the present invention may periodically verify fund availability until the auction is complete or until the prospective buyer is no longer the high bidder. If the prospective buyer's payment means cannot support the amount bid, the prospective buyer's bid may be cancelled and the buyer with the previous high bid is preferably reinstated as the high bidder at his or her highest bid.
The seller and high bidder are notified, preferably via E-mail, when the transaction time specified by the seller has elapsed (Block 250 ) assuming the transaction was an auction. Alternatively, where the seller has chosen a traditional sale transaction, the seller and buyer may be notified when the buyer elects to purchase the license plate. As described above, the notification preferably includes instructions and documentation necessary to legally transfer the seller's rights in the license plate to the high bidder. If no high bidder exists, the present invention notifies the seller of the end of the transaction and gives the seller the option to list the license plate again.
Payment for the transaction is then processed against the buyer, whether the buyer is the high bidder in an auction or the buyer in a sales transaction (Block 255 ). The buyer's payment is preferably processed and held in escrow until confirmation is received that the license plates have been properly transferred to the buyer.
The present invention then waits for confirmation that the license plates have been properly transferred to the buyer (Block 260 ). In a preferred embodiment, the seller is given a fixed period of time, such as ten business days, within which to surrender the license plates to the issuing state or federal agency or otherwise legally transfer the plates to the buyer. Effective license plate transfer is preferably confirmed by the state or federal agency issuing the license plates. Where a state or federal agency provides license plate transfer confirmation, the present invention may refund at least a portion of the buyer's payment (Block 275 ) if confirmation is not received within a given period of time, such as ten business days (Block 270 ).
In an alternative embodiment, confirmation may be provided by the prospective buyer. Where prospective buyer confirmation is used, the present invention may provide payment to the seller if the prospective buyer has not confirmed transfer within a given period of time after the license plates were to have been transferred, such as twenty business days after transaction completion. Such time should be long enough to allow the prospective buyer to lodge a complaint in the event the license plates are not transferred in a timely manner so that the prospective buyer can be refunded or other actions taken as appropriate.
Through the system and methods described above, the present invention allows license plate owners to legally transfer their rights in the license plates to others. While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | A system and methods through which a person to whom a license plate is issued may trade and transfer rights in the license plate with another person, preferably a resident of the same state. The present invention sets up a marketplace through which such trading can be performed, including providing escrow and other such services for buyers and sellers as necessary to effect such a transaction. | 6 |
CORRESPONDING RELATED APPLICATIONS
The present application is a continuation of U.S. application Ser. No. 10/734,678, filed Dec. 15, 2003, now U.S. Pat. No. 7,175,377, which is incorporated by reference herein in its entirety, which is continuation in part of U.S. application Ser. No. 10/336,033 filed on Jan. 3, 2003, now U.S. Pat. No. 6,827,531, which is incorporated by reference herein in its entirety. Additionally, the present application is related to U.S. application Ser. No. 09/874,979 filed on Jun. 7, 2001, and U.S. application Ser. No. 10/109,051 filed on Mar. 29, 2002 by Mark D. Snyder et al., which are incorporated by reference herein in their entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to fasteners for securing loads to a track, and more particularly, to adjustable fasteners for securing loads to a track mounted in or near a truck bed.
2. Background of the Invention
Fasteners for securing loads to framing, tracks, and channels have been commercially available for some time. Some conventional fasteners used in automotive track applications will be briefly described below.
Conventional track fasteners have been designed to be removable and/or relocateable along a track slot length. Many of these conventional track fasteners employ a rotatable locking base portion that engages locking teeth inside the track slot or on a locking mechanism to securely retain the fastener within the track slot, and to facilitate relocation along the track slot length. These devices, however, can be difficult to install and use, which detracts from their desirability in consumer environments such as original equipment manufactured (OEM) vehicles such as pickup trucks, mini-vans, sport-utility vehicles or other vehicles. Often, conventional track fasteners can only be loaded from an end of the track slot, because their design does not facilitate top down loading, and are thus difficult to replace if broken. Also problematic, many of these fasteners have limited load capacities, such as fasteners available on roof racks, and are thus unsuitable for applications such as truck beds and cargo areas where heavier loads are placed.
Other conventional track fasteners (e.g., U.S. Pat. Nos. 4,410,298, 4,784,552, and Re. 36,681, which are incorporated by reference herein in their entirety) have been designed with a center through bolt to apply pressure between a top plate mounted above the track slot and a base plate mounted within the track slot. The bolt can be tightened to clamp the fastener in place, thereby securely retaining the fastener within the track slot, or loosened to allow relocation along the track slot length. Clamp styled fasteners are often used to temporarily attach rails to the top side of a truck bed for tonneau covers and the like, and generally allow relocation along the length of the track slot. These devices, however, often require a user to have a wrench to loosen or tighten the bolt, which detracts from their ease of use.
Thus, a need exists for an improved track slot fastening device.
SUMMARY OF THE INVENTION
The present invention is directed to overcoming or at least reducing the effects of one or more of the problems set forth above and other problems in the prior art.
According to embodiments of the invention described below, there is provided a fastener assembly for securing loads to a track, the fastener assembly being retainable within a track slot of the track. The fastener assembly may include a retainer adapted to fit at least partly within a track slot and a rotatable handle operating on the retainer, the rotatable handle being rotatable between at least an engagement position and a release position. A pressure applicator is positioned between the track and the rotatable handle, the pressure applicator having a bottom surface for applying a pressure on a top surface of the track in response to the position of the rotatable handle. The pressure applicator includes at least one projection projecting from an interior region of the bottom surface and adapted to engage a positioning scallop of the track.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing advantages and features of the invention will become apparent upon reference to the following detailed description and the accompanying drawings, of which:
FIG. 1 is a perspective view of a fastener assembly according to an embodiment of the present invention;
FIG. 2 is a bottom perspective view of the fastener assembly of FIG. 1 ;
FIG. 3 is a bottom perspective view of the fastener assembly of FIG. 1 mounted on a track slot with the track slot cut in a mid-region to show an interface between the fastener assembly and the track slot;
FIG. 4 is a perspective view of a shaft coupled to a retainer according to an embodiment of the present invention;
FIG. 5 is a top perspective view of a rotatable handle according to an embodiment of the present invention;
FIG. 6 is a bottom perspective view of the rotatable handle of FIG. 5 ;
FIG. 7 is a sectional view of the fastener assembly of FIG. 1 viewed from plane VII-VII;
FIG. 8 is a sectional view of the fastener assembly of FIG. 1 viewed from plane IIX-IIX;
FIG. 9 is a sectional view of a fastener assembly with ramped or angled portions according to another embodiment of the present invention; and
FIG. 10 is a partial sectional view of the fastener assembly of FIG. 9 viewed from plane X-X.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to presently preferred embodiments of the invention. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
The following description of the present invention will describe implementations of the present invention in reference to a track slot used in a truck bed. One such implementation is described in copending U.S. patent application Ser. No. 09/874,979 filed Jun. 7, 2001, by Michael D. Anderson et al., which is incorporated by reference herein in its entirety. Additional improvements and variations are described in the aforementioned corresponding related applications. Other implementations are also contemplated, as would be readily apparent to one of skill in the art after reading this disclosure.
It should be appreciated that the term track slot as used in the present specification refers to the entire internal volume of the track. Hence, track slot includes the space substantially between two upper inwardly protruding portions at the top of the track, and the volume underneath the protruding portions to a bottom surface of the track. It should also be appreciated that the term load as used in the present specification refers to a force applied to a fastener assembly by an object secured thereto. This load may include, for example, a horizontal force acting substantially along a plane of a vehicle body, a vertical force acting upwards and away from the aforementioned plane of the vehicle body, or a combination of the two.
A fastener assembly 1000 retainable within a track slot 605 of a track 600 according to a first embodiment of the present invention is shown in FIGS. 1 through 8 . The fastener assembly 1000 includes a rotatable handle 1010 , such as a thumb-wheel, which is shown best in FIGS. 5 and 6 . The rotatable handle 1010 is disposed within an outer tie down 1011 for securing loads to the fastener assembly 1000 . The rotatable handle 1010 is operably connected to a retainer 1050 by way of a shaft 1020 . Retainer 1050 is configured to function in conjunction with a pressure plate 1040 to apply a mechanical clamping force on the track 600 when in an engaged or locked configuration.
According to the first embodiment of the present invention as shown in FIG. 2 , a plurality of projections 1090 are configured to extend from a bottom surface 1041 of pressure plate 1040 . Preferably, the projections 1090 extend from a region located generally in the interior of the bottom surface 1041 of pressure plate 1040 . In this configuration, the projections 1090 may be spaced from one or both of the ends 1042 and 1044 of pressure plate 1040 and from one or both of sides 1046 and 1048 of pressure plate 1040 , or a plurality of combinations thereof. It can be appreciated that spacing the projections 1090 an approximately equal distance on opposite sides of shaft 1020 will ensure an equal load distribution across the bottom surface of the pressure plate 1040 . Preferably, projections 1090 are positioned in a configuration shown in FIG. 2 .
The projections 1090 may include four periphery portions 1091 formed in a shape conforming to that of scallops 1095 in track 600 to promote engagement therebetween and slot guide portions 1093 to further assist in positioning the fitting in the track. A clearance may also be provided to facilitate ingress and egress of the projections 1090 . In the embodiment of the invention shown in FIGS. 1 to 8 , the scallops are in the shape of a portion of a circle having a radius of about 5 mm (such as 5.37 mm) and thus each of the four periphery portions 1091 are in the shape of a portion of a circle having a radius of about 5 mm. In this particular embodiment, the non-scalloped portion of the top of the track slot is about 21 mm wide (such as 21.45 mm) and thus portions 1093 on each projection 1090 are spaced apart about 21 mm. In this particular embodiment, the centers of curvature of adjacent scallops are about 40 mm apart and thus the centers of curvature of the portions 1091 are about 40 mm apart. Other variations are also plausible, as will be readily apparent to one of ordinary skill in the art after reading this disclosure. For example, the scallops and periphery portions can have other arc-shaped geometries in addition to circular geometries. Projections 1090 are illustrated to project from pressure plate 1040 at an angle of 90° from the bottom surface 1041 . However, it is contemplated that the projections 1090 may extend at a variety of angles to increase engagement with corresponding scallops 1095 .
As shown in FIGS. 5 through 8 , the rotatable handle 1010 may be formed of a multi-piece or multi-section construction. By way of example, the rotatable handle 1010 may include a top 1012 including a threaded nut 1014 , for translating the threaded portion 1025 of shaft 1020 , and a washer 1016 which prevents rotation and rocking of shaft 1020 . This multi-piece or multi-section construction allows the rotatable handle 1010 to be easily assembled and manufactured. Also, shown in FIG. 8 are fasteners 1013 , which hold the tie-down portion 1011 to pressure plate 1040 and a clip 1015 which retains the shaft 1020 to the rest of the fitting.
In order to insert the fastener assembly 1000 in track 600 , the longitudinal axis of the fastener assembly 1000 is initially placed transverse to the longitudinal axis of the track 600 . Next, the retainer 1050 is positioned such that the longer axis is oriented parallel to and above the slot. The retainer 1050 is then placed in the longitudinally extending slot 605 of the track 600 . The fastener assembly 1000 is then rotated 90° in the clockwise or counterclockwise direction, thus aligning with track 600 so that the retainer 1050 is also rotated 90°. In this manner, the fastener assembly 1000 can be inserted in track 600 in a top-down method and easily secured to the track 600 .
To secure fastener assembly 1000 to track 600 , the fastener assembly 1000 is first inserted in the track 600 , as described above. Next, the fastener assembly 1000 is placed along the track 600 such that projections 1090 engage corresponding scallops 1095 formed in the track 600 . The rotatable handle 1010 is then rotated clockwise about a central axis defined by shaft 1020 , which in turn rotates a central threaded portion 1014 of the rotatable handle 1010 . Rotation of the rotatable handle 1010 operates to translate the threaded portion 1025 of shaft 1020 , thereby translating shaft 1020 relative to rotatable handle 1010 . As the shaft 1020 is translated the retainer 1050 , which is coupled to the shaft 1020 , contacts a lower surface 610 of a flange 615 formed on the track 600 . The retainer 1050 and pressure plate 1040 combine to exert a clamping force on the track 600 , thereby retaining the fastener assembly 1000 in a secured position on track 600 . In this manner, the fastener assembly 1000 can be securely coupled to the track 600 in a plurality of locations along the track 600 for fastening loads thereto.
A fastener assembly 400 retainable within a track slot of a track 110 according to a second embodiment of the present invention is shown in FIGS. 9 and 10 . A portion of FIG. 9 viewed from plane X-X is shown in greater detail in FIG. 10 . The fastener assembly 400 according to this embodiment includes a rotatable handle 410 , such as a thumb-wheel, within an outer tie down 411 for securing loads to the fastener assembly 400 . The rotatable handle 410 operates retainer 450 via shaft 420 . A spring 430 is provided in a space between the rotatable handle 410 and a pressure plate 440 , such that the spring 430 applies a vertical force on a pin 443 with respect to the pressure plate 440 . The pressure plate 440 is secured to the tie down 411 by screws 435 .
To operate the fastener assembly 400 , the rotatable handle 410 includes an angled running surface 445 interfacing pin 443 . As the rotatable handle 410 is rotated between a locked position and a released position, the angled running surface 445 vertically displaces the pin 443 which is coupled to the retainer 450 by shaft 420 . The rotatable handle 410 is limited in vertical displacement due to intersecting a portion of the outer tie down 411 .
The interface between the angled running surface 445 and the pin 443 may be formed to prevent overtightening of the fastener assembly 400 and to default to a tightened condition during partial tightening of the rotatable handle 410 . By way of example, the angled running surface 445 may include a notch (not shown) for receiving the pin 443 at a loosened state near the top of the angled running surface 445 . If an operator only partially loosens the fastener assembly 400 , thereby not engaging the notch, the spring 430 forces the pin 443 to slide down the angled running surface 445 into a tightened or engaged position. To prevent overtightening, the spring 430 is configured to apply the maximum retention force on the retainer 450 when the pin 443 is at the bottom of the angled running surface 445 . Therefore, overtightening may be prevented and default engagement may be achieved by the present invention.
The foregoing description of preferred embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. For example, other types of retainers such as nuts or other fasteners may be used. The embodiments were chosen and described in order to explain the principles of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined with reference to the claims appended hereto, and their equivalents. | A fastener assembly secures loads to a track in a truck bed and is retainable within a track slot of the track. The fastener assembly may include a retainer adapted to fit at least partly within a track slot and a rotatable handle operating on the retainer, the rotatable handle being rotatable between at least an engagement position and a release position. A pressure applicator is positioned between the track and the rotatable handle, the pressure applicator having a bottom surface for applying a pressure on a top surface of the track in response to the position of the rotatable handle. The pressure applicator includes at least one projection projecting from an interior region of the bottom surface and adapted to engage a positioning scallop of the track. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is generally directed to the drilling of oil and gas wells, and, more particularly, to the setting of a compression set packer in such wells.
2. Description of the Related Art
The use of a compression set packer within a well to isolate various regions of a formation for selective production is well known in the industry. Traditionally, the setting of a compression set packer within a well has required the manipulation of a pipe string to which the compression set packer is attached.
The setting of a compression set packer using the aforementioned pipe string manipulation method requires the generation of approximately one-quarter turn of the pipe string at the location of the compression set packer within the well. Depending on the depth of the well and the configuration of the well, this requirement for a quarter-turn of the pipe string at the compression set packer may require approximately four to five turns of the pipe string at the well platform. The problem is even greater with respect to deviated wells, wherein the number of turns required at the platform to generate a one-quarter turn at the compression set packer may be greater.
Additionally, as is well known to those skilled in the art, in the drilling of sub sea wells, a plurality of control lines, typically hydraulic lines, are run from the sub sea well head located at the ocean floor to the offshore drilling platform. These lines are typically coupled to the drill pipe as a compression set packer is lowered into the well for setting at the appropriate location. However, given the presence of these hydraulic lines, the rotation of the pipe string is undesirable during the traditional technique of setting the compression set packer in that it may lead to tangling of the lines or damage to the lines.
The present invention is directed to a method and apparatus that solves or reduces some or all of the aforementioned problems.
SUMMARY OF THE INVENTION
The present invention is directed to a device for setting a compression set packer. The device is comprised of a housing, a moveable member positioned adjacent said housing, and a release device. The release device is adapted for engagement with at least the housing and the moveable member. The moveable member is positionable to a first position where a setting mandrel is maintained in a non-engaged position with respect to the compression set packer, and to a second position where the release device is free and the setting mandrel is free to move with respect to the compression set packer.
The present invention is also directed to a method for setting a compression set packer in a well. The method comprises coupling a setting device to a portion of the packer, positioning a setting mandrel within the packer and the setting device, and securing the setting mandrel into a non-engaged position with respect to the compression set packer. The method further comprises positioning the compression set packer at a desired location in the well, releasing the setting mandrel so that it is free to travel with respect to the compression set packer, and setting the compression set packer by lowering the setting mandrel into engagement with the compression set packer.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements, and in which:
FIG. 1 is a partial cross-sectional view of a compression set packer and a setting device with a setting mandrel in a non-engaged position with respect to the compression set packer;
FIG. 2 is a partial cross-sectional view of the apparatus of FIG. 1 showing a moveable member of the setting device in a position whereby the setting mandrel is free to travel with respect to the compression set packer;
FIG. 3 is a view of the compression set packer engaged with the setting mandrel and set in the well;
FIG. 4A is a side view of an indexing lug that may be used with the present invention; and
FIG. 4B is a top view of the indexing lug shown in FIG. 4A.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
Illustrative embodiments of the invention are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
As shown in FIGS. 1-3, a compression set packer 10 may be releasably coupled to a packer setting device 20. The compression set packer 10 is generally comprised of a plurality of slips 12, a plurality of friction pads 14 positioned within a friction pad housing 16, and a packer setting mandrel 18. The configuration of the compression set packer 10 is illustrative only and does not constitute a limitation of the present invention. Those of skill in the art will readily recognize that there are a variety of commercially available compression set packers that are suitable for use with the present invention.
In one embodiment, the setting device 20 may be comprised of a housing 21, a plurality of collet fingers 22, a moveable member 24, a bottom sub 26, and an actuating device 28. The setting device 20 may further include a gauge ring 30, a plurality of seals 50, 52, 54, 56, a retention device 38, and a test opening 34. In one embodiment, the actuating device 28 is a rupture disk 36 and the retention device 38 is a plurality of shear pins 40. The setting device 20 is adapted to be releasably coupled to the lower end 13 of the friction pad housing 16, which is part of the compression set packer 10. In one embodiment, the setting device 20 is releasably coupled to the lower end 13 of the compression set packer 10 by a threaded connection 42.
As is readily apparent to those skilled in the art, the various configurations of the components of the setting device 20 shown in the drawings are illustrative only and do not constitute a limitation of the present invention. For example, the housing 21 is depicted in the drawings as a sleeve through which the setting mandrel 18, as well as other pipe, may pass. Those skilled in the art recognize that the housing 21 could be configured in any number of ways and still accomplish the purposes of the present invention. Similarly, the moveable member 24 is depicted in the drawings as a piston type device. Again, those skilled in the art will recognize that the moveable member 24 could be configured in a variety of shapes and still accomplish the purposes of the invention.
The components of the setting device 20 may be manufactured from a variety of materials depending upon the particular environment in which the device will be used. For example, the setting device 20 and all of its associated metallic components may be made from carbon or stainless steel. Similarly, the seals 50, 52, 54 and 56 may be made from any material that is suitable for the particular design conditions under consideration. In one embodiment, the seals 50, 52, 54 and 56 are O-rings that may be made of viton.
The operation of the setting device 20 will now be explained with reference to FIGS. 1-3. Initially, the setting device 20 is assembled and attached to the compression set packer 10 on the well platform prior to attaching the completed compression set packer 10 and setting device 20 assembly to a pipe string (not shown) for lowering to the sea floor. For example, an upper portion 17 of the packer setting mandrel 18 and a lower portion 27 of the bottom sub 26 may be attached to a pipe string (not shown) by threaded connections.
As shown in FIG. 1, the housing 21 is positioned within the bottom sub 26 and rests on shoulders 62 and 63 formed on an interior surface of the bottom sub 26. The packer setting mandrel 18 has a rib 60 that is engaged with a shoulder 61 formed on the housing 21. As shown in FIG. 1, the collet fingers 22 are in their engaged position. The collet fingers 22 are retained in this engaged position by their engagement with the moveable member 24. In their engaged position, the collet fingers 22 are also engaged with a recess 23 formed in the housing 21. The collet fingers 22 may be attached to the compression set packer 10 by, for example, a threaded connection 42, to collet finger housing 92.
The moveable member 24 is retained in the position shown in FIG. 1 by the retention device 38. The purpose of the retention device 38 is to prevent unanticipated downward movement of the moveable member 24 after the setting device 20 is assembled and as the combined compression set packer 10 and setting device 20 assembly is in the process of being lowered to the sea floor. As those skilled in the art will recognize, this purpose can be accomplished by numerous techniques. In one embodiment, the retention device 38 is comprised of a plurality of shear pins 40.
A gauge ring 30 may be attached to the bottom sub 26 to insure that the moveable member 24 does not engage the inner surface of the well casing (not shown) as the compression set packer 10 and setting device 20 assembly is lowered downhole. The gauge ring 30 acts to insure that the moveable member 24 is free to move at the appropriate time.
As shown in FIG. 1, when assembled, the setting device 20 defines two pressure chambers 67 and 68. The pressure chamber 67 is defined by the moveable member 24, housing 21, and seals 50 and 52. The pressure chamber 68 is defined by the bottom sub 26, moveable member 24, housing 21 and seals 52, 54 and 56. During assembly, the pressure chambers 67 and 68 are tested to insure their integrity. With the moveable member 24 in the position shown in FIG. 1, but prior to the attachment of the rupture disk 36 to the moveable member 24, the pressure chamber 67 is tested to insure its integrity. Thereafter, the rupture disk 36 is attached to the moveable member 24. The pressure chamber 68 is next pressure tested through the test opening 34.
The actuating device 28 is, when actuated, adapted to allow the moveable member 24 to move relative to the housing 21 and the bottom sub 26. In one embodiment, the actuating device 28 is a rupture disk 36 that is designed to rupture at a specific pressure that is determined by design considerations. As is readily apparent to those skilled in the art, the use of the rupture disk 36 as the actuating device 28 is illustrative only and the same function may be provided by a variety of different techniques.
After being configured as shown in FIG. 1, the compression set packer 10 and setting device 20 assembly is lowered in the well. During this process, the moveable member 24 is initially retained in the position shown in FIG. 1 by the plurality of shear pins 40. In this position, the packer setting mandrel 18 is prevented from moving downward due to the engagement of the rib 60 with the shoulder 61 formed in the housing 21 and the engagement of the collet fingers 22 with the recess 23 in the housing 21. The collet fingers 22 are maintained in engagement with the recess 23 by the moveable member 24. During this process, the setting mandrel 18 is not engaged with the compression set packer 10, and, thus, the compression set packer 10 is not set. Moreover, in the position shown in FIG. 1, the compression set packer 10 cannot be set because downward movement of the packer setting mandrel 18 is prevented. As shown in FIG. 1, the slips 12 are in their retracted position and they do not engage the casing (not shown) of the well as the compression set packer 10 and setting device 20 assembly is lowered into the well. During the lowering of this assembly, the spring-loaded friction pads 14 engage the inner surface of the well casing.
As is readily apparent to those skilled in the art, the pressure inside the well may be very high, for example, 10,000 pounds per square inch (psi). The pressure chambers 67 and 68, having been assembled and sealed at the surface, are at a pressure of approximately 14.7 psi. The moveable member 24 is designed such that the pressure in the well acts to keep the moveable member 24 in the position shown in FIG. 1. In one embodiment, this is accomplished by providing sufficient area on the sloped surface 58 such that, with a pressure of approximately 14.7 psi in the pressure chamber 67, the well pressure acting on the sloped surface 58 will maintain the moveable member 24 in the position shown in FIG. 1.
In one embodiment, rupturing the rupture disk 36 causes an increase in the pressure in the pressure chamber 67 from approximately 14.7 psi to the well pressure, for example, 10,000 psi. The moveable member 24 is designed such that, when the pressure chamber 67 is at well bore pressure, the moveable member 24 suddenly moves to the position shown in FIG. 2. The increase of the pressure in the pressure chamber 67 provides sufficient force to allow the moveable member 24 to shear the shear pins 40.
The moveable member 24 is driven from a first position shown in FIG. 1, where the setting mandrel 18 is not engaged with the compression set packer 10, to a second position, as shown in FIG. 2, where the collet fingers 22 are released and the setting mandrel 18 is free to travel with respect to the compression set packer 10. Further downward movement of the setting mandrel 18 will result in the setting of the compression set packer 10, as discussed more fully below. As stated above, in one embodiment, the actuating device 28 is a rupture disk 36 that may be designed for a particular application. For example, if it is desired that the compression set packer 10 be set at a depth in the well at which the hydrostatic pressure is 9800 psi, then a rupture disk 36 designed to rupture at a higher pressure, e.g, 10,000 psi, would be used. Thus, with the compression set packer 10 positioned at the appropriate level at which the hydrostatic pressure in the well is 9800 psi, the rupture disk 36 could be caused to rupture with an applied pressure of 200 psi. This applied pressure is typically generated by use of pumps at the surface.
As shown in FIGS. 2 and 3, after the collet fingers 22 are released, the setting mandrel 18 may be moved downward thereby causing the sloped surface 72 of the setting mandrel 18 to engage sloped surfaces (not shown) on the back of the slips 12. The engagement of these sloped surfaces forces the slips 12 into engagement with the inner surface of the casing or concrete in the well bore. Thereafter, further weight is applied to the pipe string to expand a plurality of packer elements (not shown) that are present on currently available compression set packers 10.
As shown in FIG. 1, the collet fingers 22 may be releasably attached to the friction pad housing 16 by, for example, the threaded connection 42 to collet finger housing 92. Using this technique, the lower end 13 of the friction pad housing 16 must have threads formed thereon. As is well known to those skilled in the art, typical compression set packers may be provided with an indexing lug that is positioned within a "J"-slot formed in the setting mandrel 18. One common way of retaining such an indexing lug in position relative to the friction pad housing 16 is through a bolted connection. However, during the formation of the threaded connection 42 on the lower end 13 of the friction pad housing 16, a portion of the standard indexing lug and collet are removed. Thus, as shown in FIGS. 4A-4B, a special indexing lug 86 is useful and is attached to the friction pad housing 16 (not shown) with a screw 90.
Alternatively, the collet fingers 22 may be releasably attached to the friction pad housing 16 by, for example, a plurality of screws spaced around the perimeter of the friction pad housing 16. Using this approach, the lower end 13 of the friction pad housing 16 must be turned down, i.e., have its diameter reduced, such that the collet finger housing 92 would slip over the reduced diameter. Thereafter, the collet finger housing 92 could be secured to the friction pad housing 16 with a plurality of screws spaced around the circumference, e.g., three screws spaced 120° apart.
The inventive method disclosed herein generally comprises releasably coupling a setting device 20 to a compression set packer 10, positioning a setting mandrel 18 with the compression set packer 10 and setting device 20, securing the setting mandrel 18 into a position in which it is not engaged with the slip 12 of the compression set packer 10, positioning the compression set packer 10 at the desired depth within a well, releasing the setting mandrel 18 from its non-engaged position so that it is free to travel with respect to the compression set packer 10, and setting the compression set packer 10 into position within the well by lowering the setting mandrel 18 into engagement with the compression set packer 10, whereby the slips 12 are forced outward and engage the well casing. As is readily apparent to those skilled in the art, through use of the present technique, the compression set packer 10 may be set without rotational movement of the pipe string.
It should be noted that, through use of the present inventive methods and device, the compression set packer 10 may be reset multiple times as the compression set packer 10 is withdrawn from the well. With reference to FIG. 3, upward movement of the setting mandrel 18 releases the slips 12 of the compression set packer 10. Continued upward movement of the setting mandrel 18 causes an end 88 of the collet fingers 22 to engage an end 89 of the moveable member 24. This engagement provides sufficient resistance such that continued further upward movement of the setting mandrel 18 results in upward movement of the compression set packer 10, which is, at this time, only held in place by friction pads 14.
When the compression set packer 10 reaches the next desired setting position within the well, upward movement of the packer setting mandrel 18 is stopped. At this time, the compression set packer 10 is maintained in its new desired position by the friction pads 14. As is readily apparent to those skilled in the art, downward movement of the packer setting mandrel 18 causes the inclined surface 72 of the packer setting mandrel 18 to once again engage the inclined surfaces on the back of the slips 12, thereby forcing the slips 12 into engagement with the well casing and setting the compression set packer 10 at the new location.
The present invention may also be combined with the known technique of setting a compression set packer 10 through use of rotational movement, whereby an indexing lug 86 that is coupled to the friction pad housing 16 is free to move within a slot (known in the industry as a "J"-slot), formed in the setting mandrel 18 as the setting mandrel 18 is rotated and raised. If, in addition to being coupled to a setting device 20 disclosed herein, a compression set packer 10 is provided with standard indexing lug 86 discussed above, the compression set packer 10 may be set multiple times at depths in the well that are lower than the initial setting depth of the compression set packer 10.
The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the invention. Accordingly, the protection sought herein is as set forth in the claims below. | Disclosed herein is a method and apparatus for setting a compression seal pack in a well without rotation of the pipe string and setting mandrel. The setting device includes a release device and a moveable member. The release device secures a setting mandrel in a non-engaged position with respect to the seal packer. The moveable member is positionable to a first position, where the setting mandrel is locked in its non-engaged position, and to a second position, where the release device is free and the setting mandrel may move with respect to the seal packer. The method disclosed herein includes coupling the setting device to a compression set packer, positioning a setting mandrel within the seal packer and setting device, positioning the seal packer at the desired location in a well, releasing the setting mandrel from its non-engaged position with respect to the seal packer and lowering the setting mandrel into engagement with said packer to set the packer in the well. | 4 |
This is a division of application Ser. No. 025,040, filed Mar. 29, 1979, and now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to distribution of liquid droplets on a layer of filamentary material, and more particularly to improvements in a method of applying liquid plasticizer to a running tow of filamentary material, especially filamentary filter material which can be used for the manufacture of filter mouthpieces for cigarettes, cigars or cigarillos. Still more particularly, the invention relates to improvements in a method of applying minute droplets of atomized liquid plasticizer (such as triacetin) on a spread out layer or tow of filaments which may constitute cellulose acetate fibers of the type often employed in the manufacture of fillers for filter rod sections which are thereupon subdivided into filter mouthpieces of desired length.
It is already known to propel finely atomized liquid plasticizer against one side of a running tow of filamentary filter material. For example, U.S. Pat. No. 3,387,992 granted June 11, 1968 to Arthur et al. discloses a process and apparatus for propelling droplets of liquid plasticizer against the underside of a running tow of filamentary material by resorting to a hollow disc having several peripheral outlets. Liquid plasticizer is fed into the disc and is propelled through the outlets and against the running tow under the action of centrifugal force. The droplets which penetrate through the normally permeable spread out tow descend onto the upper side of the tow by gravity. The patent to Arthur et al. further discloses the possibility of using two hollow discs, one at each side of the running tow, when the tow is relatively dense or is non-porous or impervious to such an extent as to prevent droplets issuing from a single disc from passing through the material of the tow. Neither of the two proposals insures satisfactory (uniform) application of platicizer, i.e., such application that each and every increment or unit length of the running tow retains a fixed quantity of atomized plasticizer.
Commonly owned British Pat. No. 1,392,063 discloses a modified apparatus wherein a nozzle sprays liquid plasticizer against one side of the running tow and the other side of the tow slides along a stationary plate so that all droplets which penetrate through the tow are intercepted by the plate and are swept away by the filaments of the tow. Such apparatus insures more satisfactory distribution of plasticizer in successive unit lengths of the tow; however, its application in filter rod making or like machines is limited due to the fact that certain types of filamentary material cannot withstand continuous rubbing against a stationary surface.
OBJECTS AND SUMMARY OF THE INVENTION
An object of the invention is to provide a novel and improved method which insures uniform or practically uniform application of atomized liquid plasticizer to successive unit lengths of a running tow of filamentary material.
Another object of the invention is to provide a method according to which uniform application of atomized plasticizer to successive unit lengths of the running tow is insured in spite of the fact that the filaments of the tow need not rub against a stationary surface.
A further object of the invention is to provide a method of uniformly applying liquid plasticizer to successive unit lengths of a running tow even if the speed of the tow varies within a rather wide range.
An additional object of the invention is to provide a method which insures that portions of filaments in a running tow are plasticized without any or with negligible waste in the material of the plasticizer.
The invention resides in the provision of a method of applying droplets of liquid plasticizing to successive increments of a running foraminous tow of filamentary material. The method comprises the steps of transporting the tow lengthwise along a predetermined path (e.g., along a substantially horizontal path), propelling droplets of liquid plasticizer against successive increments of the running tow at one side of the path (preferably at the upper side if the path is substantially horizontal) whereby certain droplets adhere to the filamentary material and the remaining propelled droplets penetrate through the foraminous tow to the other side of the path, and propelling at least some of such remaining droplets against successive increments of the running tow at the other side of the path.
If the transporting step comprises conveying the tow at a variable speed, the method preferably further comprises the steps of varying the quantity of plasticizer which is propelled against the running tow at the one side of the path as a function of variations of the speed of the row so that the quantity of plasticizer which is propelled against successive unit lengths of the tow at the one side of the path remains at least substantially constant.
The method preferably further comprises the steps of interrupting the propulsion of droplets against the tow at both sides of the path in automatic response to interruption of the transporting step.
The method preferably also includes the steps of supplying liquid plasticizer to the one side of the path in the form of at least one continuous stream and atomizing successive increments of the stream or streams in the course of the first propelling step. Such atomizing can be achieved by resorting to a rotary brush which is installed at the one side of the path and whose bristles atomize successive increments of the stream or streams and propel the droplets of atomized plasticizer against the running tow. A similar brush can be utilized at the other side of the path to propel some or all of the remaining droplets (i.e., at least some of those droplets which have penetrated through the foraminous tow) against the tow at the other side of the path.
The apparatus which can be used for the practice of the above outlined method preferably comprises a housing which intercepts the remaining droplets of liquid plasticizer at the other side of the path and directs the gathered droplets into the range of bristles on the respective brush.
The transporting step preferably includes stretching the filamentary material in the longitudinal direction of the tow. This can be achieved by installing the plasticizer applying apparatus between two pairs of advancing rolls which are driven at different peripheral speeds so that the filaments of the tow are under tension during travel between the two brushes.
The novel features which are considered as characteristic of the invention are set forth in particular in the appended claims. The apparatus itself, however, both as to its construction and its mode of operation, together with additional features and advantages the improved method, will be best understood upon perusal of the following detailed description of certain specific embodiments with reference to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a partly diagrammatic and partly central longitudinal vertical sectional view of an apparatus which can be used for the practice of the method; and
FIG. 2 is a transverse vertical sectional view as seen in the direction of arrows from the line II--II of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The apparatus which is shown in FIG. 1 is installed in a filter rod making machine, e.g., a machine of the type disclosed in the aforementioned British Pat. No. 1,392,063 or in the corresponding U.S. Pat. No. 4,132,189 granted Jan. 2, 1979 to Heinz Greve et al. The tow 1 is withdrawn from a bale and is caused to pass through one or more banding devices which spread out the tow to convert the latter into a wide foraminous layer of relatively movable filaments. The means for transporting the tow 1 lengthwise comprises several sets of driven-rolls including the rolls 23 and 24 which are shown in FIG. 1 and define an elongated horizontal or nearly horizontal path along which the layer or tow 1 is advanced in the direction of arrow 2. The peripheral speed of the front rolls 23 exceeds the peripheral speed of the rear rolls 24 so that the filaments (e.g., acetate fibers) of the tow 1 are stretched in the longitudinal direction of the tow and may be nearly or exactly parallel to each other, depending on the difference between the peripheral speed of the rolls 23 and 24.
The apparatus further comprises a housing 12 which is disposed between the rolls 23, 24 and has an inlet opening 12A for admission of successive increments of the running tow 1 and an aligned outlet opening 12B where the tow leaves the housing on its way toward the nip of the transporting rolls 23. The housing 12 is installed at a plasticizer applying station 3 and confines a first or upper propelling device 4 which is a cylindrical brush having a horizontal drive shaft 4a and a set of radially outwardly extending flexible bristles 5. The housing 12 further accommodates a second or lower propelling device 8 which is a cylindrical brush having a horizontal drive shaft 8a and a set of radially outwardly extending flexible bristles 9.
The means 6 for supplying a stream of liquid plasticizer (e.g., triacetin) into the range of the bristles 5 from a vessel 17 or another suitable source comprises a conduit 15 which contains a pump 16 and admits successive increments of the liquid stream into a manifold 18a secured to or made integral with the upper portion of the housing 12. The stream which is admitted via conduit 15 is divided into several smaller streamlets which flow through the bores or ports 18 (only one shown) of the manifold 18a and are atomized by the tips of the orbiting bristles 5. The bores 18 can be replaced with an elongated slit which extends in parallelism with the axis of the brush 4 to insure uniform distribution of liquid plasticizer to all of the bristles 5. The droplets 7 of atomized plasticizer are propelled against the upper sides of successive increments of the spread out tow 1 in the housing 12 whereby certain droplets adhere to the filaments and the remaining droplets pass through the foraminous tow to be intercepted and gathered in the lower part of the housing 12. The gathered droplets flow into a trough-shaped lower end portion 12a of the housing 12. The portion 12a surrounds the lower half of the brush 8, and the gathered body of liquid plasticizer is atomized by the bristles 9 which propel droplets 11 of plasticizer against successive increments of the running tow 1 at the underside of the elongated path which extends between the openings 12A and 12B. The action of the banding device or devices (shown at 7 and 8 in FIG. 1 of the aforementioned British Pat. No. 1,392,063) is such that, as a rule, the permeability of the spread out tow 1 invariably suffices to enable a certain percentage of droplets 7 to penetrate through the running tow and to accumulate in the lower part of the housing 12. The likelihood of penetration of some droplets 7 through the tow 1 is especially pronounced when the banding action is not entirely uniform, i.e., when relatively dense longitudinally extending strip-shaped portions or streaks of the tow alternate with thinner and hence more porous strip-shaped portions. It has been found that the provision of the second propelling device (brush 8) opposite the brush 4 contributes significantly to uniformity of the plasticizing action, i.e., the quantity of liquid plasticizer which is applied to successive unit lengths of the running tow is uniform or practically uniform. Furthermore, the filaments of the tow 1 need not rub against one or more stationary surfaces because the width of the openings 12A and 12B can be readily selected in such a way that the filaments need not contact the housing 12 during travel toward or away from the space between the rotating brushes 4 and 8.
The walls of the lower part of the housing 12 slope toward the trough-shaped lower end portion 12a so that the latter collects all droplets 7 which have penetrated through the tow 1 and maintains the thus accumulated recovered body of liquid plasticizer in the range of the orbiting bristles 9. In normal operation, the brush 8 can atomize all of the liquid which accumulates in the lower end portion 12a of the housing 12. Moreover, the gathered body of liquid plasticizer is atomized practically without delay and the atomized particles or droplets 11 are propelled against the undersides of successive increments of the tow 1 to insure a more uniform plasticizing action. Those droplets 11 which fail to adhere to the filaments of the running tow 1 descend into the lower end portion 12a or are entrained by the ascending droplets 11.
The lowermost part of the end portion 12a has an outlet 13 which is normally sealed by an adjustable closing device 14, preferably a solenoid-operated valve which can be caused to close when the drive shafts 4a, 8a begin to rotate the respective brushes and to open in automatic response to stoppage of the shafts 4a and 8a, i.e., as soon as the propelling action of the brushes 4 and 8 is interrupted or terminated. This prevents stagnation of gathered liquid plasticizer in the trough-shaped portion 12a of the housing 12. When the valve 14 is open, the outlet 13 admits liquid plasticizer into a conduit 10 which returns the liquid into the source 17.
The pump 16 is preferably a variable-delivery pump adapted to cause a stream of liquid plasticizer to flow into the manifold 18a at a rate which is a function of the speed of lengthwise movement of the tow 1. This insures that each unit length of the tow 1 receives the same quantity of atomized plasticizer regardless of whether the speed of lengthwise movement of the tow (arrow 2) is increased or reduced. For example, the pump 16 can derive motion from a variable-speed prime mover 25 (e.g., a DC-motor) for the transporting rolls 23 and 25. If the pump 16 is driven by a separate variable-speed motor, the speed of the motor 25 is monitored by a tachometer generator which transmits appropriate signals to the amplifier for the discrete pump motor. Synchronization of the rate of delivery of liquid plasticizer to the manifold 18a with the speed of the tow 1 insures that the quantity of plasticizer which is applied per unit length of the tow 1 does not change when the tow is accelerated or decelerated, for example, when a monitoring device ascertains that the resistance which the filler of the filter rod offers to axial flow of a gas therethrough deviates from a desired value.
FIG. 2 shows a prime mover 21 which transmits torque to the drive shafts 4a and 8a of the brushes 4 and 8. It is preferred to employ a prime mover 21 which is a constant-speed motor. The motor 21 is automatically arrested in response to stoppage of the tow 1. To this end, the apparatus comprises a sensor 22 which is associated with the transporting rolls 23 or 24 or with the motor 25 and transmits a signal to arrest the motor 21 as soon as the lengthwise movement of the tow 1 is terminated. The sensor 22 can also monitor the tow 1 to transmit a signal when the tow is arrested. Furthermore, the sensor 22 transmits signals to the circuit of the solenoid 14a of the valve (via conductor means 26) to open the valve 14 when the motor 21 is arrested. Still further, the element 22 may constitute a two-position switch which is in circuit with the motor 25 and solenoid 14a. In one of its positions, the switch completes the circuit of the motor 25 and deenergizes the solenoid 14a so that the valve 14 closes and prevents the flow of liquid plasticizer from the trough-shaped lower end portion 12a of the housing 12 into the vessel 17. In the other position of the switch, the valve 14 is open and the motor 25 is arrested. The conductor means 27 denotes the operative connection between the monitoring element 22 and the motor 21, and the conductor means 28 denotes the operative connection between the element 22 and the motor 25.
An advantage of the outlet 13, valve 14 and conduit 10 is that the lower end portion 12a of the housing 12 cannot accumulate a relatively large body of liquid plasticizer while the brush 8 is idle. In the absence of the valve 14, the bristles 9 of the brush 8 would abruptly propel a large quantity of atomized plasticizer against the underside of the tow 1 in immediate response to renewed starting of the motor 21. The valve 14 closes automatically as soon as the motors 21 and 25 are started, i.e., as soon as the tow 1 begins to move lengthwise.
Stoppage of the brushes 4 and 8 in immediate response to interruption of lengthwise movement of the tow 1 is desirable and advantageous because excessive accumulations of plasticizer in certain portions of the tow 1 could interfere with proper operation of the filter rod making machine.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readilly adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic and specific aspects of our contribution to the art and, therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the claims. | A spread out foraminous tow of tensioned filamentary filter material is transported through a housing between an upper and a lower rotating cylindrical brush. The upper brush propels atomized liquid plasticizer against the upper side of the tow whereby a certain amount of plasticizer penetrates through the tow and is gathered in the housing within the range of bristles on the lower brush which propels the gathered plasticizer against the underside of the tow. The rate of feed of plasticizer to the upper brush is varied in response to changes in the speed of the tow, and the brushes are arrested when the transporting rolls for the tow are brought to a standstill. The lower portion of the housing constitutes a trough which surrounds the lower half of the lower brush and from which the gathered plasticizer is evacuated when the brushes are idle. | 3 |
FIELD
Embodiments herein relate to hydraulic fracturing including proppant placement.
BACKGROUND
A standard approach to optimization under uncertainty is based on original Markovitz portfolio theory and more recently was tailored to oilfield applications with modified definition of efficient frontier (U.S. Pat. No. 6,775,578 B. Couet, R. Burridge, D. Wilkinson, Optimization of Oil Well Production with Deference to Reservoir and Financial Uncertainty, 2004) and Value of Information (Raghuraman, B., Couët, B., Savundararaj, P., Bailey, W. J. and Wilkinson, D.: “Valuation of Technology and Information for Reservoir Risk Management,” paper SPE 86568, SPE Reservoir Engineering, 6, No. 5, October 2003, pp. 307-316). However, these methods employ mean-variance approach and do not provide a much needed insight into the inherent uncertainty of the optimized model and, more importantly, any quantitative guidance on reducing this uncertainty, which is very desirable from the operational point of view.
Application of Global Sensitivity Analysis to address various problems arising in oilfield industry has been described for reservoir performance evaluation, for measurement screening under uncertainty, for pressure transient test design and interpretation, for design and analysis of miscible fluid sampling clean-up, and for targeted survey design. However, these disclosures were focusing only on quantifying uncertainty in specific physical quantities and using that analysis to gain a new insight about the measurement program design and interpretation. The references did not look at optimization of the underlying physical processes.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a workflow summarizing adaptive GSA-optimization approach.
FIG. 2 is a workflow summarizing the inputs and outputs for the example proppant placement and fracture conductivity calculation.
FIG. 3 is a schematic diagram providing a definition of cycle phase shift and perforation spacing for two injectors from a vertical well into a vertical fracture.
FIG. 4 is a schematic diagram illustrating the length of the cycle and length of the proppant-laden portion.
FIG. 5 is a schematic diagram for one example considered. The final placed distribution of proppant is also influenced by mixing between the proppant-laden and clean fracturing fluid portions. The mixing process is characterized by a single mixing length.
FIG. 6 is a workflow illustrating the inputs, outputs, and workflow for the example proppant placement and fracture conductivity calculation.
FIG. 7 is a chart plotting three points of the efficient frontier from the optimization using initial ranges for uncertain variables. Lower values of the objective function (μ−λσ) for increasing values of λ illustrate the inherent penalty for risk.
FIG. 8 is a chart plotting three points of the efficient frontier from the optimization using GSA-updated ranges for uncertain variables. Initial efficient frontier points are also included for comparison. Lower values of the objective function (μ−λσ) for increasing values of λ illustrate the inherent penalty for risk.
SUMMARY
Embodiments herein relate to apparatus and methods for delivering and placing proppant to a subterranean formation fracture including identifying control variables and uncertain parameters of the proppant delivery and placement, optimizing a performance metric of the proppant delivery and placement under uncertainty, calculating sensitivity indices and ranking parameters according to a relative contribution in total variance for an optimized control variable, and updating a probability distribution for parameters, repeating optimizing comprising the updated probability distribution, and evaluating a risk profile of the optimized performance metric using a processor. Some embodiments may deliver proppant to the fracture using updated optimized values of control variables.
DETAILED DESCRIPTION
This disclosed approach combines Global Sensitivity Analysis (Saltelli et al., 2004) with optimization under uncertainty in an adaptive workflow that results in guided uncertainty reduction of the optimized model predictions. Embodiments herein relate to a general area of optimization under uncertainty. The application of the disclosed method relates to well stimulation and hydraulic fracturing in particular. Heterogenous Proppant Placement (HPP) strategies seek to increase propped fracture conductivity by selectively placing the proppant such that the fracture is held open at discrete locations and the reservoir fluids can be transported through open channels between the proppant. Schlumberger Technology Corporation provides well services that include introducing proppant into the fractures in discrete slugs (Gillard, M. et al., 2010; Medvedev, A. et al., 2013). For the purposes of technology development and optimal implementation, tools must be developed for predicting the conductivity of the heterogeneously propped fractures during the increase in closure stress resulting from flow-back and subsequent production. In the presence of uncertainty in formation properties, optimal HPP strategies will result in inherently uncertain predictions of fracture conductivity. Herein, we describe a method to reduce uncertainty in predicted fracture conductivity and identify an optimal HPP operational strategy for an acceptable level of risk.
Embodiments herein show how a predictive physics-based HPP model is used to estimate fracture conductivity under a given closure stress. The input parameters of the model are divided into control variables (operational controls may include dirty pulse fraction, injector spacing, proppant Young's modulus etc.) and uncertain variables (uncertain formation properties may include Poison ratio, Young's modulus, proppant diffusion rates etc.). The model is first optimized to obtain values of control variables maximizing mean fracture conductivity (for a given closure stress) under initial uncertainty of formation properties. An efficient frontier may be obtained at this step to characterize dependence between the optimized mean value of fracture conductivity and its uncertainty expressed by the standard deviation. Global sensitivity analysis (GSA) is then applied to quantify and rank contributions from uncertain input parameters to the standard deviation of the optimized values of fracture conductivity. Uncertain parameters are ranked according to their calculated sensitivity indices and additional measurements can be performed to reduce uncertainty in the high-ranking parameters. Constrained optimization of the model with reduced ranges of uncertain parameters is performed and a new efficient frontier is obtained. In most cases, the points of the updated efficient frontier will shift to the left indicating a reduction in the risk associated with achieving the desired fracture conductivity. The disclosed method provides an adaptive GSA-optimization approach that results in uncertainty reduction for optimized HPP performance.
The workflow is applied for HPP optimization, which requires a capability for the prediction of the placement of proppant and the resultant conductivity within a potentially rough fracture under any prescribed closure stress. This capability receives inputs relating to the pumping schedule, proppant properties and formation properties and provides a prediction of the achieved fracture conductivity. For example, in our demonstration, we utilize the methods in U.S. Provisional Patent Application Ser. No. 61/870,901, filed Aug. 28, 2013 which is incorporated by reference herein in its entirety where the combination of fracture and proppant is represented by a collection of asperities arranged upon a regular grid attached to two deformable half-spaces. The deformation characteristics of the deformable half-spaces are pre-calculated, allowing for very efficient prediction of the deformation of the formation on either side of the fracture. The method automatically detects additional contact as the fracture closes during increasing closure stress (such as during flow-back and production). In addition, the asperity mechanical response is modified to account for the combined mechanical response of the rough fracture surface and any proppant that may be present in the fracture at that location. In this way, the deformation of any combination of fracture roughness and heterogeneous arrangement of proppant in the fracture can be evaluated. The deformed state is then converted into a pore network model which calculates the conductivity of the fracture during flow-back and subsequent production. Embodiments herein allow one to progressively reduce uncertainty in the performance of an optimized HPP operational strategy by iterative reduction of uncertainty in identified properties of the reservoir.
Optimization Under Uncertainty and Global Sensitivity Analysis
Let us consider a general case when the underlying physical process is modeled by a function y=f(α, β), where α={α 1 . . . α N } and β={β 1 . . . β M } are two sets of parameters. Here, α represents the set of control parameters (to be used in optimization), and β denotes the set of uncertain parameters. Mathematically, β's are considered to be random variables represented by a joint probability density function (pdf). Therefore, for each vector of control variables α, the output of the model is itself a random variable with its own pdf (due to uncertainty in β). A mean-variance approach is commonly used for optimization, i.e. a function of the form
F =μ(α,β)−λσ(α,β)
where μ, and σ are the mean and standard deviation of the output y of the numerical simulation, and λ is a non-negative parameter defining a tolerance to risk (uncertainty). The optimization problem can then be formulated as
max
α
F
(
α
,
β
)
For each optimization iteration, a sample of the random vector β is chosen, and the values of y(α, β) are first computed using this sample for a given a and then averaged over β.
Various optimization algorithms can then be used to find the optimal value of α. The process of optimizing under uncertainty will lead to a set of parameters α opt that provide the optimum of the objective function F. Therefore, an optimized model is now available:
y=f (α opt ,β)
Note that the optimized model still has inherent uncertainty due to the uncertainty in parameters β.
A set of solutions to the optimization problem can be plotted in (μ, σ) coordinates, where optimal points corresponding to pre-defined values of λ will form an efficient frontier ( FIG. 7 ). This represents a risk profile of the underlying modeled process. The positive slope of the frontier illustrates the penalty for additional uncertainty (risk).
From the operational perspective, the goal is to reduce this risk while maintaining the same level of expected performance (represented by μ). In order to reduce the uncertainty, one needs to understand where it is coming from. Therefore, a quantitative link between uncertainties in input parameters (β) and uncertainty in the output is desirable. This link can be quantified using Global Sensitivity Analysis based on variance decomposition.
Global sensitivity analysis (Saltelli et al., 2004) based on variance decomposition is used to calculate and apportion the contributions to the variance of the measurement signal V(Y) from the uncertain input parameters {X i } of the subsurface model.
For independent {X i }, the Sobol' variance decomposition (Sobol', 1993) can be used to represent V(Y) as
V ( Y )=Σ i=1 N V i +Σ 1≦i<j≦N V ij + . . . +V 12 . . . N , (1)
where V i =V[E(Y|X i )] are the variance in conditional expectations (E) representing first-order contributions to the total variance V(Y) when X i is fixed i.e., V(X i )=0. Since we do not know the true value of X i a priori, we have to estimate the expected value of Y when X i is fixed anywhere within its possible range, while the rest of the input parameters {X ˜i } are varied according to their original probability distributions. Thus,
S 1 i =V i /V ( Y )
is an estimate of relative reduction in total variance of Y if the variance in X i is reduced to zero.
Similarly, V ij =V[E(Y|X i , X j )]−V i −V j is the second-order contribution to the total variance V(Y) due to interaction between X i and X j . Notice, that the estimate of variance V[E(Y|X i , X j )] when both X i and X j are fixed simultaneously should be corrected for individual contributions V i and V j .
For additive models Y(X), the sum of all first-order effects S1 i is equal to 1. This is not applicable for the general case of non-additive models, where second, third and higher-order effects (i.e., interactions between two, three or more input parameters) play an important role. The contribution due to higher-order effects can be estimated via total sensitivity index ST:
ST i ={V ( Y )− V[E ( Y|X ˜i )]}/ V ( Y ),
where V(Y)−V[E(Y|X ˜i )] is the total variance contribution from all terms in Eq. 1 that include X i . Obviously, ST i ≧S1 i , and the difference between the two represents the contribution from the higher-order interaction effects that include X i .
There are several methods available to estimate S1 i and ST i (see (Saltelli et al., 2008) for a comprehensive review).
In one embodiment, we apply Polynomial Chaos Expansion (PCE) [Wiener, 1938] to approximate the underlying optimized function y=f(α opt ,β). The advantage of applying PCE is that all GSA sensitivity indices can be calculated explicitly once the projection on the orthogonal polynomial basis is computed (Sudret, 2008).
In another embodiment, GSA sensitivity indices can be calculated using an algorithm developed by Saltelli (2002) that further extends a computational approach proposed by Sobol' (1990) and Homma and Saltelli (1996). The computational cost of calculating both S1 i and ST i is N(k+2), where k is a number of input parameters {X i } and N is a large enough number of model calls (typically between 1000 and 10000) to obtain an accurate estimate of conditional means and variances. However, with underlying physical model taking up to several hours to run, this computational cost can be prohibitively high. Therefore, we can use proxy-models that approximate computationally expensive original simulators. Quasi-random sampling strategies such as LPτ sequences (Sobol, 1990) can be employed to improve the statistical estimates of the computed GSA indices.
Once sensitivity indices are computed, uncertain β-parameters can be ranked according to values of S 1 . Parameters with the highest values of S 1 should be selected for targeted measurement program. Reduction in uncertainty of these parameters will result in largest reduction in uncertainty of predicted model outcome. Parameters with lowest values of ST (typically, below 0.05) can be fixed at their base case value, thus reducing dimensionality of the underlying problem and improving the computational cost of the analysis.
The summary of the proposed general workflow is given in FIG. 1 .
The main steps include:
1. Identify control variables (α) and uncertain parameters (β). If applicable, define ranges for control variables. Define probability distribution functions (pdfs) for uncertain parameters. 2. Perform optimization under uncertainty (max F (α, β), where F=μ−λσ) and construct relevant points on the efficient frontier for various values of λ. 3. For a given point on the efficient frontier (defined by prescribed value of λ and corresponding values of control parameters α λ ), calculate GSA sensitivity indices and rank uncertain parameters β according to values of S 1 . 4. Perform additional measurements to reduce uncertainty of parameters β with high values of S 1 and redefine pdfs for those parameters. 5. Optional: fix values of parameters β with low (e.g., below 0.05) values of ST to reduce dimensionality of the optimization problem. 6. Perform steps 2-5 until acceptable level of risk is achieved or until the decision is made that the desired level of performance cannot be achieved with the acceptable level of risk.
Illustrative Example: HPP Optimization Under Uncertainty
We now describe the application to a problem of HPP optimization demonstrating the method.
The underlying physical model along with the methods and numerical tools developed to simulate it are disclosed in “Method for Predicting Heterogeneous Proppant Placement and Conductivity” (U.S. Provisional Patent Application Ser. No. 61/870,901, filed Aug. 28, 2013 which is incorporated by reference above). Below we provide a short description of the main steps involved in calculating fracture conductivity resulting from HPP.
FIG. 2 shows a flow diagram highlighting the inputs and outputs utilized in our specific example of fracture conductivity when considering the heterogeneous placement of proppant from a vertical well intersecting a vertical hydraulic fracture as depicted in FIG. 3 . In this instance, the heterogeneity of proppant in the fracture is achieved through a combination of pulsing of the proppant into the fracture (see FIG. 4 ) and mixing phenomena (see FIG. 5 ) that are characterized by a mixing length.
FIG. 6 shows in more detail how the inputs are broken down into those related to the placement of the proppant and those related to the subsequent deformation and conductivity calculations. The complete list of model inputs utilized by the example application is provided in Table 1 along with descriptions of the inputs, their units and initial ranges used in this example.
We start by following the steps of the workflow disclosed in FIG. 1 .
Step 1. Identify control variables (α) and uncertain parameters (β) and define their ranges and probability distributions.
Control variables (α) include:
1. Injector spacing
2. Pumping rate
3. Full cycle length
4. Proppant pulse length
5. Injector phase shift
6. Proppant Young's modulus
7. Proppant permeability (parameter was fixed in this study since the dominating flow mechanism in successful HPP job should be though the channels formed between the proppant pillars rather than through the proppant itself)
Ranges for control variables are given in Table 1. FIG. 4 illustrates some of these variables related to heterogeneous placement of proppant and consequently some systems can accommodate a pumping schedule that includes variations in proppant concentration with time.
Uncertain variables (β) include:
1. Fracture aperture during placement
2. Proppant mixing length
3. Formation Young's modulus
4. Formation Poisson ratio
Ranges for uncertain variables are given in Table 1. All variables were assumed to be uniformly distributed, except for “Proppant mixing length” that was assumed to be uniformly distributed on a log scale.
TABLE 1 List of inputs for fracture conductivity calculation applied to injection into a vertically oriented fracture from a vertical well. Input Description Units Range Injector Vertical distance between Length (m) 0.5-3 spacing injectors Pumping Volume per 0.1-0.5 rate unit time (bpm) Full cycle Length in time of repeated Time (s) 15-25 length cycle of heterogeneous injection Proppant Fraction of total injection Non- 0.25-0.75 pulse length period dedicated to dimensional proppant injection Injector The systematic delay be- Non- 0-1 phase shift tween the cycles of the dimensional injectors (as fraction of total cycle length) Fracture Fracture assumed to have Length (mm) 3-7 aperture constant aperture during during displacement for this placement demonstration. Proppant The permeability of the Length*Length fixed at permeability permeability can be stress (m 2 ) 10 −10 under stress dependent. In this demonstration it was assumed constant. Proppant Characteristic length scale Length (m) 0.001-0.25 mixing over which proppant and length clean fracturing fluid mix during placement Proppant Assumed elastic constant Stress (MPa) 50-500 Young's characterizing compression modulus of proppant. Formation Stress (GPa) 5-50 Young's modulus Formation Non- 0.15-0.35 Poisson dimensional ratio Closure Stress (MPa) 0.1-30 stress levels
Step 2. Perform optimization under uncertainty (max F (α, β), where F=μ−λσ) and construct relevant points on the efficient frontier for various values of λ.
The underlying quantity to be optimized is fracture conductivity at a predefined closure stress (20 MPa in this example). In general, the objective function can be based on other performance metrics of proppant delivery and placement in the fracture including total hydrocarbon produced through the fracture, hydrocarbon production rate, and a financial indicator characterizing profitability of the fracturing job. Results of the optimization step comprise a risk profile shown in FIG. 7 . Corresponding values of mean, standard deviation for three λ points along with P10-P50-P90 estimates for facture conductivity corresponding to these three operational scenarios are given in Table 2.
TABLE 2 Results of optimization with initial uncertainty. λ = 0 λ = 1 λ = 2 Mean fracture conductivity (D · m) 248.15 232.05 193.6 Mean fracture conductivity (log 10) −9.605 −9.634 −9.713 Standard deviation (log10 cycles) 1.21 1.15 1.10 P90 (D · m) 2.21 2.79 2.83 P50 (D · m) 562 507 408 P10 (D · m) 4582 3619 2622
Step 3. For a given point on the efficient frontier (defined by prescribed value of λ and corresponding values of control parameters α λ ), calculate GSA sensitivity indices and rank uncertain parameters β according to values of S1.
We apply Polynomial Chaos Expansion approach to calculate GSA sensitivity indices for optimized models corresponding to values λ=0, 1, 2. The values for first-order sensitivity index (S1) and total sensitivity index (ST) for each uncertain parameter β are given in Table 3. For all three optimal points on the efficient frontier, “Proppant mixing length” is responsible for almost 70% of variance in predicted fracture conductivity. The second largest contributor is “Fracture aperture during placement” (15-20% of variance).
TABLE 3 GSA sensitivity indices for optimized models (uncertain parameters ranked according to S1). λ = 0 λ = 1 λ = 2 S1 ST S1 ST S1 ST Proppant mixing length 0.72 0.75 0.69 0.73 0.65 0.70 Fracture aperture during 0.17 0.18 0.17 0.18 0.19 0.20 placement Formation Young's modulus 0.08 0.11 0.09 0.13 0.11 0.15 Formation Poisson ratio 0.00 0.00 0.00 0.00 0.00 0.00
Step 4. Perform additional measurements to reduce uncertainty of parameters β with high values of S 1 and redefine pdfs for those parameters.
Based on results of Step 3, “Proppant mixing length” was identified as a single largest contributor to variance of fracture conductivity at 20 MPa. For illustration, we assume that additional measurements were performed to reduce the uncertainty range of this parameter from 0.001 m-0.25 m (slightly more than two log 10 cycles) to 0.005-0.05 (one log 10 cycle) with uniform distribution on log scale.
Step 5. Optional: fix values of parameters β with low (<0.05) values of ST to reduce dimensionality of the optimization problem.
Analyzing total-sensitivity values, we notice that “Formation Poisson ratio” has values very close to zero. Therefore, fixing this parameter in the middle of its original uncertainty range (0.15-0.35) will not significantly affect the outcome of the subsequent analysis (Sobol, 2001) while improving its computational cost since the dimensionality of the problem will be reduced.
Step 6. Perform optimization step 2 with updated ranges of uncertain parameters.
Results of the optimization step are shown in FIG. 8 . Three points of the initial efficient frontier are also included for comparison. The updated efficient frontier has moved to the left (desired reduction in uncertainty) and slightly up. We note that the vertical direction of the shift in efficient frontier depends on underlying values in the physical quantity of interest (fracture conductivity) in the updated range of the uncertain parameter (Proppant mixing length). Corresponding values of mean, standard deviation for three λ points along with updated P10-P50-P90 estimates for facture conductivity corresponding to these three operational scenarios are given in Table 4. We observe the significant reduction in standard deviation (on log scale) compared to the initial case. The reduction in P10-P90 range on a linear scale is also noticeable.
TABLE 4
Results of optimization with updated
uncertainty ranges (based on GSA).
λ = 0
λ = 1
λ = 2
Mean fracture conductivity (D · m)
743.39
698.31
589.72
Mean fracture conductivity (log 10)
−9.129
−9.156
−9.229
Standard deviation (log10 cycles)
0.68
0.59
0.53
P90 (D · m)
81
109
103
P50 (D · m)
981
943
782
P10 (D · m)
4494
3010
2219
The shift of efficient frontier to the left is expected in most cases. With the rare exception when the local variance underlying of values in the physical quantity of interest in the updated range of the uncertain parameter is higher than that in the initial range. Although even for this exception case, we argue that the disclosed approach provides iterative way to accurately estimate risk-reward profile for a given HPP job and allows one to avoid costly mistakes that would result in an underperforming fracture.
We disclosed a method for adaptive optimization of heterogeneous proppant placement under uncertainty. A predictive physics-based HPP model is used to estimate fracture conductivity under the desired closure stress. The input parameters of the model are divided into control variables and uncertain variables. The model is first optimized to obtain values of control variables maximizing mean fracture conductivity (at given closure stress) under initial uncertainty of formation properties. An efficient frontier may be obtained at this step to characterize the dependence between the optimized mean value of fracture conductivity and its uncertainty expressed by the standard deviation. Global sensitivity analysis is then applied to quantify and rank contributions from the uncertain input parameters to the standard deviation of the optimized values of fracture conductivity. The uncertain parameters are ranked according to their calculated sensitivity indices and additional measurements can be performed to reduce uncertainty in the high-ranking parameters. Constrained optimization of the model with reduced ranges of uncertain parameters is performed and a new efficiency frontier is obtained. In most cases, the points of the updated efficient frontier will shift to the left indicating reduction in risk associated with achieving the desired fracture conductivity. The disclosed method provides an adaptive GSA-optimization approach that results in iterative improvement of estimated risk-reward profile of an optimized HPP job under uncertainty.
Some embodiments may use a computer system including a computer processor (e.g., a microprocessor, microcontroller, digital signal processor or general purpose computer) for executing any of the methods and processes described herein. The computer system may further include a memory such as a semiconductor memory device (e.g., a RAM, ROM, PROM, EEPROM, or Flash-Programmable RAM), a magnetic memory device (e.g., a diskette or fixed disk), an optical memory device (e.g., a CD-ROM), a PC card (e.g., PCMCIA card), or other memory device. The memory can be used to store computer instructions (e.g., computer program code) that are interpreted and executed by the processor. | Apparatus and methods for delivering and placing proppant to a subterranean formation fracture including identifying control variables and uncertain parameters of the proppant delivery and placement, optimizing a performance metric of the proppant delivery and placement under uncertainty, calculating sensitivity indices and ranking parameters according to a relative contribution in total variance for an optimized control variable, and updating a probability distribution for parameters, repeating optimizing comprising the probability distribution, and evaluating a risk profile of the optimized performance metric using a processor. Some embodiments may deliver proppant to the fracture using updated optimized values of control variables. | 4 |
CROSS REFERENCE TO A RELATED APPLICATION
This application claims the benefit of U.S. Provisional Patent Application No. 60/368,773 filed 29 Mar. 2002.
FIELD OF THE INVENTION
This invention relates to a modular system having at least one bioreactor for the anaerobic treatment of waste water and a bioreactor support module that houses support equipment for operating one or more bioreactors.
BACKGROUND OF THE INVENTION
Anaerobic waste water treatment provides a means for converting dissolved organic waste into methane and carbon dioxide. More particularly, anaerobic waste water treatment is often referred to as a pre-treatment process since the discharge from an anaerobic waste water treatment process often needs further treatment prior to discharge into the environment. Dissolved organic waste in a volume of waste water is often measured by “chemical oxygen demand” or “COD”. COD is usually given as a unit weight per unit volume or may be given as a unit weight in a given time period to rate the treatment capacity of a facility. COD reflects the amount of organic material by unit weight present in a unit volume of water.
An anaerobic waste water treatment process is particularly advantageous because only a small percentage of carbon and nitrogen in the organic waste is converted by the anaerobic microbial cultures into new cell mass. This results in far less waste material arising from the excess production of microbes. Moreover, the anaerobic digestion of waste can be conducted within a much smaller volume of space than with an aerobic process. Anaerobic waste water treatment is particularly adapted for treating the waste water produced by alcohol fermentation processes such as might be found in brewery or in a facility that produces fuel grade ethanol. Waste water produced by such facilities generally contains materials which can be most easily digested in an anaerobic process.
Typically, an anaerobic waste water treatment facility includes bioreactors, which are usually tanks having fluidized beds composed of many thousands of microbial granules containing colonies of microbes. These microbial granules are colonies consisting of various organisms. The microscopic organisms in these granules ingest organic waste and convert it primarily into methane and carbon dioxide. Other support equipment regulates the make up and the flow rate of the feed moving into and the products moving out of the bioreactors. Often, in anaerobic waste water treatment systems, some of the liquid product from the bioreactors is discharged from the system as treated water while most of the liquid product from the bioreactors is routed to a recycle tank. The recycle tank in such a system initially receives waste water for treatment and mixes it with recycled, treated water from the bioreactors. A recycle pump conveys the resulting mixture of waste water and recycled treated water to the bioreactors. The recycle tank can also be used as the place for conditioning the temperature, pH, and the nutrient content of the mixture entering the bioreactors in order to maintain the health of the above described microbial organisims. The bioreactors also produce carbon dioxide gas and methane gas. Methane gas does not dissolve in water and so it is collected at the top of the bioreactors. The methane gas can be routed to an outside process to help supply energy to that outside process or it can be flared off.
In the past, anaerobic waste water treatment systems have been constructed on site to meet the waste water treatment needs at that site. Typically, all of the components of the anaerobic waste water treatment system are sized, designed and constructed to meet the needs of the site. Since each component must be placed and installed on site, the cost of adding such a system capable of processing on the order of thousands of pounds of dissolved organic waste per day can be significant. Such a custom designed system would often require significant redesign in order to expand or enlarge a system to process larger amounts of waste. Accordingly, what is needed is a modular system that can be built off site, transported and then installed with a minimum of effort. A modular system is needed having standard support equipment capable of supporting the operation of between one and a significantly larger number of bioreactors so that bioreactors may be added at a later time with little additional cost.
Thus, there has long been a need in the industry, for a modular system for digesting organic waste that can be constructed and mostly assembled off site, transported and then installed at a desired location. There has also been a long felt need in the industry to have a modular system that is expandable to operate between one and a significantly larger number of bioreactors without having to change or modify other basic equipment in the modular system. Still further, there has been a long felt need in the industry to have a system that has its components placed within a small area so that an operator can access those components with an absolute minimum of time and effort.
SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to provide an improved modular, biological, waste treatment system that can be fabricated off site and easily transported to a desired location in a minimum number of transportable units. Another object of this invention is to provide an improved modular anaerobic, biological waste treatment system that has a standard support equipment module including components sized to accommodate one or more bioreactors, so that a system, once installed can be easily and inexpensively expanded to accommodate a larger number of bioreactors thereby multiplying the capacity of the waste treatment system with a minimum of additional cost. Yet another object of this invention is to provide a waste treatment system that has its components placed within a small area so that they are easily and quickly accessible to an operator.
These and other objects of the invention are attained in an improved, modular, anaerobic, waste water treatment system for removing organic waste from waste water to produce treated water or effluent that is suitable for re-use or further treatment prior to release. The system includes a bioreactor support module and at least one anaerobic bioreactor. The bioreactor support module includes components necessary for receiving waste water, mixing the waste water with bioreactor recycle water and otherwise supporting the operation of one or several bioreactors. The bioreactor support module includes a frame sized for over-the-road transport via truck to which is mounted a recycle tank, a recycle pump, a effluent discharge pump, a decarbonator, a bio-gas scrubber, a flare, a nutrient tank and a control panel as well as appropriate in-line level and flow control devices which maintain flow, temperature and pH within the system. The recycle tank receives waste water and formulates a mixture from waste water, recycled treated water produced by the bioreactors and nutrients which are mixed and fed back to the bioreactors. Like the other components in the bioreactor support module, the recycle tank is preferably sized to support the operation of up to six bioreactors but may also be sized to support more bioreactors. Within the nutrient tank, a mixture is formulated that includes nutrients required by the anaerobic organism present in the bioreactors. A nutrient feed pump responds to signals from the control panel, as the control panel monitors the amount of waste water fed into the system and conveys the amounts of nutrients into the recycle tank that are needed to sustain the microbial cultures in the bioreactors. The amount, temperature and pH of the liquid in the recycle tank are also monitored and controlled by the control panel. The control panel responds to values outside pre-determined limits by changing the feed rates in lines leading to the recycle tank. The control panel may activate a valve to introduce a caustic solution into the recycle tank to adjust pH. The control panel may also cause sparge steam to enter the recycle tank to increase recycle tank temperature to a temperature within an optimum range. Accordingly, the control panel functions to insure that the mixture received by the bioreactors from the recycle tank is optimized for the microbial cultures in the bioreactors. The control panel also monitors the level in the recycle tank and adjusts the discharge from the system to maintain a pre-determined level in the recycle tank.
In the preferred embodiment, the recycle pump is sized to feed the mixture from the recycle tank to as many as six anaerobic bioreactors. The bioreactors contain fluidized beds of granular anaerobic bacterial colonies. The mixture from the recycle tank enters each bioreactor at the base of the bioreactor and interacts with the microbial bed as the microbial colonies convert organic waste in the water to methane gas and carbon dioxide. As the granular microbial colonies convert the organic waste, they sprout methane gas bubbles and rise to the top of the bioreactor. Separators situated at the top of each bioreactor return the granules back to the bottom of the bioreactor as they shed their methane gas bubbles. The carbon dioxide that is given off is soluble in water. A gas product consisting mostly of methane gas exits the top of the bioreactor, while treated water flows by gravity from the top of the bioreactors back to the decarbonator which is mounted to the frame of the bioreactor support module.
The decarbonator strips dissolved carbon dioxide from the bioreactor effluent. The effluent that exits the decarbonator is split into a recycle line and a discharge ine. The recycle line carries most of the effluent back to the recycle tank while the discharge line conveys some of the effluent to the effluent discharge pump which discharges the treated effluent.
The gas product venting from the tops of the bioreactors contains mostly methane gas but also contains small amounts of hydrogen sulfide gas. Accordingly, the gas product is piped to a bio-gas scrubber containing iron sponge material that captures the hydrogen sulfide and separates it from the methane gas. Condensate from the bio-gas scrubber is routed back to the recycle tank while the remaining methane gas is either burned off by the bio-gas flare mounted to the frame of the bioreactor support module or is routed to be mixed with other natural gas supplies to augment the energy available for other processes.
As can be seen from the forgoing description, the bioreactor support module carries equipment that encompasses substantially all of the waste water treatment process except the bioreactors. Accordingly, the complex arrangement of components, pumps and interconnecting piping of the bioreactor support module can be assembled in a standardized, manufacturing setting instead of at a construction site. The bioreactor support module can be designed to have standardized interfaces with the facility that it services and with a group of bioreactors that are also located and arranged in a standardized manner.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention and its many attendant objects and advantages will become better understood upon reading the following detailed description of the preferred embodiment in conjunction with the following drawings, wherein:
FIG. 1 is an elevation of the bioreactor support module shown with two bioreactors.
FIG. 2 is a sectional view taken from plane 2 — 2 of FIG. 1 showing primarily the lower level of the bioreactor support module.
FIG. 3 is a sectional view taken from plane 3 — 3 of FIG. 1 showing primarily the upper level of the bioreactor support module as well as additional bioreactors.
FIG. 4A is a process diagram showing the process arrangement of the components that are located in or on the bioreactor support module.
FIG. 4B is a process diagram showing the process equipment directly associated with the bioreactors.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings, wherein like reference numerals identify identical or corresponding elements, and more particularly to FIG. 1 thereof, a modular waste water treatment system 10 is shown including a bioreactor support module 12 and bioreactors 102 A and 102 B.
Bioreactor support module 12 is generally a transportable module. Preferably, bioreactor support module 12 houses all of the control equipment for treatment system 10 , systems for adding needed nutrients and chemicals, pumps for re-circulation and product discharge and heat control systems required to maintain appropriate operating temperatures. Bioreactor support module 12 includes a frame 14 to which is mounted a number of items of equipment. Frame 14 is preferably sized to fit on the trailer bed of a large tractor trailer for highway transport and is preferably fabricated from structural steel. The items of equipment mounted on the upper level of frame 14 may be removed temporarily during highway transport, however, all of the items of equipment mounted on the lower level may be installed in a factory setting prior to highway transport. The major items of equipment mounted to the lower level of frame 14 are a recycle tank 20 , a nutrient tank 30 , a control panel 40 , a discharge pump 110 , a recycle pump 24 and a nutrient pump 32 . A decarbonator 50 , a bio-gas scrubber 60 and a bio-gas flare 70 are mounted to the upper level of frame 14 . However, decarbonator 50 , bio-gas scrubber 60 and bio-gas flare 70 while significantly enhancing the efficiency of the system are not required for the operation of the system.
FIG. 2 , is a sectional view taken from plane 2 — 2 of FIG. 1 showing the lower level of bioreactor support module 12 where a recycle pump 24 , a nutrient pump 32 and a effluent discharge pump 110 are also mounted. FIG. 3 is a sectional view taken from plane 3 — 3 of FIG. 1 showing the upper level of frame 14 . FIG. 3 provides further illustration of the relative positions of decarbonator 50 , bio-gas scrubber 60 and bio-gas flare 70 . In FIG. 3 a line 106 collects and gravity feeds effluent from bioreactors 102 A and 102 B (and additional bioreactors 102 C and 102 D) to decarbonator 50 where carbon dioxide gas is stripped from the treated water. Also in FIG. 3 , a line 108 conveys methane gas from bioreactors 102 A and 102 B (and additional bioreactors 102 C and 102 D) to bio-gas scrubber 60 . Other lines passing between the various components shown in FIG. 1 , FIG. 2 and FIG. 3 are omitted for clarity. The various lines and pipes connecting the various items of equipment shown in FIG. 1 , FIG. 2 and FIG. 3 are diagrammed in FIG. 4 A and FIG. 4 B.
It is an important feature of this modular system that the system lines 106 and 108 , as shown in FIG. 3 include provisions such that they can be easily extended to receive methane and treated water from additional bioreactors 102 C and 102 D which are preferably substantially identical to bioreactors 102 A and 102 B. Although not shown in FIG. 3 , feed pipes leading to the bioreactors 102 A and 102 B would be similarly extended and connected with additional bioreactors 102 C and 102 D. These feed lines and discharge lines can even be further extended to serve two more bioreactors for a total of six bioreactors. Six bioreactors is for practical reasons the preferred maximum number of bioreactors that should be serviced by one bioreactor support module.
Also shown in FIG. 1 is an enclosing structure 90 that extends out between the columns of bioreactors to cover at least the feed piping leading to the bioreactors. Enclosing structure 90 provides sheltered access to the bases of the bioreactors. Operators working in inclement weather will find that sheltered access to all of the components of the system is an important advantage of this novel arrangement.
FIG. 4 A and FIG. 4B should be considered together. They provide a schematic diagram for illustrating the functions of the various components of the system. The components shown in FIG. 4A are located within or on top of bioreactor support module 12 . Decarbonator 50 , bio-gas scrubber 60 and bio-gas flare 70 are located on the upper level of bioreactor support module 12 while recycle tank 20 , nutrient tank 30 as well as all three pumps: recycle pump 24 , nutrient pump 32 and effluent discharge pump 110 are located on the lower level of bioreactor support module 12 . The bioreactors 102 A and 102 B shown in FIG. 4B are located outside the bioreactor support module. Accordingly, almost all of the components shown in FIG. 4 A and FIG. 4B with the notable exception of bioreactors 102 A and 102 B are mounted within or on top of bioreactor support module 12 . One of the major advantages of this invention is that bioreactor support module 12 carries almost all of the equipment needed for the waste water treatment system so that most of the waste water treatment system can be fabricated and assembled in a controlled, efficient factory environment. Another major advantage of this invention is that the equipment mounted within and on top of bioreactor support module 12 is preferably sized to accommodate the operation of up to six bioreactors so that the system can be easily expanded with a minimum of additional cost.
As noted above, FIG. 4A illustrates the operation of equipment situated within and on bioreactor support module 12 . A comparison of FIG. 4 A and FIG. 4B will inform the reader that most of the system components as shown in the relatively crowded FIG. 4A are mounted within or on bioreactor support module 12 . As will be explained in more detail below, support module 12 is designed to support the operation of bioreactors 102 A and 102 B and includes equipment for receiving and conditioning wastewater, supplying that conditioned waste water to the bioreactors at a controlled flow rate and receiving treated water from the bioreactors.
As can be seen in FIG. 4A , wastewater for treatment is received into the system from waste water source 200 via line 200 A. A composite sampler 200 B is used to sample the organic make up of the incoming waste water. Line 200 A carries the entering waste water to recycle tank 20 . Recycle tank 20 also receives a significant portion of the decarbonated, treated water that exists decarbonator 50 via line 50 B. Recycle tank 20 also receives a small amount of condensate from bio-gas scrubber 60 via line 60 A.
Decarbonated, treated water that does not enter recycle tank 20 is discharged from the system by effluent discharge pump 110 to effluent discharge line 300 . This is the treated water suitable for release. Composite sampler 3008 collects samples of the treated water for analysis. The amount of flow leaving in effluent discharge line 300 is roughly equivalent to the amount of flow entering from waste water source 200 .
A constant level is maintained in recycle tank 20 using an arrangement well known in the art. A level indicator 20 L senses the level of fluid in recycle tank 20 and transmits a responsive signal to a control valve 300 B in effluent discharge line 300 A. If the level in recycle tank 20 falls too low, the output of effluent discharge line 300 A is decreased by partially closing valve 300 A which causes more treated water from decarbonator 50 to flow through T fitting 110 A into recycle tank 20 thus increasing the level in recycle tank 20 . Conversely, if the level in recycle tank 20 rises too high, the output of effluent discharge line 300 A is increased by opening of valve 300 A which causes less treated water from decarbonator 50 to flow through T fitting 110 A into recycle tank 20 thus decreasing the level in recycle tank 20 .
Recycle tank 20 also receives other inputs directed toward controlling the nutrient mixture, pH and temperature of the mixture that is fed to the bioreactors. Recycle tank also receives and holds air for decarbonator 50 . Decarbonator fan 50 A blows air into recycle tank 20 which then passes to decarbonator 50 via line 50 B. A steam source 205 provides steam to recycle tank 20 via line 205 A when steam valve 20 E is opened. Steam valve 20 E opens in response to control signals from control panel 40 (FIG. 1 ). Control panel 40 receives temperature signals from temperature sensor and transmitter arrangement 20 D. If the temperature in recycle tank 20 is too low, steam valve 20 E opens to provide steam that is sparged into recycle tank 20 . In a similar way a caustic solution from a caustic solution source is introduced by the action of valve 20 G via line 207 A in response to control panel signals that are responsive to pH measurements taken by pH sensor and transmitter 20 B.
Appropriate concentrations of elements such as nitrogen, calcium, potassium, phosphorus and magnesium are required in small amounts by the biological culture in bioreactors 102 A and 102 B ( FIG. 4A ) for growth and maintenance. Most of these nutrients are supplied to recycle tank 20 from nutrient tank 30 via pump 32 and line 32 A. Nutrient tank 30 receives phosphates from phosphate tank 224 via pump 224 A and line 224 B. The nutrients supplied to recycle tank 20 also include iron chloride from iron chloride tank 222 which is a 55 gallon drum. Iron chloride pump 222 A delivers the iron solution to recycle tank 20 via line 222 B. Other nutrients are added manually to nutrient tank 30 . A fresh water supply 32 B provides fresh water for making up the nutrient mixture in nutrient tank 30 .
Recycle pump 24 provides a constant flow of a resulting diluted waste water having a proper temperature, pH and nutrient mix to bioreactors 102 A and 102 B. As can be seen in FIG. 4B , bioreactors 102 A and 102 B receive the incoming mixture at their bases via line 24 A. The anaerobic granular cultures in bioreactors 102 A and 102 B convert the waste into methane and carbon dioxide as they sprout insoluble methane bubbles and rise to the top of the bioreactors, structures inside the bioreactors facilitate the separation of the methane bubbles from the granules to allow the granules to sink back to the bottom of the bioreactors to begin another cycle. Because waste water is entering each bioreactor from the bottom, treated water must drain from the top of each bioreactor via line 106 to decarbonator 50 . Decarbonator 50 is a means for stripping a substantial portion of the dissolved carbon dioxide gas from the treated water. As noted above, treated, decarbonated water leaving decarbonator 50 either exits the system via effluent discharge pump 110 or re-enters recycle tank 20 . Also as noted above, other bioreactors can be added to bioreactors 102 A and 102 B shown in FIG. 4B by merely extending lines 24 A, 106 and 108 .
Although a small amount of condensate from bio-gas scrubber 60 flows into recycle tank 20 , the primary purpose of bio-gas scrubber 60 is not to supply condensate to recycle tank 20 . The purpose of bio-gas scrubber 60 is to remove small amounts of highly noxious and corrosive hydrogen sulfide gas from the methane produced by bioreactors 102 A and 102 B. Bio-gas scrubber 60 is a means for removing hydrogen sulfide gas from the methane produced by bioreactors 102 A and 102 B. Those skilled in the art can select from a number of processes for performing this function. Bio-gas scrubber 60 receives methane gas from the bioreactors via line 108 . Hydrogen sulfide in the methane gas, in this embodiment, is removed by an iron sponge media inside bio-gas scrubber 60 . The resulting methane gas is then conveyed to bio-gas flare 70 via line 60 E. Bio-gas flare 70 is also supplied by a natural gas source 230 for maintaining a pilot flame and an outside air source 232 to assist combustion. In the alternative, bioreactor methane leaving bio-gas scrubber 60 can be used as a fuel in other plant processes outside the waste water treatment process.
As can be seen from the forgoing description, bioreactor support module 12 encompasses a complex array of process equipment, control systems, pumps, valves and interconnecting lines that function to serve an array of bioreactors. All of the elements encompassed in bioreactor support module 12 which are illustrated in FIG. 4A as well as FIG. 1 , FIG. 2 and FIG. 3 are preferably sized to accommodate an array of bioreactors. The inventors have found that sizing such equipment to support the operation of six bioreactors is economically optimized in terms of initial equipment size and costs and the demands of the market for system expandability. While six or perhaps eight may be a practical limit to the number of bioreactors that may be supported by a single bioreactor support module, the theoretical limit of how many could be accommodated may be much larger.
This arrangement allows the system fabricator to create a standardized design that can be assembled efficiently in a standardized, controlled, assembly process. Because of this, in the market, the costs of oversized equipment for a system supporting only one or two bioreactors is more than offset by the above noted cost savings inherent in assembling a modular system. Because the standardized, modular design can accommodate additional bioreactor units with an absolute minimum of costs, once installed, a system can be easily expanded to greatly multiply its initial capacity. Those skilled in the art will also appreciate how the bioreactor support module portion of the present invention can be designed to have standard interfaces. With standard interfaces, a purchasing facility can easily route their existing lines to meet those interfaces so that the installation of the module can be conducted with an absolute minimum of on-site effort. With standardized interfaces, the module can essentially be plugged into an existing facility with a minimum of effort.
Moreover, the arrangement of the bioreactor support module in combination with the closely spaced side by side pattern of bioreactors as illustrated in FIG. 3 makes it possible to add an enclosing structure 90 (shown in FIG. 1 .). Enclosing structure 90 extends out between the bioreactors to provide sheltered access to the closely spaced bioreactors. This is a significant advantage for operators who must take samples from various points in the process or who may need to open or close valves leading to the bioreactors. The space saving, compact arrangement of equipment within the bioreactor support module and proximate location and close spacing of the bioreactors allows operators to access system equipment with an absolute minimum of walking time and distance. This decreases operator time and effort.
Numerous modifications and variations of these preferred embodiments may occur to those skilled in the art in light of this disclosure. Accordingly, it is expressly to be understood that these modifications and variations, and equivalents thereof, shall be considered to be within the spirit and scope of the invention as defined in following claims: | The modular waste water treatment system receives waste water from a waste water source containing organic waste and produces a treated water effluent. The modular system includes bioreactors and a bioreactor support module. The bioreactors receive a waste water mixture from the bioreactor support module and produce treated water substantially free of organic waste. The bioreactor support module is a transportable unit fabricated upon a frame adapted for transport by a truck upon a public roadway. The bioreactor support module includes items of equipment needed for conditioning waste water for intake by the bioreactors, items of equipment for receiving, processing and discharging treated water from the bioreactors and may include other items of equipment for receiving and processing other byproducts from the bioreactors. The transportable bioreactor support module is sized to support the operation of between one and preferably as many as six bioractors. Accordingly, the modular waste water treatment system can be fabricated off site in a controlled shop environment, transported to a site, placed at a site and even later expanded to include additional bioreactors for increased capacity with a minimum of cost, time and effort. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a travel safety apparatus for a vehicle.
[0003] Priority is claimed on Japanese Patent Application No. 2005-173338, filed Jun. 14, 2005, the content of which is incorporated herein by reference.
[0004] 2. Description of Related Art
[0005] There is conventionally known an anti-collision system for vehicles that uses an object-detecting means such as a radar for detecting the presence of an obstruction in the vicinity of a subject vehicle, estimates the path of travel of the obstruction and the path of travel of the subject vehicle, calculates the possibility of collision between the obstruction and the subject vehicle based on the estimated paths of travel, and, in accordance with the calculated collision possibility, automatically controls the running state of the subject vehicle (such as by controlling vehicle velocity) so as to prevent a collision with the obstruction (refer, for example, to Japanese Unexamined Patent Application, First Publication No. H07-104062).
[0006] Since such an anti-collision system in the prior art serves to prevent collisions solely by controlling the running state of the subject vehicle, in the event of the system judging a collision to be unavoidable based on travel control of the subject vehicle, collision reduction control is performed simply to reduce the impact of a collision, regardless of the possibility of a change in the travel state of the obstruction. As a result, in the event of the obstruction executing appropriate evasive action, excessive or unnecessary travel control ends up being applied to the subject vehicle.
SUMMARY OF THE INVENTION
[0007] The present invention was made in view of the above circumstances, and has as its object to provide a vehicle travel safety apparatus that executes appropriate evasive action when there is the possibility of a collision between a subject vehicle and a moving object in the vicinity of the vehicle.
[0008] A first aspect of the present invention recites a travel safety apparatus for a vehicle, the apparatus including: an object detecting device that detects objects around the vehicle; a first travel path estimating device that estimates a travel path of a moving object among the objects; a velocity calculating device that calculates the velocity of the moving object based on a detection result of the object detecting device; a travel state detecting device that detects a travel state of the vehicle; a second travel path estimating device that estimates the travel path of the vehicle based on a detection result of the travel state detecting device; a collision judgment device that determines whether or not there is a possibility of a collision occurring between the moving object and the vehicle based on an estimated moving object travel path that is estimated by the first travel path estimating device, an estimated vehicle travel path that is estimated by the second travel path estimating device, the velocity of the moving object calculated by the velocity calculating device, and the travel state; and a travel control device that controls the travel of the vehicle when a determination result of the collision judgment device indicates a possibility of a collision occurring, wherein the collision judgment device estimates an ease of evasive action in the event of the moving object avoiding a collision with the vehicle, and the travel control device controls the travel of the vehicle so that the ease of evasive action increases.
[0009] According to the aforementioned vehicle travel safety apparatus, when the travel control device controls the travel of a subject vehicle so as to avoid a collision between a moving object and the subject vehicle or reduce the force of impact when a collision occurs, it performs such control so that the ease of evasive action in the event of the moving object avoiding a collision with the subject vehicle rises. Thereby, even in the event of a collision being judged as unavoidable solely by travel control of the subject vehicle, the possibility of a collision occurring can be reduced due to evasive action on the part of the moving object. In addition, in the event of a collision being judged as avoidable solely by travel control of the subject vehicle, by taking into account the predicted evasive action of the moving object, only a minimal level of required travel control is performed on the subject vehicle. Thus, it is possible to prevent excessive or unnecessary travel control from being executed on the subject vehicle.
[0010] The collision judgment device may estimate the point of collision between the moving object and the vehicle based on the estimated travel path of the moving object, the estimated travel path of the vehicle, the velocity of the moving object, and the travel state, and the travel control device may control the travel of the vehicle so that the vehicle moves away from the collision point and the moving object.
[0011] Executing travel control of the subject vehicle so that the subject vehicle moves away from the point of collision and the moving object can improve the ease of the moving object to take evasive action, raise the possibility of a collision being avoided, and prevent the execution of excessive or unnecessary travel control on the subject vehicle.
[0012] The travel safety apparatus for a vehicle of the present invention may further include a velocity control device that controls a velocity of the vehicle, wherein the collision judgment device may estimate an amount of overlap of the vehicle and the estimated moving object travel path in the width direction of the estimated moving object travel path at the point in time when the moving object is estimated to arrive at the collision point, based on the estimated moving object travel path, the estimated vehicle travel path, the velocity of the moving object calculated by the velocity calculation device, and the travel state, and the velocity control device may control the velocity of the vehicle so that the amount of overlap decreases.
[0013] In this case, controlling the velocity (i.e., acceleration or deceleration) of the subject vehicle so that the amount of overlap between the estimated travel path of the moving object and the subject vehicle in the width direction of the estimated travel path of the moving object decreases can increase the ease of the moving object to take evasive action, and so increase the possibility of a collision being avoided.
[0014] The ease of evasive action may be one in the event of the moving object avoiding a collision with the vehicle by a steering operation. In this case, controlling the travel of the subject vehicle so as to reduce the amount of steering by the steering mechanism of the moving object required to avoid a collision can increase the ease of the moving object to take evasive action, and so increase the possibility of a collision being avoided.
[0015] The vehicle travel safety apparatus of the present invention may further include a velocity control device that controls the velocity of the vehicle, wherein the collision judgment device may estimate the collision point between the moving object and the vehicle based on the estimated travel path of the moving object, the estimated travel path of the vehicle, the velocity of the moving object calculated by the velocity calculation device and the travel state of the vehicle, and calculate an amount of movement when the moving object avoids the vehicle in a lateral direction before arriving at the collision point, and the velocity control device controls the velocity of the vehicle so that the amount of movement decreases.
[0016] In this case, controlling the velocity (i.e., acceleration or deceleration) of the subject vehicle so as to reduce the amount of movement when the moving object moves in the lateral direction by steering of a steering mechanism can increase the ease of the moving object to take evasive action, and so increase the possibility of a collision being avoided.
[0017] At least one of a moving distance in the lateral direction, a yaw rate, a lateral acceleration, and a steering angle of the moving object may be used as the amount of movement. In this case, by equating the amount of movement with at least any one of the moving distance in the lateral direction, the yaw rate, the lateral acceleration, and the steering angle of the moving object, the amount of movement of the moving object can be calculated with good accuracy.
[0018] The ease of evasive action may be one in the event of the moving object avoiding a collision with the vehicle by a braking operation. In this case, controlling the travel of the subject vehicle so as to reduce the braking force when the moving object applies braking by means of a braking device or the like can increase the ease of the moving object to take evasive action, and so as to increase the possibility of a collision being avoided.
[0019] The vehicle travel safety apparatus of the present invention may further include a steering control device that controls steering of the vehicle, wherein the collision judgment device may determine whether or not the moving object is to collide with a side portion of the vehicle based on the estimated moving object travel path, the estimated vehicle travel path, the velocity of the moving object calculated by the velocity calculation device, and the travel state, and the steering control device controls the steering of the vehicle so that the vehicle moves away from the moving object when it is determined that the moving object is to collide with the side portion of the vehicle.
[0020] In this case, controlling the steering of the subject vehicle so as to move away from the moving object can increase the ease of the moving object to take evasive action in the event of avoiding a collision by, for example, decelerating, and so increase the possibility of a collision being avoided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a block diagram showing the constitution of the vehicle travel safety apparatus according to an embodiment of the present invention.
[0022] FIG. 2 is a drawing showing an example of the estimated travel path of an object vehicle in its present travel state and the estimated position of the subject vehicle in the case of maintaining its present travel state.
[0023] FIG. 3 is a drawing showing an example of the estimated travel path of an object vehicle in its present travel state and the estimated position of the subject vehicle in the case of acceleration.
[0024] FIG. 4 is a drawing showing an example of the estimated travel path of an object vehicle in its present travel state and the estimated position of the subject vehicle in the case of deceleration.
[0025] FIG. 5 is a flowchart showing the operation of the vehicle travel safety apparatus shown in FIG. 1 .
[0026] FIG. 6 is a drawing showing an example of the estimated travel path of an object vehicle that turns to the right or to the left and the estimated position of the subject vehicle in the case of maintaining its present travel state.
[0027] FIG. 7 is a drawing showing an example of the estimated travel path of an object vehicle that turns to the right or to the left and the estimated position of the subject vehicle in the case of acceleration.
[0028] FIG. 8 is a drawing showing an example of the estimated travel path of an object vehicle that turns to the right or to the left and the estimated position of the subject vehicle in the case of deceleration.
[0029] FIG. 9 is a flowchart showing the operation of the vehicle travel safety apparatus according to the first modification of the embodiment.
[0030] FIG. 10 is a drawing showing an example of the estimated travel path of an object vehicle in its present travel state and the estimated position of the subject vehicle in the case of turning to move away from the object vehicle.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The vehicle travel safety apparatus according to one embodiment of the present invention shall now be described with reference to the accompanying drawings.
[0032] As shown in FIG. 1 , a vehicle travel safety apparatus 10 according to the present embodiment is mounted in a vehicle that transmits drive power from an internal combustion engine 11 to the drive wheels of the vehicle by means of a transmission 12 such as an automatic transmission (AT) or a continuously variable transmission (CVT), and has a constitution provided with a processing unit 13 , a brake actuator 14 , an external sensor 15 , a vehicle state sensor 16 , and an EPS actuator 17 .
[0033] In addition, the processing unit 13 has a constitution provided with an object vehicle position detection portion 21 , an object vehicle velocity detection portion 22 , an object vehicle travel path estimating portion 23 , a subject vehicle travel path estimating portion 24 , a collision judgment portion 25 , and a travel control portion 26 .
[0034] The external sensor 15 has a constitution provided with a camera consisting of a CCD camera or CMOS camera capable of performing imaging in the visible-light region and infrared region, an image processing portion, a laser-light or millimeter-wave radar, and a radar control portion.
[0035] The image processing portion performs specific image processing such as filtering and binarization of external images in the travel direction of the subject vehicle obtained by imaging of the camera, generates image data consisting of two-dimensionally arranged pixels, and outputs the image data to the processing unit 13 .
[0036] In addition, the radar control portion emits a laser-light or millimeter-wave transmission signal from the radar in an appropriate detection direction (for example, forward in the travel direction), receives a reflected signal produced by the transmission signal being reflected by an object external to the subject vehicle, generates a beat signal by mixing the reflected signal and the transmission signal, and outputs the beat signal to the processing unit 13 .
[0037] The vehicle state sensor 16 has a constitution provided with a velocity sensor that detects the velocity (vehicle velocity) of the subject vehicle; a position sensor that detects the present position and travel direction of the subject vehicle based on a positioning signal such as a global positioning system signal that measures the position of a vehicle using a satellite and a position signal transmitted from an information transmitter on the exterior of the subject vehicle, and moreover the detection result of an appropriate gyro sensor and acceleration sensor; a yaw rate sensor that detects the yaw angle (angle of rotation of the vehicle's center of gravity about the vertical axis) and the yaw rate (angular velocity of the vehicle's center of gravity about the vertical axis); a steering angle sensor that detects the steering angle (magnitude in the direction of steering angle input by the driver) and the actual steering angle corresponding to the steering angle, and sensors for detecting the ON/OFF state of the direction indicators and brakes, as vehicle information of the subject vehicle.
[0038] The object vehicle position detection portion 21 of the processing unit 13 detects a moving object, such as an object vehicle, that exists in the detection area of the camera or radar in the traveling direction of the subject vehicle based on the image data or beat signal input from the external sensor 15 , and calculates the position of the object vehicle.
[0039] The object vehicle velocity detection portion 22 detects the velocity of the object vehicle based on the temporal change of the location of the object vehicle detected by the object vehicle position detection portion 21 .
[0040] The object vehicle travel path estimating portion 23 estimates the travel path of the object vehicle based on the change in position of the object vehicle detected by the object vehicle position detection portion 21 .
[0041] The subject vehicle travel path estimating portion 24 estimates the travel path of the subject vehicle based on the temporal change in the position of the subject vehicle detected by the vehicle state sensor 16 , the running state of the subject vehicle, such as the velocity (vehicle velocity) of the subject vehicle detected by the vehicle velocity sensor, and the yaw rate of the subject vehicle as detected by the yaw rate sensor.
[0042] The collision judgment portion 25 judges whether or not there is a possibility of the subject vehicle and the object vehicle coming into contact or colliding based on the vehicle velocity of the object vehicle input from the object vehicle velocity detection portion 22 , the object vehicle travel path input from the object vehicle travel path estimating portion 23 , the travel path of the subject vehicle input from the subject vehicle travel path estimating portion 24 , and the position of the subject vehicle detected by the vehicle state sensor 16 .
[0043] As shown in FIGS. 2 to 4 , the collision judgment portion 25 estimates the arrival time TR required for an object vehicle Q to arrive at a predicted collision region O, which is the region where an estimated travel path PT of a subject vehicle P and an estimated travel path QT of the object vehicle Q intersect.
[0044] As shown for example in FIG. 2 , the collision judgment portion 25 calculates an amount of overlap L 0 between the estimated travel path QT and an estimated position P 0 of the subject vehicle in the direction along the width direction of the estimated travel path QT. P 0 is the estimated position at the point in time where in the subject vehicle P has traveled over the arrival time TR in the state of having maintained its present drive state (for example, its current velocity v 0 and the like). When there is no overlap between the estimated travel path QT and the estimated position P 0 , the overlap amount L 0 is zero or a negative value.
[0045] Based on the overlap amount L 0 , such as the overlap amount L 0 being greater than zero, the collision judgment portion 25 judges there to be a possibility of the subject vehicle and an object vehicle coming into contact or colliding.
[0046] In the event of judging there to be a possibility of the subject vehicle and the object vehicle coming into contact or colliding, as shown in FIG. 3 , the collision judgment portion 25 computes an amount of overlap L 1 between the estimated travel path QT and an estimated position P 1 of the subject vehicle in the direction along the width direction of the estimated travel path QT. P 1 is the estimated position at the point of the subject vehicle having accelerated over arrival time TR in the state of maintaining a specified acceleration a 1 from the current velocity v 0 in order for the subject vehicle P to move away from the predicted collision region O and the object vehicle Q.
[0047] In addition, as shown in FIG. 4 , the collision judgment portion 25 computes an amount of overlap L 2 between the estimated travel path QT and an estimated position of the subject vehicle P 2 in the direction along width direction of the estimated travel path QT. P 2 is the estimated position at the point of the subject vehicle having decelerated over arrival time TR in the state of maintaining a specified deceleration a 2 from the current velocity v 0 in order for the subject vehicle P to move away from the predicted collision region O and the object vehicle Q.
[0048] Then the collision judgment portion 25 compares overlap amounts L 0 , L 1 , and L 2 for each of the travel states of the subject vehicle P and thereby estimates the ease of the object vehicle Q to take evasive action in the event of avoiding a collision with the subject vehicle P. That is, as the amount of overlap L 0 , L 1 , L 2 becomes smaller, the collision judgment portion 25 judges there to be an increase the ease of the object vehicle Q to take evasive action in the event of avoiding a collision with the subject vehicle P.
[0049] In accordance with the ease of evasive action by the object vehicle that is input from the collision judgment portion 25 , the travel control portion 26 controls the travel of the subject vehicle so that the ease of evasive action increases.
[0050] As shown in FIGS. 2 to 4 , in the event of the ease of the object vehicle Q to take evasive action changing depending on the velocity of the subject vehicle P, the travel control portion 26 , so as to bring about an increase in the ease of evasive action by the object vehicle Q, outputs a control signal to control the drive power of the internal combustion engine 11 , a control signal to control shifting of the transmission 12 , and a control signal to control deceleration by the brake actuator 14 to execute acceleration control or deceleration control of the subject vehicle P.
[0051] The vehicle travel safety apparatus 10 according to the embodiment of the present invention has the aforementioned constitution. The operation of the vehicle travel safety apparatus 10 shall next be described.
[0052] First, in step S 01 shown in FIG. 5 , the travel path of the object vehicle is estimated based on the position of the object vehicle detected from the output of the external sensor 15 , and the travel path of the subject vehicle is estimated based on the travel state of the subject vehicle (such as the vehicle velocity and yaw rate) measured by the vehicle state sensor 16 .
[0053] Then in step S 02 , the arrival time TR required for the object vehicle Q to reach the predicted collision region O, where the estimated travel path PT of the subject vehicle P and the estimated travel path QT of the object vehicle Q intersect is calculated. In addition, the aforementioned amounts of overlap L 0 , L 1 , and L 2 are calculated.
[0054] Next in step S 03 , it is determined whether or not the amount of overlap L 0 is greater than zero. If the determination result is “YES”, the processing proceeds to step S 05 described below.
[0055] If the determination result is “NO”, i.e., it is determined that there is no possibility of the subject vehicle P and the object vehicle Q coming into contact or colliding, the processing proceeds to step S 04 .
[0056] In step S 04 , the execution of the drive control is stopped and the series of processes thereby ends.
[0057] In step S 05 , it is determined whether or not the overlap amount L 0 is greater than the overlap amount L 1 , or whether or not the overlap amount L 0 is greater than the overlap amount L 2 .
[0058] When the determination result is “NO”, i.e., it is determined that the ease of the object vehicle Q to take evasive action in the event of avoiding a collision with the subject vehicle P is higher by the subject vehicle P maintaining its current drive state and the processing proceeds to step S 04 .
[0059] On the other hand, when the determination result is “YES”, the processing proceeds to step S 06 .
[0060] In step S 06 , it is determined whether or not the overlap amount L 1 is smaller than the overlap amount L 2 .
[0061] When the determination result is “NO”, i.e., it is determined that the ease of the object vehicle Q to take evasive action in the event of avoiding a collision with the subject vehicle P is highest when the subject vehicle P travels at a specified deceleration a 2 from the current velocity v 0 , the processing proceeds to step S 07 , and the subject vehicle P is decelerated, whereby the series of processes ends.
[0062] On the other hand, when the determination result is “YES”, i.e., it is determined that the ease of the object vehicle Q to take evasive action in the event of avoiding a collision with the subject vehicle P is highest when the subject vehicle P travels at a specified acceleration a 1 from the current velocity v 0 , the processing proceeds to step S 08 , and the subject vehicle P is accelerated, whereby the series of processes ends.
[0063] As described above, the vehicle travel safety apparatus 10 of the present embodiment controls the velocity (that is, acceleration or deceleration) of the subject vehicle so as to reduce the amount of overlap between the estimated travel path of the object vehicle and the estimated position of the subject vehicle in the direction along the width direction of the estimated travel path of the object vehicle. Thus, it is possible to improve the ease of the object vehicle to take evasive action by velocity control or steering control in the case of avoiding contact or a collision with the subject vehicle.
[0064] Due to the aforementioned action, evasive action by the object vehicle can reduce the possibility of contact or collision occurring even when it is judged that a collision is unavoidable solely based on travel control of the subject vehicle. In addition, in the case of a judgment that a collision is avoidable solely by travel control of the subject vehicle, in accordance with the predicted evasive action by the object vehicle, the minimum travel control required can be performed on the subject vehicle. It is thus possible to prevent excessive or unnecessary travel control from being executed on the subject vehicle.
[0065] In the above-described embodiment, the collision judgment portion 25 , in accordance with the overlap amounts L 0 , L 1 , and L 2 corresponding to the respective travel states of the subject vehicle P, judges whether there is the possibility of the subject vehicle P and the object vehicle Q coming into contact or colliding, and estimates the ease of evasive action in the event of the object vehicle Q avoiding a collision with the subject vehicle P, but the embodiment is not limited thereto. As a first modification example of the aforementioned embodiment, the collision judgment portion 25 , in accordance with the amount of movement when the object vehicle avoids the subject vehicle in the lateral direction at the collision point between the subject vehicle and the object vehicle, may judge whether there is the possibility of the subject vehicle and the object vehicle coming into contact or colliding, and estimate the ease of evasive action in the event of the object vehicle avoiding a collision with the subject vehicle.
[0066] In the first modification example, the collision judgment portion 25 first estimates the estimated travel paths for the subject vehicle and the object vehicle in the case of both maintaining their present travel states. Then, it estimates a collision point CP where there is the possibility of the object vehicle coming into contact or colliding with the subject vehicle at an appropriate time, and estimates the amount of movement when the object vehicle avoids the subject vehicle in the lateral direction with respect to the collision point CP.
[0067] As shown in FIG. 6 , the collision judgment portion 25 computes a rightward travel distance DR and a leftward travel distance DL in the event of the subject vehicle P traveling in the state of having maintained its present drive state (for example, its current velocity v 0 ). The travel distances DR and DL are lateral distances that the object vehicle Q, by turning to the right or left of its travel direction QD by means of its turning mechanism, is required to travel for avoiding contact or a collision with the estimated position P 0 of the subject vehicle at an appropriate time. A lateral direction here means a direction perpendicular to the travel direction of the object vehicle Q, such as the width direction of the object vehicle Q. Then, the smaller of the distances DR and DL (that is, min (DR, DL)) is set as the required steering evasion amount D 0 .
[0068] Based on the required steering evasion amount D 0 , such as the case when the required steering evasion amount D 0 is greater than zero, the collision judgment portion 25 judges there to be a possibility for the subject vehicle and the object vehicle to make contact or collide.
[0069] In the first modification example, as shown in FIG. 6 , the change, in the lateral direction, of the position of the center of the back end portion of the object vehicle Q in the width direction at the point of having avoided contact with the subject vehicle P is set as the distance DR and DL, without being limited thereto. The distances DR and DL may be set with respect to a suitable position of the object vehicle Q.
[0070] When the collision judgment portion 25 has judged there to be a possibility for the subject vehicle and the object vehicle to make contact or collide, as shown in FIG. 7 , it computes a rightward travel distance DR 1 and a leftward travel distance DL 1 in the case of accelerated travel of the subject vehicle P in the state of maintaining a specified acceleration a 1 from the current velocity v 0 in order to move away from the object vehicle Q. The travel distances DR 1 and DL 1 are lateral distances that the object vehicle Q, by turning to the right or left, respectively, of its travel direction QD by means of its turning mechanism, is required to travel for avoiding contact or collision with the estimated position P 1 of the subject vehicle at an appropriate time. Then, the smaller of the distances DR 1 and DL 1 (that is, min (DR 1 , DL 1 )) is set as the required steering evasion amount D 1 .
[0071] In addition, as shown in FIG. 8 , the collision judgment portion 25 computes a rightward travel distance DR 2 and a leftward travel distance DL 2 in the case of decelerated travel of the subject vehicle P in the state of maintaining a specified deceleration a 2 from the current velocity v 0 in order to move away from the object vehicle Q. The travel distances DR 2 and DL 2 are lateral distances that the object vehicle Q, by turning to the right or left, respectively, of its travel direction QD by means of its turning mechanism, is required to travel for avoiding contact or collision with the estimated position P 2 of the subject vehicle at an appropriate time. Then, the smaller of the distances DR 2 and DL 2 (that is, min (DR 2 , DL 2 )) is set as the required steering evasion amount D 2 .
[0072] Then, the collision judgment portion 25 compares the required steering evasion amounts D 0 , D 1 , and D 2 corresponding to each of the travel states of the subject vehicle P and thereby estimates the ease of evasive action in the event of the object vehicle Q avoiding a collision with the subject vehicle P. That is, as the required steering evasion amounts D 0 , D 1 , and D 2 becomes smaller, the collision judgment portion 25 judges there to be an increase in the ease of evasive action in the event of the object vehicle Q avoiding a collision with the subject vehicle P.
[0073] The operation of the vehicle travel safety apparatus 10 according to the first modification example shall next be described.
[0074] First, in step S 11 shown in FIG. 9 , the travel path of the object vehicle is estimated based on the position of the object vehicle detected from the output of the external sensor 15 , and the travel path of the subject vehicle is estimated based on the running state of the subject vehicle (such as the vehicle velocity and yaw rate).
[0075] Then in step S 12 , the required steering evasion amounts D 0 , D 1 , and D 2 are determined in the aforementioned manner.
[0076] Next in step S 13 , it is determined whether or not the required steering evasion amount D 0 is greater than zero. If the determination result is “YES”, the processing proceeds to step S 15 described below.
[0077] If the determination result is “NO”, i.e., it is determined that there is no possibility of the subject vehicle P and the object vehicle Q coming into contact or colliding, and the processing proceeds to step S 14 .
[0078] In step S 14 , the execution of the drive control is stopped and the series of processes thereby ends.
[0079] In step S 15 , it is determined whether the evasion amount D 0 is greater than the evasion amount D 1 , or whether the evasion amount D 0 is greater than the evasion amount D 2 .
[0080] When the determination result is “NO”, i.e., it is determined that the ease of the object vehicle Q to take evasive action in the event of avoiding a collision with the subject vehicle P is higher by the subject vehicle P maintaining its current drive state, and the processing proceeds to step S 14 .
[0081] On the other hand, when the determination result is “YES”, the processing proceeds to step S 16 .
[0082] In step S 16 , it is determined whether or not the evasion amount D 1 is smaller than the evasion amount D 2 .
[0083] When the determination result is “NO”, i.e., it is determined that the ease of the object vehicle Q to take evasive action in the event of avoiding a collision with the subject vehicle P is highest when the subject vehicle P travels at a specified deceleration a 2 from the current velocity v 0 , the processing proceeds to step S 117 , and the subject vehicle P is decelerated, whereby the series of processes ends.
[0084] On the other hand, when the determination result is “YES”, i.e., it is determined that the ease of the object vehicle Q to take evasive action in the event of avoiding a collision with the subject vehicle P is highest when the subject vehicle P travels at a specified acceleration a 1 from the current velocity v 0 , the processing proceeds to step S 18 , and the subject vehicle P is accelerated, whereby the series of processes ends.
[0085] In the first modification example, the amount of movement when the object vehicle avoids the subject vehicle in the lateral direction was computed as a distance in the lateral direction (that is, the rightward travel distance DR and the leftward travel distance DL), but is not limited thereto. For example, it may be any one of the yaw rate, lateral acceleration, and steering angle (or actual steering angle) of the object vehicle that is required to avoid the occurrence of contact or collision with the subject vehicle.
[0086] The aforementioned embodiment estimated the ease of the object vehicle to take evasive action, which changes in accordance with the velocity state of the subject vehicle (that is, whether the subject vehicle is in an accelerating or a decelerating), but it is not limited thereto. A second modification example of the aforementioned embodiment may estimate the ease of the object vehicle to take evasive action as changing in accordance with the steering state of the subject vehicle.
[0087] In the second modification example, as shown in FIG. 10 , the collision judgment portion 25 estimates an estimated travel path PT 0 of the subject vehicle P and estimated travel path QT of the object vehicle Q in the case of both vehicles maintaining their current travel states, based on the vehicle velocity of the object vehicle input from the object vehicle velocity detection portion 22 , the travel path of the object vehicle input from the object vehicle travel path estimating portion 23 , the travel path of the subject vehicle input from the subject vehicle travel path estimating portion 24 , and the position of the subject vehicle detected by the vehicle state sensor 16 . The collision judgment portion 25 then judges whether or not there is the possibility of the object vehicle Q coming into contact or colliding with the side portion of the estimated position P 0 of the subject vehicle at an appropriate time.
[0088] When this determination result is such that it is determined that there is a possibility of the object vehicle Q coming into contact or colliding with the side portion of the estimated position P 0 of the subject vehicle, it is determined that in the case of the subject vehicle P turning in a direction to the side opposite the side with which the object vehicle Q will come into contact or collide (that is, in a direction away from the object vehicle Q), the ease of the object vehicle Q to take evasive action increases. On the other hand, it is determined that in the case of the subject vehicle P turning in a direction of the side with which the object vehicle Q will come into contact or collide (that is, the direction approaching the object vehicle Q), the ease of the object vehicle Q to take evasive action decreases. In both cases, the directions in which the subject vehicle P turns are lateral directions, that is, directions perpendicular to the travel direction of the subject vehicle P.
[0089] Depending on the ease of the object vehicle to take evasive action as input from the collision judgment portion 25 , the travel control portion 26 outputs a control signal that controls the steering of the subject vehicle by the steering mechanism (not illustrated) by an EPS actuator 18 .
[0090] FIG. 10 shows the example of the travel control portion 26 outputting a control signal to instruct the subject vehicle P to turn in a direction away from the object vehicle Q so that the ease of the object vehicle Q to take evasive action increases. Thereby, the subject vehicle P travels along estimated travel path PT 1 , turning in a direction leftward of the travel direction. An estimated position P 1 of the subject vehicle in the case of traveling along this estimated path PT 1 is a distance E 0 further from the object vehicle Q along the estimated travel path QT than the estimated position P 0 at the appropriate time. It is thus possible to improve the ease of the object vehicle Q to take evasive action in the event of avoiding contact or a collision with the subject vehicle P by velocity control (i.e., deceleration control) or steering control, and to reduce the possibility of the occurrence of the two vehicles coming into contact or colliding.
[0091] The aforementioned embodiment described the case of the object vehicle approaching from the side of the subject vehicle, but it is not limited thereto. For example, in the case of the object vehicle approaching from the front or rear of the subject vehicle, controlling the steering of the subject vehicle so that the amount of overlap between the estimated path of the object vehicle and the estimated position of the subject vehicle in the direction along the width direction of the estimated path of the object vehicle, or acceleration or deceleration of the subject vehicle so as to move away from the object vehicle may be performed at the point in time in which the distance between the subject vehicle and the object vehicle at the front or rear of the subject vehicle is equal to zero.
[0092] While preferred embodiments of the invention have been described and illustrated above, it should be understood that these are exemplary of the invention and are not to be considered as limiting. Additions, omissions, substitutions, and other modifications can be made without departing from the spirit or scope of the present invention. Accordingly, the invention is not to be considered as being limited by the foregoing description, and is only limited by the scope of the appended claims. | A vehicle travel safety apparatus which includes: an object detecting device that detects objects around the vehicle; a first travel path estimating device that estimates the travel path of a moving object among the objects; a velocity calculating device that calculates the velocity of the moving object; a travel state detecting device that detects the travel state of the vehicle; a second travel path estimating device that estimates the travel path of the vehicle; a collision judgment device that determines whether or not there is a possibility of a collision occurring between the moving object and the vehicle; and a travel control device that controls the travel of the vehicle, wherein the collision judgment device estimates an ease of evasive action in the event of the moving object avoiding a collision with the vehicle, and the travel control device controls the travel of the vehicle so that the ease of evasive action increases. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application Ser. No. 61/926,528, filed Jan. 13, 2014. The disclosure of the prior application is considered part of (and is incorporated by reference in) the disclosure of this application.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
This invention was made with the Department of Energy National Nuclear Security Administration under Award Number(s) DE-NA0000979 and DOE Cooperative Agreement No. DE-FC08-01NV14049 with the University of Nevada, Las Vegas. The Government has certain rights in the invention.
TECHNICAL FIELD
This document relates to methods, systems, and devices for using x-rays to promote desired decomposition reactions. In some cases, methods, systems, and devices provided herein can use hard x-rays having an irradiation energy adapted to break a specific bond in a specific molecule to trigger a desired decomposition reaction.
BACKGROUND
Hazardous substances, such as toxins and explosives, can be used by terrorists to inflict harm on an unsuspecting public. For example, toxins, such as a pathogenic bacteria or chemical agent, could be included in a letter or package and sent to an unsuspecting victim. In addition to the mail recipient(s), these toxins also are potentially dangerous to workers in the sorting room, as mail sorting equipment can cause the release of certain toxins (e.g., spores of Bacillus anthracis). In some cases, inspecting the mail can be hazardous or damaging to the contents of the packages or letters.
Explosives also pose a significant threat to public safety. When an explosive device is identified, a common method of neutralizing the explosive device is to clear the area and explode it with other explosives. Such an explosion, however, can cause significant property damage. Another option for neutralizing an explosive device is to disassemble it physically, but that can require specialized personnel to interact closely with the explosive device and can put specialized personnel at considerable risk.
SUMMARY
Methods, systems, and devices provided herein can include using x-rays to promote desired decomposition reactions. X-rays can have an irradiation energy adapted to trigger a desired decomposition reaction of a particular compound. For example, x-rays can be directed towards a location that possibly includes one or more explosives and/or toxins to trigger decomposition reactions for the explosive(s) and/or toxin(s) to neutralize the explosive(s) and/or toxin(s). In some cases, a desired decomposition reaction can be promoted to produce a desired compound in a desired location. In some cases, x-rays can be used as described herein to promote a desired reaction in a remote or difficult to access location. In some cases, x-rays can be used to release typically gaseous and mobile reactants (e.g., O 2 , H 2 , N 2 , F 2 , or Cl 2 ) via decomposition reactions of particular compounds, which can provide for a more efficient delivery of reactants.
In some cases, a method provided herein can be used to destroy a hazardous substance. A method of destroying a hazardous substance provided herein can include identifying a location that potentially includes a hazardous substance and directing x-rays towards that location. The hazardous substance can include at least one bond having a bond distance and the x-rays can have an irradiation energy that corresponds to said bond distance in order to induce a decomposition of said hazardous substance by breaking said at least one bond. In some cases, the x-rays can have an irradiation energy of at least 7 keV. In some cases, the x-rays can have an irradiation energy of between 7 keV and 80 keV. In some cases, the x-rays can have an irradiation energy of between 5 keV and 40 keV. In some cases, the x-rays can have an irradiation energy that is equal to hc/λ, wherein h is the Planck constant, c is the speed of light, and 2λ is the bond distance or some integral multiple thereof. In some cases, x-rays focused at the location are tuned to the irradiation energy used to break the bond. In some cases, directing x-rays towards the location does not heat the location by more than 50° C., by more than 10° C., by more than 5° C., by more than 2° C., or by more than 1° C. In some cases, the hazardous substance can be an explosive substance and said directing of x-rays towards said location can deactivate or weaken the explosive substance. In some cases, a hazardous substance deactivated by a method, device, or system provided herein, can include an oxidizer having at least one bond and x-rays provided herein can be used to decompose that oxidizer by breaking that bond. For example, KClO 3 , KIO 3 , KBrO 3 , KClO 4 , and combinations thereof, are suitable oxidizers. Wherein said directing of x-rays towards said location induces an acatalytic decomposition reaction of said oxidizer to produce O 2 and KC1. In some cases, the hazardous substance can be TATB and the x-ray irradiation can have an irradiation energy of about 9 keV, or some integer multiple thereof, and used to break a C—C bond in said TATB having a bond distance of about 1.4 Å. In some cases, the hazardous substance is a toxin. For example, a suspected location of a toxin can be a package or envelope. Possible toxins include botulinum toxin, tetanus toxin, staphylococcus, Enterotoxins B, Tricothecenes, Aflatoxin, Anatoxin, Microcystins, Brevetoxin, Saxitoxin, Anthrax, Phosgene, Diphosgene, Ricin, Abrin, Sarin, Tabun, Soman, VX, Sulphur Mustard, Nitrogen Mustards, Lewisites, Hydrogen Cyanide, Cyanogen Chloride, 2-Chloroacetophenone, 2-Chlorobenzilidenemalononitrile, Dibenz (b, f)-1,4-oxazepine, LSD, 3-quinuclidinyl benzilate, Batrachotoxin, Palytoxin, Snake venoms, and combinations thereof.
Methods of treating organisms are also provided herein. In some cases, an organism can be treated by identifying a disease state in a location of said organism and directing x-rays towards that location. The location can include a chemical compound including at least one bond having a bond distance and the x-rays can have an irradiation energy that corresponds to the bond distance in order to induce a decomposition of chemical compound to produce a reaction product. The reaction product can be adapted to kill or weaken cells in said location. In some cases, the x-rays can have an irradiation energy of at least 7 keV. In some cases, the x-rays can have an irradiation energy of between 7 keV and 80 keV. In some cases, the x-rays can have an irradiation energy of between 15 keV and 40 keV. In some cases, the x-rays can have an irradiation energy that is equal to hc/λ, wherein h is the Planck constant, c is the speed of light, and 2λ is the bond distance or some integral multiple of energy. In some cases, directing the x-rays towards the location does not heat the location by more than 50° C. In some cases, directing x-rays towards said location does not heat the location by more than 5° C. The x-rays focused at the location can be tuned to an irradiation energy adapted to break a particular bond. In some cases, a method provided herein can include delivering a chemical compound to a location in an organism and using x-rays to decompose that chemical compound. For example, a delivered chemical compound can be selected from the group consisting of urea, KClO 3 , KIO 3 , KBrO 3 , KClO 4 , C 6 F 14 (or other fluorocarbon) and combinations thereof. In some cases, a chemical compound can be urea and the reaction product is hydrogen cyanide.
Methods provided herein can include delivering a reactant to a chemical reaction by directing x-rays towards a reactor apparatus. For example, a chemical compound can be placed in a predetermined location and x-rays used to induce a decomposition of the chemical compound to produce a reactant at that predetermined location. The chemical compound can include at least one bond having a bond distance and the x-rays can have an irradiation energy that corresponds to that bond distance. In some cases, the x-rays can have an irradiation energy of at least 7 keV. In some cases, the x-rays can have an irradiation energy of between 7 keV and 80 keV. In some cases, the x-rays can have an irradiation energy of between 15 keV and 40 keV. In some cases, the x-rays can have an irradiation energy that is equal to hc/λ, wherein h is the Planck constant, c is the speed of light, and 2λ is the bond distance or some integral multiple thereof. In some cases, directing the x-rays towards a location in a reactor apparatus does not heat the location by more than 50° C. In some cases, directing the x-rays towards a location in a reactor apparatus does not heat the location by more than 5° C. The x-rays focused at the location can be tuned to an irradiation energy adapted to break a particular bond. In some cases, a method provided herein can include delivering a chemical compound to a particular location. In some cases, a chemical compound can be decomposed to produce O 2 or H 2 . In some cases, the chemical compound can be selected from the group consisting of NH 3 BH 3 , KClO 3 , KIO 3 , KBrO 3 , KClO 4 , N 2 H 4 , CCl 4 , ICl 3 , C 6 F 14 , NaClO 3 , NaIO 3 , NaBrO 3 , NaClO 4 and combinations thereof. In some case, the reaction apparatus can be a hydrogen fuel cell. In some cases, the reaction apparatus can be a semiconductor fabricator.
Systems provided herein can be adapted to neutralize hazardous substances in packages. A system provided herein, can include an x-ray accelerator (adapted to provide x-rays) having an irradiation energy that corresponds to a bond distance (of a bond in a hazardous substance) in order to induce a decomposition of said hazardous substance by breaking said bond and a conveyor adapted to move packages past the x-ray accelerator to expose the contents of said packages to the x-rays. In some cases, the packages can include envelopes.
Systems provided herein can be adapted to contain a nuclear reactor. In some cases, a substance is included in the nuclear facility and adapted to decompose to produce one or more neutron-moderating gases when exposed to gamma and x-rays from the reactor. The substance can be positioned in the nuclear facility so that said one or more neutron-moderating gases flow to the reactor core. For example, the substance can be NH 3 BH 3 and it can decompose to release H 2 when exposed to x-rays provided herein. In some cases, the one or more neutron-moderating gases include boron, hydrogen, or a combination thereof. The details of one or more embodiments are set forth in the accompanying description below. Other features and advantages will be apparent from the description, drawings, and the claims.
DETAILED DESCRIPTION
Methods, systems, and devices provided herein can include using x-rays to promote desired decomposition reactions. In some cases, penetrating and/or energetic hard x-rays can be used to trigger a decomposition reaction of a hazardous substance. In some cases, penetrating and/or energetic hard x-rays can be used to trigger a decomposition reaction to deliver a desired compound to a desired location. For example, penetrating and/or energetic hard x-rays can be used to trigger a decomposition reaction of a molecule within an organism to produce a therapeutic agent that treats the organism. In some cases, penetrating and/or energetic hard x-rays can be used to release typically gaseous and mobile reactants (e.g., O 2 , H 2 , N 2 , Cl 2 , F 2 or a combination thereof) via decomposition reactions. In some cases, x-ray induced reactions can be triggered with a minimal input of heat and/or without the presence of catalysts. In some cases, penetrating and/or energetic hard x-rays can initiate decomposition reactions in compounds subjected to high pressures. In some cases, penetrating and/or energetic hard x-rays can initiate decomposition reactions in compounds subject to pressures between 0.1 GPa and 20 GPa. In some cases, penetrating and/or energetic hard x-rays can initiate decomposition reactions in compounds at an ambient pressure. In some cases, the methods, systems, and devices provided herein can include using x-rays to induce reactions in sealed or isolated regions of a sample or device. In some cases, the methods, systems, and devices provided herein can include using x-rays to induce reactions from a distance of greater than 10 cm, 1 meter, or 10 meters, depending on the thickness of air, energy of the incident x-rays, and on the chemical composition (e.g. metal or concrete) and thickness of any confining barriers.
In some cases, the methods, systems, and devices provided herein can be used to induce the release of reactant gases and cause crystalline damage, fractures, and/or dislocations that further enhance the molecular diffusion of the gasses, thus improving the diffusion and delivery of reactant gasses throughout a sample or device. For example, the methods, systems, and devices provided herein can be used to open channels for small molecules or reactant gasses to diffuse into deep (e.g., greater than 2 microns, greater than 5 microns, greater than 10 microns, or greater than 100 microns) and/or isolated regions of a sample. In another example, the diffusion of reactant gasses into a deep region of a semiconductor device being manufactured can result in the production of dopant layers or adhesion layers.
X-Rays:
Methods, systems, and devices provided herein can use x-rays adapted to break a specific bond in a specific compound. In some cases, the x-rays can be hard x-rays (i.e., x-rays having an irradiation energy greater than about 7 keV). In some cases, x-rays used in the methods, systems, and devices provided herein can have irradiation energies of between 7 keV and 80 keV. In some cases, x-rays used in the methods, systems, and devices provided herein can have irradiation energies of between 15 keV and 40 keV.
X-rays used in the methods, systems, and devices provided herein can be produced in any appropriate manner. In some cases, the methods, systems, and devices provided herein can produce x-rays using an accelerator (e.g., from Varian) to produce x-rays which irradiate the samples of interest. In some cases, irradiation energy of the x-rays can be selected or varied to tune the irradiation energy to be resonant with standing waves within the unit cell of the solid that enhance absorption within bonds of the molecule and cause chemical decomposition of the target molecule/compound. In some cases, a decomposition reaction can produce gas and/or other inert or toxic products.
In some cases, x-rays used in the methods, systems, and devices provided herein can have an irradiation energy near E=hc/λ, where h is the Planck constant, c is the speed of light, and 2λ is any characteristic, repeated distance to create standing waves within the unit cell such as a bond distance of a selected bond that the decomposition reaction seeks to break. In some cases, irradiation energies for x-rays used to trigger a desired decomposition reaction can be empirically determined via experiment. For example, experiments can measure the decomposition rate as a function of irradiation energy to find irradiation energy used in a method, system, or device provided herein. Using tuned irradiation energies for x-rays used in methods, systems, and devices provided herein can enhance the efficiency of the chosen decomposition reaction(s) by choosing energies that maximize the decomposition/absorption-of-energy rate. In some cases, the methods, systems, and devices provided herein can produce a decomposition reaction acatalytically and with little or no introduction of heat. In some cases, the methods provided herein can produce a temperature increase at the location of a decomposition reaction of less than 50° C., less than 25° C., less than 10° C., less than 5° C., or less than 1° C. In some cases, heat can accelerate dangerous reactions that result in undesired chemical reactions, which may even cause an explosion, whereas a method provided herein can break down desired compounds in a controlled fashion with a limited external introduction of heat.
Applications:
Neutralizing Hazardous Substances
Methods, systems, and devices provided herein can use x-rays to neutralize safely hazardous substances, such as explosives and toxins. In some cases, methods, systems, and devices provided herein can use x-rays that can penetrate metal, paper, wood, plastic, and/or ceramics to trigger a decomposition reaction that can neutralize one or more hazardous substances. As discussed above, methods, systems, and devices provided herein can use x-rays having energies tuned to induce the breaking of a particular bond in a particular compound. As discussed above, methods, systems, and devices provided herein can induce decomposition reactions without the presence of a catalyst. As discussed above, methods, systems, and devices provided herein can induce decomposition reactions with a limited temperature increase (e.g., an increase that is less than 50° C., less than 25° C., less than 10° C., less than 5° C., or less than 1° C.
In some cases, methods, systems, and devices provided herein can direct x-rays towards packages, envelopes, or other postal items to target specific toxins that may be present in the mail. In some cases, a system provided herein can include a conveyor belt that carries packages or envelopes past an x-ray accelerator to deliver x-rays towards each package or envelop to induce a decomposition reaction of one or more toxins if those toxins are present. For example, x-rays can be tuned to trigger a decomposition reaction that can neutralize anthrax and spores of Bacillus anthracis. In some cases, x-rays used in methods, systems, and devices provided herein can be tuned to trigger a decomposition reaction in one or more of the following toxins or hazardous materials: Botulinum toxin, Tetanus toxin, Staphylococcus toxins, Enterotoxins B, Tricothecenes, Aflatoxin, Anatoxin, Microcystins, Brevetoxin, Saxitoxin, Anthrax, Phosgene, Diphosgene, Ricin, Abrin, Sarin, Tabun, Soman, VX, Sulphur Mustard, Nitrogen Mustards, Lewisites, Hydrogen Cyanide, Cyanogen Chloride, 2-Chloroacetophenone, 2-Chlorobenzilidenemalononitrile, Dibenz (b, f)-1,4-oxazepine, LSD, 3-quinuclidinyl benzilate, Batrachotoxin, Palytoxin, and Snake venoms. In some cases, methods, systems, and devices provided herein can target phosgene, a nerve toxin, by targeting a C—Cl bond having a bond distance of about 1.74 Å by irradiating a location suspected of having phosgene (e.g., a letter or package) with x-rays having an irradiation energy of about 14 keV. The use of x-rays tuned to induce a decomposition reaction can permit the neutralizing of toxins potentially in packages or envelopes without causing significant damage to other desired contents of the package or envelope. Unlike neutron irradiation methods, directing x-rays towards a package or letter does not cause the package or letter to become radioactive. Additionally, methods, systems, and devices provided herein can neutralize toxins without opening the packages or envelopes and/or prior to sorting the packages or envelopes.
Explosive devices also can pose a threat to public safety. Methods, systems, and devices provided herein can neutralize explosive devices from a safe distance without causing the explosive device to explode. In some cases, explosive devices can include TATB, which includes a carbon-carbon bond having a bond distance of about 1.4 Å. In this case, a method, system, or device provided herein can direct x-rays tuned to an irradiation energy of about 18 keV (to maximize decomposition efficiency) towards such an explosive device to break that carbon-carbon bond and neutralize the TATB explosive. In some cases, explosive devices can include inorganic oxidizers such as KClO 3 , KIO 3 , KBrO 3 , KClO 4 , N 2 H 4 , CCl 4 , NaClO 3 , NaIO 3 , NaBrO 3 , and/or NaClO 4 which can help drive an explosive reaction. In these cases, a method, system, or device provided herein can direct x-rays tuned to an irradiation energy adapted to drive a decomposition reaction of those oxidizers to detonate or slowly decompose (depending on the x-ray flux) and thus, at least partially, disable an explosive device. In some cases, oxygen can be a key component of explosive chemical reactions. While a rapid release of oxygen may cause detonation in some explosive devices, a slower release of oxygen in some explosive devices can deflagrate or just decompose the explosive device. Accordingly, in some cases, methods provided herein can use x-ray flux and energy to chemically control a decomposition reaction in an explosive device.
Therapeutic Applications
Methods, systems, and devices provided herein can, in some cases, use x-rays to trigger a decomposition reaction of a molecule within an organism to produce a therapeutic agent that treats the organism. In some cases, cancer can be treated by introducing an inert or low toxicity substance capable of releasing a substance toxic to cancer cells upon irradiation. In some cases, the x-rays and/or the inert or low toxicity substance can be directed towards and/or isolated in cancerous tissue. For example, urea can be irradiated with x-rays to decompose the urea into decomposition products that can treat cancer cells. In some cases, it may be possible to decompose urea to form hydrogen cyanide and other residues. Hydrogen cyanide is toxic to cells and can kill cancer cells that have imbibed the urea in a targeted, focused, or controlled fashion. The release of a gas under Room Temperature and Pressure (RTP) conditions can help remove peripheral cancer cells. For example, penetrating and energetic hard x-rays can be used to trigger a decomposition reaction of a molecule within an organism to produce a therapeutic agent that treats the organism. In some cases, oxygen producing reactions, such as 2KClO 3 +hv (15 keV)→2KCl+3O 2 and KClO 4 +hv→KCl+2O 2 , can be used to release oxygen within cancer cells, which can kill cancer cells and cells on the periphery of tumors due to diffusion of molecular oxygen once produced reducing damage to healthy tissue. Thus, KCLO 3 or KClO 4 can be introduced in solution up to a safe concentration and will be imbibed by cells. In some cases, irradiation of selected regions/tumors within organisms can release oxygen, which is generally toxic to cancer cells and may kill them. In some cases, oxygen can diffuse outward from a tumor and eradicate tumor cells on the periphery of the tumor, which can be more difficult to kill or remove by conventional methods such as surgery.
Nuclear Applications
Methods, systems, and devices provided herein can, in some cases, use x-rays to trigger a release of neutron-moderating gases. In some cases, released neutron-moderating gases can include light elements such as boron and/or hydrogen. In some cases, a container containing a powder such as NH 3 BH 3 can be placed in nuclear facility and irradiated with x-rays to decompose the NH 3 BH 3 to release H 2 . In some cases, if a reactor core begins to meltdown, a large increase in gamma and x-rays from the reactor can cause a release of gas upward into the reactor core, which may reduce the neutron flux and thus reduce (at least temporarily) the chances for meltdown. In some cases, method of neutron mitigation provided herein can be completely passive, without dependence on machines, mechanical or electrical controls.
Delivering Reactants
Methods, systems, and devices provided herein can provide a rapid release and diffusion of reactant gases, which can be used in further reactions or in reactors. For example, methods, systems, and devices provided herein can use x-rays in the 7-30 keV energy range to decompose ammonia borane (NH 3 BH 3 ) to release molecular hydrogen, which can be used in a fuel cell. In some cases, systems and devices provided herein can include fuel cells that include ammonia borane and an x-ray generating accelerator or x-ray tube adapted to provide x-rays towards the ammonia borane to produce hydrogen used by the fuel cell to produce electricity. In some cases, a fuel cell provided herein can include KClO 3 , KIO 3 , KBrO 3 , KClO 4 , N 2 H 4 , CCl 4 , NaClO 3 , NaIO 3 , NaBrO 3 , and/or NaClO 4 and an accelerator adapted to provide x-rays towards the KClO 3 , KIO 3 , KBrO 3 , KClO 4 , N 2 H 4 , CCl 4 , NaClO 3 , NaIO 3 , NaBrO 3 , and/or NaClO 4 to trigger a decomposition reaction to produce molecular oxygen as a reactant gas. The use of x-rays in methods, systems, and devices provided herein can produce O 2 and H 2 within a few seconds (e.g., less than 10 seconds, less than 5 seconds, less than 2 seconds) in order to deliver reactant gases quickly to a fuel cell. The x-ray induced release of gases, crystalline damage, fractures, dislocations, or a combination thereof can aid molecular diffusion and, thus, the diffusion and delivery of reactants throughout a sample.
In some cases, a reactor device provided herein can be a semiconductor fabricator and x-rays can be used to deliver reactants to select areas of a semiconductor device under production. For example, select compounds can be irradiated with x-rays to decompose to yield reactants to drive reactions that enhance adhesion of dissimilar, stressed, and/or sandwiched surfaces (e.g., layers of semiconductors that form p-n junctions). Methods, systems, and devices provided herein can open channels for small molecules or reactant gasses to diffuse into deep (e.g., greater than 2 microns, greater than 5 microns, or greater than 10 microns) and/or isolated regions of a semiconductor device being fabricated. For example, the diffusion of reactant gasses into a deep region of a semiconductor device being manufactured can result in the production of dopant layers or adhesion layers. In some cases, additional reactions using reactants produced using x-ray decomposition methods provided herein can produce GaN in a semiconductor device. Oxygen or other gases released inside the semiconductor using these methods may be used as a novel means to carry current. | This document provides methods, systems, and devices for inducing a decomposition reaction by directing x-rays towards a location including a particular compound. The x-rays can have an irradiation energy that corresponds to a bond distance of a bond in the particular compound in order to break that bond and induce a decomposition of that particular compound. In some cases, the particular compound is a hazardous substance or part of a hazardous substance. In some cases, the particular compound is delivered to a desired location in an organism and x-rays induce a decomposition reaction that creates a therapeutic substance (e.g., a toxin that kills cancer cells) in the location of the organism. In some cases, the particular compound decomposes to produce a reactant in a reactor apparatus (e.g., fuel cell or semiconductor fabricator). | 1 |
FIELD OF THE INVENTION
[0001] The invention relates to providing information to enhance managers of fleet equipment to manage their fleets by receiving data from a local server on one or more of the pieces of equipment in order that they may react to immediate problems and to plan for future utilization based upon the fleet's pasts performance and utilization. The information is received in the form of either snapshot reports on current conditions, or summary reports based on data gathered over a period of time.
BACKGROUND OF THE INVENTION
[0002] Current Fleet Management systems have proven to be ineffective for Fleet Managers to manage their fleets. Fleet Managers manage their fleets with outdated and hand collected data that makes it hard for them to react to immediate problems and plan for future fleet utilization based on their fleet's past performance and utilization.
[0003] Further, the collected information may be a collection of current conditions and past conditions which are cumbersome to assimulate by the receiver of the information.
[0004] Therefore, the principal object of this invention is to provide a method of collecting data from a plurality of machines in a fleet of machines, wherein snapshot reports of current conditions, or summary reports on the historical state of a machine, can be generated and can be forwarded to the fleet manager at a remote monitoring system.
[0005] A further object of this invention is to provide a method for remote monitoring equipment for an agricultural machine which will permit the capture of additional information about the machine and its use without ever visiting the machine.
[0006] These and other objects will be apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 is a flow sheet showing internationalization of machine data;
[0008] [0008]FIG. 2 is a flow sheet showing configuring the controllers for different machine types;
[0009] [0009]FIG. 3 is a flow sheet showing machine settings and call-in schedule;
[0010] [0010]FIG. 4 is a flow sheet showing monitor machine information;
[0011] [0011]FIG. 5 is a flow sheet showing polling machine status; and
[0012] [0012]FIG. 6 is a flow sheet showing stop engine alert notification.
SUMMARY OF THE INVENTION
[0013] The method of this invention offers a complete management system composed of the remote monitoring equipment for an agricultural machine (which is part of a fleet of agricultural machines). The monitoring equipment comprises a communications controller/computer provided on the agricultural machine, one or more connections to the machine's data buses (CAN, CCD, RS232), and other controllers on the machine. The controllers are connected to a machine data bus and to sensors which pass alert information derived from these sensors to the communications controller/computer which automatically generates and sends snapshot and summary reports to a central information server. A central information server comprising a communications server handles the over-the-air communications protocol to the remote agricultural machines communications controller/computer and the network communications to a data server. The data server accepts the snapshots and summary reports from the agricultural machine and when requested, generates fleet level snapshot reports, machine level snapshot reports, fleet level summary reports and machine level summary reports, which are sent to a customer service application. The customer service application takes requests from a fleet manager via network for a fleet level snapshot report, a machine level snapshot report, or a fleet level summary report on a machine level summary report, and passes the report requests to a data service and then displays the report to the fleet manager.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] The invention proposes monitoring equipment that monitors information about the historical state of the machine primarily when it is working, transporting, idling or when it is not operating at all. The information about the historical state of the machine, also known as the summary report, can determine the productivity of the machine or a fleet of machines over a period of time. This report is capable of generating configurable utilization information about which can include the area covered, engine hours, ground speed, engine speed, fuel used, fuel used/hour, load Factor and rear PTO speed. Advice given in the summary report is automatically sent to the equipment manager for an immediate response.
[0015] A second feature of the invention is its ability to provide machine management snapshot reports to the user. This feature functions in a similar way as the previous component with the main difference being the users ability to request snapshot reports about the current machine state. When an emergency or red alert call occurs, a snapshot report is automatically sent transmitted. A red alert is operational data predetermined to be an emergency condition, such as fire, or an overturned machine, for example. The snapshot capability provides a map with the current location of the machine that enables the service personnel to locate the machine once a problem occurs. The fleet level snapshot report includes a map which is also capable of providing current locations of all machines in the fleet, which could possibly be used by a fuel truck operator to fuel the fleet. Another unique feature about this report is its ability to poll the machine or the entire fleet of machines for configurable current settings such as fuel tank level, ground speed, engine speed, hydraulic oil temperature, engine coolant temperature wheel slips and gears. The snapshot report is capable of providing the current status of the machine or machines indicating whether the machine is currently working, idling, transporting in an “off” mode. The primary difference between the snapshot and the summary reports is the time frame in which the data is collected in the reports. The snapshot report contains instantaneous data. The summary report contains data that was collected over a period of time.
[0016] The data is obtained from the machines of the fleet through an informational retrievable system.
[0017] The system is composed of a remote monitoring equipment for an agricultural machine (which is part of a fleet of agricultural machines) comprising a communications controller/computer provided on the agricultural machine; one or more connections to the machine's data buses (CAN, CCD, RS232); and other controllers on the machine which are connected to a machine data bus and to sensors which pass alert information derived from these sensors to the communications controller/computer. The latter component automatically generates and sends red alert and alert log reports to a central information server. The system further includes a central information Server comprising a communications server which handles the over-the-air communications protocol to the remote agricultural machines communications controller/computer and the network communications to the data server. The data server accepts the red alert and alert log reports from the agricultural machine and automatically sends red alert emails to a list of email addresses. When requested, it generates alert log reports and sends the reports to the customer service application. The customer service application takes requests from a fleet manager via a network for an alert log report and passes the report request to the data service and then displays the report that comes from data service to the fleet manager.
[0018] The primary feature of this system is the way in which the raw data is transferred throughout the system. Data, such as the configuration file, is transferred throughout this system using a method comprised of two different protocols: A low-level communication protocol that allows the communication controller (CC) to use a mobile asset management device to communicate to communication services (CS) and a high level connection based communication protocol, that transfers configuration data from the CS to the CC. The advantage of this latter protocol is the ability for both sides to actively communicate with each other as long as a connection is maintained.
[0019] Once a user requests a customer service application configuration selection for a specific machine, the machine is then triggered causing information to be passed to data services (Database) to create the configuration file. After the file is created, it is then passed via a message to communications services. Communications services (CS) then calls the CC on the specific machine and transfers the configurations file to the communications controller (CC) via an over-the-air protocol. An over-the-air protocol allows for direct configuration of the asset management device by CS.
[0020] When communication occurs between the CC and the CS a Snapshot/machine status report and an alert log if necessary, are then generated and sent to the user. This Snapshot/machine status report is sent each time to make sure that the data coming from the CC will be associated with the right configuration ID in the CC. When this report is sent, the date, time and position of the data become known. The configuration ID is essential at this point because, it is unique to each CC; it is used by the CS to track the configuration of the CC; and it is updated with each new configuration download to the CC.
[0021] The primary structure of the configuration file consists of different types of configuration records. These configuration records are essential because they help the CC to monitor information on the (CAN & CCD data) buses.
[0022] The configuration records that are sequentially transmitted includes, broadcast parameters, query parameters, attributes, utilization, snapshot, performance alert, machine state, call-in schedule and system configuration. These records are used to define to the CC how to acquire a parameter (data items which are available on the bus such as GPS speed, hitch position, time, etc.) that are being broadcast on the bus. The two types of parameters (broadcast, query) are used to define the items that are monitored on the CC, commonly known as “attributes”. Attributes are monitored for collecting performance data, for generating current machine status (snapshot report/values) and for monitoring performance alerts. The machine status consists of the machine position, machine state (off, idle, working, transporting). Once attributes are generated, they are then used to collect utilization reports, which transmits all complete reporting period data for duration of 1 hour.
[0023] The distinct features of this invention exist for both the individual machine and the entire fleet of machines. The ability to produce a summary and snapshot report through remote monitoring enables the user to get information about the historical and current state of the machine (working, transporting, idling or off), the current settings or utilization breakdowns as described in 2 A, a means to know how the machine or all machines within the fleet have been operated over a period of time, a means to know how productive the machine or fleet of machines have been over a period of time and a real-time fleet schedule for refueling a machine. Generating summary and snapshot reports about configurable aspects of the machine greatly increases the users ability to track the productivity of the machine in 1 hour increments, track the productivity of the operator of the machine and track the current location of each machine enabling the user to dispatch service personnel immediately is a red alert code is given. These report capabilities also enables the user to potentially increase output of the machine and operator as well as immediately preserving resources by knowing exactly where the machine is located and how it is being utilized on an hourly, daily, weekly, monthly and yearly basis. This invention is clearly a benefit because it provides fleet managers and other users automatically collected information which tells them if they are over or under equipped and by ensuring them that their needs are being met at all times with the equipment they have, it reduces the possible down-time of a machine within the fleet and it keeps the user from expending unnecessary resources to resolve the problem.
[0024] It is therefore seen that this invention will achieve at least all of its stated objectives. | A method of providing information from a plurality of fleet machines located at a plurality of locations for purposes of permitting a manager of fleet equipment to make management decisions pertaining to a fleet comprised of such equipment, monitoring functional operational data from individual machines in a fleet of machines, conveying the monitored data to a remote server, converting the monitored data into a first group pertaining to current existing operational data, and into a second group comprised of past historical data, and transmitting by wirelss means to a person having responsibility for the fleet information at least one of the groups of data. | 6 |
This application is a division of application Ser. No. 08/272,081, filed Jul. 8,1994, now U.S. Pat. No. 5,476,975 on Jun. 5, 1997.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the extraction of toxic organic contaminants, e.g., pentachlorophenol, polychlorinated dibenzo-p-dioxins, and polychlorinated dibenzofurans, from treated wood, e.g., utility poles, railway ties, fence posts, etc. This invention also includes such extraction steps and the subsequent photodegradation of such extracted toxic organic contaminants. In addition, this invention relates to the photodegradation of toxic organic contaminants.
Toxic organic contaminants include polychlorinated dibenzo-p-dioxins and polychlorinated dibenzofurans, which are large groups of chloro-organic compounds which have become ubiquitous in industrial societies. Of the various possible isomers of these compounds, the following are reportedly extremely toxic: 2,3,7,8-tetrachlorodibenzo-p-dioxin, 1,2,3,7,8-pentachlorodibenzo-p-dioxin, 2,3,7,8-tetrachlorodibenzofuran, 1, 2,3,7,8 -pentachlorodibenzofuran, 2,3,4,7,8 -pentachlorodibenzofuran, 1,2,3,6,7,8-hexachlorodibenzo-p-dioxin, 1,2,3,7,8,9-hexachlorodibenzo-p-dioxin, 1,2,3,4,7,8-hexachlorodibenzo-p-dioxin, 1,2,3,6,7,8-hexachlorodibenzofuran, 1,2,3,7,8,9-hexachlorodibenzofuran, 1,2,3,4,7,8-hexachlorodibenzofuran, and 2,3,4,6,7,8-hexachlorodibenzofuran.
Polychlorinated dibenzo-p-dioxins and polychlorinated dibenzofurans are known to cause a temporary form of a skin ailment known as "chlor-acne". Also, polychlorinated dibenzo-p-dioxins and polychlorinated dibenzofurans (particularly 2,3,7,8-tetrachlorodibenzo-p-dioxin) have been found to be extremely toxic to certain animals in laboratory studies.
Because of this reported high level of toxicity in a laboratory tests, there is a general concern as to the long-term effects of polychlorinated dibenzo-p-dioxins and polychlorinated dibenzofurans on human physiology. Accordingly, there is an important need to remove or substantially reduce the content of polychlorinated dibenzo-p-dioxins and polychlorinated dibenzofurans from used telephone poles, used railway ties, used fence posts, etc., prior to disposal or reuse of the waste. There is also a need for a process for treating solutions containing toxic organic contaminants, as described above, and including toxic organic contaminants which have been removed from treated wood, so that they can be disposed of safely.
2. Description of the Prior Art
Pentachlorophenol-treated utility poles contain high levels of pentachlorophenol and related contaminants, and consequently can not be disposed of in landfill sites. It has been suggested to use bioremediation as a possible way of decontaminating these materials. Poles removed from service have a high pentachlorophenol content, i.e., of the order of about 5,000-27,000 ppm in the outer 20 mm zone. This high level of pentachlorophenol is toxic to most microorganisms which have been suggested for use in the bioremediation process. Accordingly, it is necessary to pre-treat the pole material to reduce the content of such contaminants before biological remediation.
Physical or chemical methods can be used for the pre-treatment process. Physical methods, e.g., dilution, i.e., mixing the pentachlorophenol-containing sawdust with large amounts of uncontaminated sawdust or other materials, so that the pentachlorophenol concentration is low enough for the microorganisms to survive, is not feasible economically. It also has the problem of generating a much larger volume of contaminated waste. Therefore, any kind of dilution approach is not considered to be suitable.
Solvent extraction is probably the easiest and most effective laboratory method of removing pentachlorophenol from contaminated wood. However, extraction using organic solvents is also not considered appropriate commercially, because of environmental concerns and the hazards involved in a large scale operation.
Chemical treatment has also been suggested for pre-treating the pentachlorophenol-containing wood before bioremediation. Pentachlorophenol is, however, very stable and only a few systems can modify and/or degrade this molecule. Because of the strong, relatively non-polar covalent C--Cl bonds in pentachlorophenol, removal of the chlorine by hydrolysis is difficult. Pentachlorophenol is an electron-deficient molecule and should be more reactive towards reduction than oxidation. Potassium-graphite-intercalate has been suggested as an agent for dechlorination of a number of compounds including pentachlorophenol and octachlorodibenzo-p-dioxin. This system, however, requires inert atmosphere, high temperature and absolute anhydrous conditions and is impractical for large scale applications.
Electrochemical reduction has been suggested for use for treating waste waters containing low concentrations of chlorinated organics. Such process was considered not suitable since, for electrochemical processes to work, the electrodes must maintain clean surfaces. Moreover, the oil and other contaminants in pentachlorophenol-treated wood would contaminate the electrodes very quickly.
Reductive dechlorination of chlorinated organic compounds by photochemical reactions has also been suggested to detoxify pentachlorophenol-containing materials. Photochemical degradation of pentachlorophenol and lower chlorophenols in the presence, or absence, of various photosensitizers and catalysts have furthermore been suggested. It is known that polychlorinated biphenyls may be dechlorinated in the presence of visible dyes and amines using visible light.
Oxidation of chlorophenols by enzymes has also been suggested. Laccases may be used to remove chlorophenols from water through polymerization. This method, however, does not provide a permanent solution to the problem. The oxidation of phenolic pollutants by lignin peroxidase, an enzyme from Phanerochaete chrysosporium, has also been suggested. On the other hand, it is known that chlorophenols could be converted to much more toxic polychlorodibenzo-p-dioxins by peroxidase catalyzed oxidation.
Supercritical fluids have also been suggested to extract cellulosic materials. A supercritical fluid (SCF) is a fluid at a temperature above its critical value. An SCF has properties which are intermediate between those of gases and liquids. It has a viscosity which is lower than that of a liquid and a density which is higher than that of a gas. These properties allow SCFs to penetrate matrices easily, while retaining reasonable dissolving power. Supercritical fluid extraction (SFE) is a technique in which gases are compressed under supercritical conditions to form a fluid, which is then used to remove chemicals from a matrix. Among the various solvents suitable for SFE, carbon dioxide is the most commonly used, because it is non toxic, non-flammable, and inexpensive. Carbon dioxide also has low critical temperature and pressure, thus having a minimum requirement for equipment design. SFE provides superior extraction to routine solvent extraction in several aspects. For example, SFE leaves no solvent residue in the matrix after extraction, since carbon dioxide is a gas at normal temperature and pressure. The extract is automatically separated from the solvent when the pressure is released (carbon dioxide under noncritical conditions can hardly dissolve any of the extract), and since it eliminates the solvent-extract separation step, it is very energy efficient. In addition, SFE can be done in a closed system where carbon dioxide is continuously recycled.
Supercritical fluid technology has been applied to materials processing and pollution control. For example, it is known that supercritical ethylene may be used to remove trichlorophenol from soil. It is also known that various supercritical fluids, including carbon dioxide may be used to extract organic materials from tar sands. In addition, it is known that supercritical fluids including carbon dioxide may be used to remove hazardous organic materials from environmental solids, e.g. such as soil.
SCF extraction has been particularly useful for obtaining aromatic and lipid components from plant tissues. For example, the oil industry relies extensively on processes by which vegetable oils, e.g., soybean, cottonseed and corn oils, are removed from their vegetative components. The coffee industry uses supercritical processes for removing caffeine from coffee, and flavor extraction using SCFs has been applied to, e.g., hops, vegetables, fruits (lemons), and spices. SCF extractions have also been used to extract fragrances.
Various other uses of supercritical fluids in the processing of materials are now known. For example, supercritical carbon dioxide has been used to remove tall oil and turpentine from coniferous woods; to extract lignin from the black liquor produced by the Kraft process for pulp production; to treat refinery sludges; to regenerate absorbents used in waste water treatment systems; to sterilize pharmaceuticals; to remove off-flavor materials from textured vegetable products; to remove gamma-linolenic acid from fruit seeds; and to decaffeinate coffee; to treat citrus wastes to obtain essential oils by cooking the citrus wastes in the aqueous phase under autogenous pressure at a temperature of about 350° C. to 750° C., in the absence of air or oxygen; to extract of animal-derived materials for enzymatic treatment, e.g., endogenous and/or exogenous enzymatic treatment; for supercritical extraction of essential oils from plants with carbon dioxide for preparing pharmaceutical products; for the isolation of diosgenin, a building block for sterols from plant cell culture; and for the solubilization of biomolecules, e.g. sterols, in carbon dioxide based supercritical fluids.
Ritter et al, in paper entitled "Supercritical Carbon Dioxide Extraction of Simultaneous Pine and Ponderosa Pine", Wood and Fiber Science , Jan 1991, V.23 P.98 et seq, described the extraction of pine wood and bark using supercritical carbon dioxide. The authors also taught that the addition of ethanol to bark prior to the supercritical carbon dioxide extraction produced higher yield of extracts relative to extraction without the addition of the ethanol.
The patent literature is also replete with teachings of SFE extraction procedures. Fremont, in U.S. Pat. No. 4,308,200, taught a process for the extraction of tall oil and terpentine from coniferous woods with fluid carbon dioxide and other supercritical fluids.
Kamarei, in Canadian Patent No. 1,270,623, patented Jun. 26, 1990, provided a process for the supercritical fluid extraction of animal-derived material.
U.S. Pat. Nos. 4,338,199 and 4,543,190 to Modell, described processes in which organic materials were oxidized in supercritical water. U.S. Pat. No. 4,338,199 included a general statement that its process could be used to remove toxic chemicals from the wastes generated by a variety of industries including forest product wastes and paper and pulp mill wastes. U.S. Pat. No. 4,543,190 described the treatment of various chlorinated organics other than dioxins with supercritical water and stated that conversion of these materials to chlorinated dibenzo-p-dioxins were not observed.
U.S. Pat. No. 5,009,746, patented Apr. 23, 1991 by Hossain et al, provided a method for removing polychlorinated dibenzofurans from secondary fibers by contacting the secondary fibers with supercritical or near supercritical carbon dioxide for a period of time at a temperature, pressure, and carbon dioxide flow rate such that a substantial reduction in the level of polychlorinated dibenzofurans associated with the fibers was achieved, and the properties of the fibers, e.g., their physical and chemical properties, were not substantially degraded. The operating conditions taught included: the use of pressures above about 60 atmospheres; temperatures above about 25° C.; carbon dioxide flow rates in the range from about 0.01 standard liters/minute/gram of dry secondary fiber (slpm/gm) to about 10 slpm/gm; and processing periods of from about 1 minute to about 3 hours.
U.S. Pat. No. 5,009,746, patented Apr. 23, 1991 by Hossain et al, provided a method for removing stickies from secondary fibers by contacting the secondary fibers with supercritical or near supercritical carbon dioxide for a period of time at a temperature, pressure, and carbon dioxide flow rate such that a substantial reduction in the level of stickies associated with the fibers was achieved, and the properties of the fibers, e.g., their physical and chemical properties, were not substantially degraded.
U.S. Pat. 5,074,958, patented Dec. 24, 1991 by Blaney et al, provided a method for removing polychlorinated dibenzofurans from secondary fibers by contacting the secondary fibers with supercritical or near supercritical carbon dioxide or propane for a period of time at a temperature, pressure, and carbon dioxide or propane flow rate such that a substantial reduction in the level of polychlorinated dibenzofurans associated with the fibers was achieved, and the properties of the fibers, e.g., their physical and chemical properties, were not substantially degraded. That patent also taught a method for removing stickies from secondary fibers by contacting the secondary fibers with supercritical or near supercritical carbon dioxide or propane for a period of time at a temperature, pressure and carbon dioxide or propane flow rate such that a substantial reduction in the level of stickies associated with the fibers was achieved, and the properties of the fibers, e.g., their physical and chemical properties, were not substantially degraded.
U.S. Pat. No. 5,213,660, patented May 25, 1993 by Hossain et al, provided a method for removing polychlorinated dibenzofurans from secondary fibers by contacting the secondary fibers with supercritical or near supercritical carbon dioxide for a period of time at a temperature, pressure, and carbon dioxide flow rate such that a substantial reduction in the level of polychlorinated dibenzofurans associated with the fibers was achieved, and the properties of the fibers, e.g., their physical and chemical properties, were not substantially degraded.
It is now known that the solubility of various chemicals in supercritical carbon dioxide is directly related to the temperature and pressure being used, as well as to the presence of different co-solvents, called "entrainers". It is known that the extraction efficiency and selectivity can be optimized by adjusting these parameters, i.e., temperature, pressure and entrainers.
Kumar et al, in a paper entitled "Effect of Fatty Acid Removal in Treatability of Douglas Fir", presented to The International Research Group on Wood Preservation, Section 4, "Process", Document No. IRG/WP 93-40008, reported on the extraction of fatty acids using supercritical carbon dioxide. The extraction was carried out using supercritical carbon dioxide and methanol or methanol and formic acid as co-solvents. The authors suggested that the addition of co-solvents in supercritical carbon dioxide extraction increases the solventing properties of the supercritical fluid.
Following up on these general teachings, U.S. Pat. No. 5,252,729, patented Oct. 12, 1993 by De Crosta et al, provided two extraction processes. One process was for extracting a compound from plant material by contacting hydrolyzed plant material with a supercritical fluid, optionally with a co-solvent, and recovering the compound from the supercritical fluid. A second process was for removing a compound from plant material, by contacting the plant material with an acid, a supercritical fluid and a co-solvent, and recovering the compound from the supercritical fluid.
That patentee also taught that the hydrolyzed plant material can be prepared by treatment of fresh or dried plant material with acid under conditions effective to promote hydrolysis. Useful acids for hydrolyzing the plant material taught by such patentee included mineral acids, e.g., sulfuric acid, hydrochloric acid, or phosphoric acid, or organic acids, e.g., formic acid, acetic acid, propanoic acid, butyric acid, o-, m- or p-toluene sulfonic acid, benzoic acid, trichloroacetic acid, trifluoroacetic acid; or mixtures of any of the above acids.
That patentee also taught that, optionally, a base could be added during or at the completion of hydrolysis of the root to neutralize any excess acid. Suitable bases, as taught by that patentee, included hydroxides, carbonates and bicarbonates of an alkali metal, e.g., sodium, lithium, or potassium, or of an alkaline earth metal, e.g., calcium or magnesium.
That patentee further taught that representative extracting (solvating) mobile phase components includes the elemental gases, e.g., helium, argon, nitrogen, and the like; inorganic compounds, e.g., ammonia, carbon dioxide, water, and the like; organic compounds, e.g., C 1 to C 5 alkanes or alkyl halides, e.g., monofluoro methane, butane, propane carbon tetrachloride, and the like; or combinations of any of the above.
The patentee also taught that the supercritical fluid could be modified by the addition of inorganic and/or organic modifiers, e.g., compounds as listed above. The patentee taught that the most preferable supercritical fluid was carbon dioxide admixed with chloroform.
That patentee further taught the use of a co-solvent which should be compatible with the supercritical fluid selected and should also be capable of at least partially dissolving the compound being extracted. Suitable co-solvents for use in conjunction with the supercritical fluid as taught by that patentee included aromatics, e.g., xylene, toluene and benzene; aliphatics, e.g., C 5 to C 20 alkanes including hexane, heptane and octane; water; C 1 to C 10 alcohols, e.g., methanol, ethanol, propanol, butanol and isopropanol; ethers; acetone; chlorinated hydrocarbons, e.g., chloroform, carbon tetrachloride or methylene chloride; or mixtures of any of the above. The co-solvent was said to be employed in amounts effective to aid in the wetting and/or hydrolysis of the plant material, and can range from excess to about one volume of solvent per one volume of acid, preferably from about 10 to one volume of solvent per one volume of acid.
The operating conditions taught by that patentee included the contacting with the supercritical fluid at temperatures ranging from about 30° C. to about 300° C., preferably from about 75° C. to about 250° C. The pressure employed was said to be sufficient to maintain the supercritical fluid, and was said to be able to be increased from ambient atmospheric pressure to about 400 atmospheres or more, preferably between about 100 and 300 atmospheres.
Accordingly, it would appear that fluid extraction using supercritical fluid (SFE) should be a viable procedure for reducing the toxic chemicals present in the wood, e.g., waste wooden pole materials and used railway ties. It has been found, however, that the extraction of toxic chemicals from wood, e.g., utility poles and used railway ties is not very efficient.
It is thought that the degradation of pentachlorophenol, polychlorinated dibenzo-p-dioxins and polychlorinated dibenzofurans in solution and in sawdust slurry may be achieved by photochemical reactions. However, such a commercially-viable photochemical degradation has not been taught by the prior art.
SUMMARY OF THE INVENTION
Aims of the Invention
Accordingly, it is an object of the present invention to provide a process for increasing the extraction efficiency of contaminants from wood using a supercritical fluid.
Another object of this invention is to provide a process for the photodegradation of such extracted contaminants.
Yet another object of this invention provides a process for the photodegradation of chlorinated organics without separation from the contaminated material.
Statement of Invention
The present invention now provides a process for extracting contaminants from wood, e.g., utility poles, railway ties, fence posts, etc., such contaminants including pentachlorophenol, polychlorinated dibenzo-p-dioxins and polychlorinated dibenzofurans, etc., which process comprises: extracting such contaminant-containing wood with a supercritical fluid (e.g., carbon dioxide) and an entrainer having wood swelling properties (e.g., water and/or methanol) and an agent, (e.g., sodium fluoride), to break the hydrogen bond between the contaminants mentioned above and the wood, at conventional supercritical fluid extraction temperatures and pressures, thereby to extract such contaminants from the wood.
The present invention also provides a process for extracting contaminants from wood, e.g., utility poles, railway ties, fence posts, etc., such contaminants including pentachlorophenol, polychlorinated dibenzo-p-dioxins, and polychlorinated dibenzofurans, etc., and the subsequent photodegradation of the extracted contaminants which process comprises: extracting such contaminant-containing wood with a supercritical fluid (e.g., carbon dioxide) and an entrainer having wood swelling properties (e.g., water and/or methanol) and an agent, (e.g., sodium fluoride), to break the hydrogen bond between the contaminants mentioned above and the wood, at conventional supercritical fluid extraction temperatures and pressures; and exposing, in a slurry of the extracted wood or in a liquid solvent phase resulting from the extraction, the contaminants to radiation including UV or sunlight, in the presence of a photosensitizing amount of a suitable photosensitizer (e.g., methylene blue or protoporphyrin IX).
The present invention also provides a process for photodegrading organic toxic chemicals including pentachlorophenol, polychlorinated dibenzo-p-dioxins, and polychlorinated dibenzofurans in a solution thereof which process comprises: exposing the solution to radiation including UV or sunlight, in the presence of a photosensitizing amount of a suitable photosensitizer.
Other Features of the Invention
By one feature of one embodiment of the invention, the supercritical fluid is carbon dioxide.
By another feature of this embodiment of the invention, the entrainer is water, methanol, ethanol, propanol, isopropanol, toluene, acetone, tetrahydrofuran, dimethylformamide or dimethylsulfoxide.
By yet another feature of this embodiment of this invention, the hydrogen-bond-breaking agent is an alkali metal fluoride, preferably lithium fluoride, or potassium fluoride or sodium fluoride.
By still another feature of the invention, the wood, prior to the supercritical fluid extraction may be reduced in size by one of the following alternative procedures: comminuting the wood; or chipping the wood; or forming flakes from the wood; or producing segments from outer sapwood of treated utility poles, and reducing such segments to flakes; or producing thin sheets of wood from outer sapwood of treated utility poles.
By a feature of the photodegradation embodiments of this invention, the radiation comprises direct sunlight.
By another feature of this embodiment of this invention, the suitable photosensitizer may be methylene blue, various porphyrins, e.g., etioporphyrin, or protoporphyrin IX, or various phthalocyanines, e.g., phthalocyanine, 2,3-naphthalocyanine.
By a further feature thereof, the solvent providing the solution is acetonitrile, methanol, ethanol, or other water-miscible solvents.
By yet another feature thereof, the process takes place in the presence of an amine, e.g., triethanolamine.
By yet other features thereof, the photodegradation to degrade the toxic organic contaminants may take place in a slurry of the contaminated wood, or the photodegradation to degrade toxic organic chemicals may take place in a liquid solvent phase.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings,
FIG. 1 is a bar graph depicting supercritical carbon dioxide extraction of pentachlorophenol-containing jackpine sapwood (0-20 mm layer) for one hour under various conditions, in which the ordinate is pentachlorophenol concentration (ppm, thousands);
FIG. 2 is a bar graph depicting the effect of various entrainers on the extraction efficiency of pentachlorophenol from the 0-20 mm zone of a jackpine pole after one hour extraction at 50° C. and 250 atmosphere with a solvent flow rate of 1 mL/minute, in which the ordinate is pentachlorophenol concentration (ppm, thousands);
FIG. 3 is a bar graph depicting the supercritical fluid extraction of the 0-20 mm zone of a jackpine pole under various conditions, extraction temperature: 50° C., pressure: 250 atmosphere, solvent flow rate: 1 mL/min., extraction time: for 1 hour or otherwise as specified, in which the ordinate is pentachlorophenol concentration (ppm, thousands);
FIG. 4 is a graph depicting the residual pentachlorophenol concentration as a function of extraction time, jackpine sapwood pre-treated with 4 mL water, extracted at 50° C., 250 atm., and 1 mL/min. solvent flow rate, in which the ordinate is residual pentachlorophenol concentration (ppm, thousands);
FIG. 5 is a bar graph depicting the change of total polychlorodibenzo-p-dioxin concentration after supercritical fluid extraction under various conditions, all extractions being carried out at 50° C. and 250 atmosphere, in which the ordinate is total polychlorodibenzo-p-dioxin concentration (ppm);
FIG. 6 is a bar graph depicting the change of octachlorodibenzo-p-dioxin concentration after supercritical fluid extraction under various conditions, all extractions being carried out at 50° C. and 250 atmosphere, in which the ordinate is octachlorodibenzo-p-dioxin concentration (ppm);
FIG. 7 is a bar graph depicting the change of total heptachlorodibenzo-p-dioxin concentration after supercritical fluid extraction under various conditions, all extractions being carried out at 50° C and 250 atmosphere, in which the ordinate is heptachlorodibenzo-p-dioxin concentration (ppm);
FIG. 8 is a bar graph depicting the change of total hexachlorodibenzo-p-dioxin concentration after supercritical fluid extraction under various conditions, all extractions being carried out at 50° C. and 250 atmosphere, in which the ordinate is hexachlorodibenzo-p-dioxin concentration (ppm);
FIG. 9 is a bar graph depicting the change of total polychlorodibenzofuran concentration after supercritical fluid extraction under various conditions, all extractions being carried out at 50° C. and 250 atmosphere, in which the ordinate is total dibenzofuran concentration (ppm);
FIG. 10 is a bar graph depicting the change of octachlorodibenzofuran concentration after supercritical fluid extraction under various conditions, all extractions being carried out at 50° C. and 250 atmosphere, in which the ordinate is octachlorodibenzo-p-dioxin concentration (ppm);
FIG. 11 is a bar graph depicting the change of total heptachlorodibenzofuran concentration after supercritical fluid extraction under various conditions, all extractions being carried out at 50° C. and 250 atmosphere, in which the ordinate is heptachlorodibenzofuran concentration (ppm); and
FIG. 12 is a bar graph depicting the change of total hexachlorodibenzofuran concentration after supercritical fluid extraction under various conditions, all extractions being carried out at 50° C. and 250 atmosphere, in which the ordinate is hexachlorodibenzofuran concentration (ppm).
DESCRIPTION OF PREFERRED EMBODIMENTS
Before describing Examples of this invention, Applicant wishes to set forth certain general features of the process.
Chemicals Used
All the chlorophenol and dihydroxychlorobenzene standards were obtained from Fluka. Pentachlorophenol was 99% pure from Aldrich and was used without further purification. Technical grade pentachlorophenol, manufactured by KMG, was provided by a preservative treating plant. Methylene blue double zinc salt, was acquired from Matheson, Coleman and Bell. Phthalocyaninetetrasulfanate sodium salt was purchased from Porphyrin Products. Protoporphyrin IX was a gift from Professor David Dolphin, Department of Chemistry, UBC. Triethanolamine (99.8%, certified) was purchased from Fisher Scientific. All solvents were spectral grade (OMNISOLV™) from BDH and all other chemicals were of analytical grade.
General Procedure
One general procedure adopted was to produce segments from the treated wood (generally the outer sapwood). While many ways are possible to produce the segments, one procedure is to produce the segments by a saw. These segments are reduced to flakes. It has been found that the use of the flakes in the SCF extraction process facilitated the process.
However, it is possible that pole sections could be used without any processing apart from reduction of length. It is also possible that the poles could be peeled to produce veneer. Moreover, it may be possible to use the SCF extraction process without processing the wood, as well as after peeling to produce veneer or flakes for OSB or waferboard.
Equipment Used
The supercritical fluid extractor was a HP 1081B modified apparatus. The GCMS was a VG Trio-1000 system equipped with a 30 meter DB-5 column. The reagent gas for chemical ionization (CI) GCMS was ultra high purity methane. GC-ECD (electron-capture detector) was carried out on a HP 5890 II GC with a 30 meter DB-1 column. Sample injection for the GC-ECD was done by using a HP 7670 autosampler.
Supercritical Fluid Extraction Procedure
The equipment used was a Hewlett-Packard 1081B modified SFE apparatus with a 40 mL extraction chamber. Liquid carbon dioxide was constantly introduced into the extraction chamber by a high pressure pump, at a constant flow rate. The extraction chamber was connected to a pressure valve, which opened when the pressure exceeded the required pressure. The wood samples were pre-treated for 24-48 hours with the solvents which were to be used as entrainers. Pentachlorophenol-treated pole material to be extracted was ground into 30 mesh powder and loaded into the extraction chamber. The pentachlorophenol retention of the wood prior to, and after extraction, was determined by the X-ray fluorescence analysis. The results presented are the average of three runs.
EXAMPLE 1
Prior Art Extraction of Pentachlorophenol
This example represents a version of the prior art extraction of pentachlorophenol from the sawdust of a jackpine pole, which was treated in 1974. The bar graph of FIG. 1 shows supercritical carbon dioxide extraction of sapwood from the jackpine (0-20 mm layer) under various conditions. The SFE of pentachlorophenol from treated jackpine sapwood, using carbon dioxide as the solvent, was not very efficient, as can be seen from FIG. 1. Varying the temperature, pressure, and flow rate had little effect on the extraction efficiency, in the ranges studied. While it is not desired to be limited by theory, it is thought that the low extraction efficiency may be caused by low solubility of pentachlorophenol in the supercritical solvent. Alternatively, while it is not desired to be limited by theory, it is thought that a strong interaction between pentachlorophenol and the wood matrix may inhibit the extraction process. The fact that increasing the solvent flow rate from 1 mL/minute to 2 mL/minute did not result in a significant pentachlorophenol reduction (FIG. 1), suggested that a strong interaction between pentachlorophenol and wood matrix was the more important factor.
EXAMPLE 2
Extraction of Pentachlorophenol in the Presence of Entrainers and Fluoride Salts
The effect of various entrainers on the extraction efficiency of pentachlorophenol from the 0-20 mm and the 20-40 mm zones of a 1974 jackpine pole after one hour extraction at 50° C. and 250 atmosphere with a solvent flow rate of 1 mL/minute with and without entrainers (4 mL), extraction time: 1 hour, or otherwise as specified, were investigated.
The extraction was enhanced by all the solvents tested (FIGS. 2 and 3). Water, which is not usually a good solvent for pentachlorophenol was found to be a moderately efficient entrainer (FIG. 2).
FIG. 4 shows the effect of extraction time on the residual pentachlorophenol concentration of wood pre-treated with water. The pentachlorophenol content was reduced by 50% in the first hour of extraction. The extraction of the remaining pentachlorophenol was more difficult, and 15% pentachlorophenol remained after 4 hours of extraction.
While it is not desired to be bound by theory, it is believed that the most plausible explanation for this behaviour is that water swells wood, thereby opening the structure and making it easier for the solvent to penetrate into the matrix. Water interacts with lignin and cellulose in the wood, thereby forming hydrogen bonding, and thus weakening the previous pentachlorophenol-wood interaction. Addition of sodium fluoride to water further improved its efficiency as an entrainer, since it has been found that fluorides will destroy hydrogen bonding between pentachlorophenol and lignin or cellulose.
While it is not desired to be bound by theory, it is believed that the organic entrainers probably increased the extraction efficiency by increasing pentachlorophenol solubility, by destroying hydrogen bonds between pentachlorophenol and wood and by swelling the wood.
EXAMPLE 3
Extraction of Dioxins in the Presence of Entrainers
The changes of total polychlorodibenzo-p-dioxin concentration and octachlorodibenzo-p-dioxin concentration in 1974 jackpine pentachlorophenol-treated pole material after supercritical fluid extraction under various conditions, all extractions being carried out at 50° C. and 250 atmosphere, were investigated.
As shown in FIG. 5, with one exception, total dioxin content decreased after extraction in all cases. The total dioxin content increased after SFE for one hour at 50° C. and 250 atmosphere without an entrainer. This was unexpected, since dioxin formation from precursors was virtually impossible under these conditions. After four hours of extraction without entrainer, the total dioxin content decreased by 80%.
As also shown in FIG. 5, a four hour extraction using water as the entrainer was less effective than that without entrainer. Toluene, on the other hand, was quite an effective entrainer. After only one hour of extraction using toluene as the entrainer, the total dioxin content decreased by over 60%. The decrease in octachlorodibenzo-p-dioxin content after SFE under various conditions was similar to that for the total dioxin as shown in FIG. 6.
The change of total heptachlorodibenzo-p-dioxin concentration after supercritical fluid extraction under various conditions, and the change of total hexachlorodibenzo-p-dioxin concentration after supercritical fluid extraction under various conditions, where all extractions were carried out at 50° C. and 250 atmosphere, were all investigated.
As seen by the bar graphs of FIGS. 5, 6, 7 and 8, the total heptachlorodibenzo-p-dioxin was reduced by SFE more easily than was octachlorodibenzo-p-dioxin. While it is not desired to be limited by theory, it is thought that presumably the heptachlorodibenzo-p-dioxin was more soluble in supercritical carbon dioxide than octachlorodibenzo-p-dioxin. After four hours of extraction without entrainer, the heptachlorodibenzo-p-dioxin was reduced by 94% (FIG. 7). Hexachlorodibenzo-p-dioxins were efficiently reduced by SFE with no hexachlorodibenzo-p-dioxins being detected after one hour of extraction using toluene as the entrainer (FIG. 8).
EXAMPLE 4
Extraction of Furans in the Presence of Entrainers and Fluoride Salts
The extraction of polychlorinated dibenzofurans from the sawdust of a jackpine pole, which was treated in 1974, was also investigated. Although under these experimental conditions, water was the best entrainer for the extraction of pentachlorophenol, it had an adverse effect on polychlorinated dibenzofurans extraction.
The change of total polychlorodibenzofuran concentration after supercritical fluid extraction under various conditions, the change of octachlorodibenzofuran concentration after supercritical fluid extraction under various conditions, and the change of total heptachlorodibenzofuran concentration after supercritical fluid extraction under various conditions, and the change of total hexachlorodibenzofuran concentration after supercritical fluid extraction under various conditions, where all extractions were carried out at 50° C. and 250 atmosphere, were all investigated.
Compared to dioxins, the level of polychlorodibenzofurans was more easily reduced by SFE (FIGS. 9-12). After 4 hours of extraction in the absence of an entrainer, the polychlorodibenzofurans were removed to below the detection limit (<10 ppb).
The present invention also provides for the photodegradation of solutions containing toxic organic chemicals. The following examples provide descriptions thereof.
EXAMPLE 5
Photochemical Degradation of Pentachlorophenol
The photochemical degradation of pentachlorophenol was first studied using 1:1 acetonitrile/water (volume) as the solvent. Table 1 below shows the results.
TABLE 1______________________________________Photochemical Degradation of Pentachlorophenol (2 × 10.sup.-3 M)in1:1 Acetonitrile/Water (volume) in the Presence ofTriethanolamine (0.02 M) and Various Sensitizers (1 × 10.sup.-3 M) Methylene ProtoporphyrinPhotosensitizer PCTS Mix* Blue IXTime (hours) PCP Concentration (ppm)______________________________________0 500 500 500 5001 165 91.6 43.2 202 71.6 28 1.2 23 36 1.6 0 04 16 0 0 05 8 0 0 06 3.2 0 0 07 1.6 0 0 0______________________________________ *A mixture of PCTS (phthalocyaninetetrasulfonate), methylene blue, and protoporphyrin IX, each at 3.33 × 10.sup.-4 M
As can be seen from Table 1, pentachlorophenol was rapidly degraded. Only pentachlorophenol and trace amount of tetrachlorophenols were detected by GCMS after acetic anhydride derivatization. Protoporphyrin IX was the most effective photosensitizer, with methylene blue only slightly less effective. Over 99% of the pentachlorophenol was destroyed within two hours using either methylene blue or protoporphyrin IX as sensitizers.
The reaction was then repeated in 50% (volume) aqueous ethanol which was cheaper and less toxic than aqueous acetonitrile.
Table 2 shows the results of such photochemical degradation.
TABLE 2______________________________________Photochemical Degradation of Pentachlorophenol (2 × 10.sup.-3 M)in1:1 Ethanol/Water (volume) in the Presence ofTriethanolamine (0.02 M) and Various Sensitizers (1 × 10.sup.-3 M) Methylene ProtoporphyrinPhotosensitizer PCTS Blue IXTime (minutes) PCP Concentration (ppm)______________________________________0 500 500 50030 229.5 110 4760 180 5.5 1.590 139 0.25 0120 103 0 0150 75.5 0 0180 46 0 0______________________________________
As can be seen from Table 2, the photochemical destruction of pentachlorophenol in this solvent was fast. Within just 1 hour, over 99% of the pentachlorophenol was degraded. Protoporphyrin was again the most effective sensitizer. The differences in the efficiencies of the three sensitizers was probably due to their different extinction coefficients as shown below in Table 3.
TABLE 3______________________________________Extinction Coefficient of Three dyes in 1:1Ethanol/Water (volume) ExtinctionDye Absorption Maxima (nm) Coefficient (M.sup.-1 cm.sup.-1)______________________________________Methylene 660 6.8 × 10.sup.4BluePhthalocyanine- 637 4.0 × 10.sup.4tetrasulfonate 669 3.99 × 10.sup.4Protoporphyrin 378 1.48 × 10.sup.5IX______________________________________
Protoporphyrin has an extinction coefficient almost four times larger than that of phthalocyaninetetrasulfonate in 50% ethanol. All three sensitizers absorb light at different wavelengths. It was thought that if the three sensitizers were mixed together, they would absorb light efficiently over a wider range of wavelength and therefore would be more efficient in degrading pentachlorophenol than any individual sensitizers. As can be seen from Table 1, the mixture system containing three sensitizers, each at one third of their regular concentrations, was more effective than phthalocyaninetetrasulfonate, but still less effective than protoporphyrin IX or methylene blue. While it is not desired to be bound by theory, it is believed that this was probably due to the low extinction coefficient of phthalocyaninetetrasulfonate.
The formation of by-products from the photochemical degradation of pentachlorophenol was carefully studied by GCMS analysis of a concentrated extract derivatized with diazomethane. Six products including 2,3,4,6-tetrachlorophenol, tetrachlorohydroquinone, tetrachloracatechol, tetrachlororesorcinol, and dichloromaleic acid were detected. These are shown below. ##STR1##
All these products were present only in trace amounts as shown below in Table 4. The identities of these products were confirmed by their mass spectra, and by comparing their GC retention times with those of standards on two different columns (DB-1 and DB-5) .
TABLE 4__________________________________________________________________________The yield (%) of some major products from the photochemical degradationof PCP under sunlight orsunlight through a regular window glass filter in the presence oftriethanolamine (0.02 M) andprotoporphyrin or methylene blue (1 × 10.sup.-3 M) in 1:1ethanol/waterExposure (hours) Protoporphyrin Methylene BlueLight 1 2 3 4 1 2 3 4Source Product* % yield__________________________________________________________________________sun- Tri-CP 0.003 0.004 0.006 0.005 0.0014 0.0011 0.0010 0.001light Tetra-CP 0.38 0.055 0.005 0.0025 6.0 1.58 0.075 0.0076 TCC 1.23 0.35 0.065 0.028 1.32 0.236 0.026 0.011 TCHQ 0.15 0.16 0.012 0.0005 0.24 0.26 0.20 0.0006 TCR 0.085 0.019 ND ND 0.33 0.10 ND NDsun- Tri-CP 0.00016 0.00075 0.001 0.0024 ND 0.0004 0.0005 0.0056light Tetra-CP 0.69 0.14 0.011 0.0045 3.54 1.25 0.08 0.0052through TCC 0.99 0.25 0.027 0.012 1.28 0.41 0.044 0.068window TCHQ 0.052 0.117 0.014 0.0024 0.21 0.23 0.22 0.016glass TCR 0.069 0.0244 0.001 ND 0.16 0.09 0.002 ND__________________________________________________________________________ *Product abbreviations: TriCP: trichlorophenols; TetraCP: tetrachlorophenols; TCC: tetrachlorocatechol; TCHQ: tetrachlorohydroquinone; TCR: tetrachlororesorcinol
It was also determined that photochemical degradation of pentachlorophenol under sunlight, through a regular window glass filter, allowed the accumulation of intermediates/products in some cases. In addition to the products identified previously, all three isomers of tetrachlorophenols, six isomers of trichlorophenols, 3,4-dichlorophenol, 2,4-dichlorophenol (and/or 2,5-dichlorophenol, 2,4- and 2,5-dichlorophenols have the same retention time on GC and could not be distinguished), a dichlorodihydroxybenzene and a trichlorodihydroxybenzene were detected, as shown below according to the following scheme. ##STR2##
The dichlorodihydroxybenzene and the trichlorodihydroxybenzene were identified only based on their mass spectra, as no standards were available. All other products were positively identified by comparing their mass spectra and their retention times with those of standards on two different GC columns (DB-1 and DB-5). The tetrachlorophenols and tetrachlorohydroquinone, tetrachlorocatechol, and tetrachlororesorcinol were present in much larger quantities under filtered sunlight than those of the reaction under direct sunlight.
Photodegradation of pentachlorophenol in a slurry of pentachlorophenol-containing sawdust in water was also studied using protoporphyrin IX and methylene blue as sensitizers. The results are summarized in Table 5 below.
TABLE 5______________________________________Photochemical treatment of sawdust (1 g, 27,000 ppm PCP) in 20 mL 1:1ethanol/water (volume) in the presence of a sensitizer (1 ×10.sup.-3 M) andtriethanolamine (0.02 M)PCP Concentration (ppm) Methylene Blue ProtoporphyrinTime (hrs) Liquid Phase Sawdust Liquid Phase Sawdust______________________________________0 540 27,000 667 27,000 (1,500)* (1,500)1 897 -- 536 --2 702 -- 237 --3 170 -- 107 --4 53.5 948 23.2 791 (517) (161)5 12.7 -- 8.3 --6 6.0 -- 4.7* --7 5.5 -- 6.1 --8 4.1 145 4.4 115 (0) (0)______________________________________ *Data in brackets was the concentration of 2,3,4,6tetrachlorophenol in pp
As can be seen from Table 5, pentachlorophenol concentration in both liquid and solid phase decrease rapidly. After eight hours of irradiation, only 4 ppm of pentachlorophenol remained in the liquid phase, and 115-145 ppm of pentachlorophenol remained in the solid phase.
EXAMPLE 6
Photodegradation of Dioxins and Furans
The change in the concentration of polychlorinated dibenzo-p-dioxins and polychlorinated dibenzofurans due to photochemical degradation of pentachlorophenol was investigated. The results are shown below in Table 6.
TABLE 6______________________________________Changes in PCDD/PCDF level after photochemical degradation of PCP(0.0300 g) under sunlight for 8 hours in the presence of protoporphyrinIX and triethanolamineAmount of PCDD/PCDF (ng)Technical PCP Pure PCPControl Photodegradation Control Photodegradation______________________________________HxCDD nd* nd nd ndHpCDD 1,700 460 nd ndOCDD 48,300 12,660 5.83 3.42HxCDF 229 143 nd ndHpCDF 2,100 558 nd ndOCDF 4,800 820 1.1 0.47______________________________________ *: nd = not detected Product Abbreviations: PCP = pentachlorophenol PCDD = polychlorinated benzop-dioxins PCDF = polychlorinated dibenzofurans OCDF = octachlorodibenzofurans OCDD = octachlorodibenzop-dioxin HpEDF = heptachlorodibenzofurans HpCDD = heptachlorodibenzop-dioxin HxCDF = hexachlorodibenzofurans HxCDD = hexachlorodibenzop-dioxin
It can be seen from Table 6 that the levels of polychlorinated dibenzo-p-dioxins and polychlorinated dibenzofurans decreased in technical pentachlorophenol dramatically after photochemical oxidation, with octachlorodibenzo-p-dioxin reduced by over 70%. After photochemical oxidation of pure pentachlorophenol, the levels of octachlorodibenzo-p-dioxin also decreased as shown in Table 6.
Photochemical treatment of toxic wastes is attractive, in that it uses a free energy source, sunlight. A disadvantage of this process is that the reactions are often slow, because only a few contaminants can strongly absorb sunlight. Pentachlorophenol has a weak absorption peak at around 330 nm, which is at the high energy end of sunlight spectrum and is degraded slowly. The use of photosensitizers and amines has been proved successful. Both pentachlorophenol and polychlorinated dibenzo-p-dioxin/polychlorinated dibenzofuran contaminants are degraded rapidly without the formation of more toxic or more recalcitrant by-products. The trace amounts of products/intermediates are more easily mineralized chemically or biologically than pentachlorophenol. Dichloromaleic acid, tetrachlorocatechol, tetrachlororesorcinol, tetrachloroquinone, and lower chlorophenols have been identified as pentachlorophenol photodegradation products. Tetrachlorohydroquinone was also detected. The formation of a number of dimeric and trimeric products during photodegradation of aqueous sodium pentachlorophenate solutions have previously been reported by others. However, no such compounds were formed under the reactions described above. In the present examples, it was found that the presence of photosensitizers and triethanolamine did not result in an increase in polychlorinated dibenzo-p-dioxin/polychlorinated dibenzofuran concentration. While it is not desired to be limited by theory, it is thought that this was probably because polychlorinated dibenzo-p-dioxins and polychlorodibenzofurans were degraded at a rate faster than their formation.
While it is not desired to be limited by theory, it is thought that the photosensitizers and triethanolamine apparently remained unchanged after the photochemical reaction. As a result, when pentachlorophenol-containing sawdust is treated as a slurry, the majority of the sensitizer and triethanolamine remains in the liquid phase and thus can be reused.
It was previously found that in the use of solar irradiation for treating soil contaminated with wood preservative wastes in solid phase, both pentachlorophenol and polycyclic aromatic hydrocarbons were degraded. The presence of anthracene, a polycyclic aromatic hydrocarbon component of the oil, enhanced the degradation of other components.
OPERATION OF PREFERRED EMBODIMENTS
The SFE of pentachlorophenol-containing heartwood of a jackpine pole with carbon dioxide alone was very inefficient. The addition of water as an entrainer reduced the pentachlorophenol concentration by 60% in 1 hour. The addition of sodium fluoride to water improved the extraction efficiency of jackpine sapwood, with the pentachlorophenol content being reduced by 50% in the first hour of extraction. Extraction of the remaining pentachlorophenol was more difficult, and 15% pentachlorophenol remained after 4 hours of extraction.
It has thus been found that supercritical carbon dioxide extraction is a promising technique for the removal of pentachlorophenol from treated poles. The pentachlorophenol concentration was easily reduced, allowing the wood to be treated with microorganisms for complete removal of toxic chlorophenols. While SFE represents only one pretreatment process according to one aspect of this invention before bioremediation using photodegradation according to another aspect of this invention, it has several advantages, including easy removal of chlorophenols and other contaminants, e.g., oil and the extremely toxic polychlorinated dibenzo-p-dioxins and polychlorinated dibenzofurans.
The process used involves the extraction of pentachlorophenol, contaminants (including polychlorinated dibenzo-p-dioxins and polychlorinated dibenzofurans) and the oil solvent from the treated wood poles after processing of the roundwood into particulate matter (i.e., chips, or flakes, or thin sheets). The gas used was carbon dioxide together with entrainers, e.g., water, methanol, ethanol, propanol, isopropanol, acetone, tetrahydrofuran, dimethylformamide or dimethylsulfoxide, as well as alkali metal fluorides, e.g., sodium fluoride, potassium fluoride and lithium fluoride. While it is not desired to be limited by theory, it is thought that the water was helpful by causing the wood cell wall to swell thereby improving access to the trapped pentachlorophenol. While it is not desired to be limited by theory, it is thought that the methanol and other agents, e.g., ethanol, propanol and acetone, behaved similarly. While it is not desired to be limited by theory, it is thought that the sodium fluoride may function by breaking the hydrogen bonding of the pentachlorophenol or impurities in the wood thereby enhancing their recovery. Other agents which break such hydrogen bonding may alternatively be used. Examples of possible other such agents include the following: potassium fluoride and lithium fluoride.
The present invention thus shows that supercritical carbon dioxide extraction, in conjunction with entrainers and hydrogen-bond-treating agents, is a promising technique for the removal of pentachlorophenol from treated poles. The pentachlorophenol concentration was easily reduced, allowing the wood to be treated with microorganisms for complete removal of toxic chlorophenols. While SFE represents only one pretreatment method before final degradation of contaminants, it has several advantages. Among such advantages are easy removal of chlorophenols and other contaminants, e.g., oil, and the extremely toxic polychlorinated dibenzo-p-dioxins and polychlorinated dibenzofurans. Photodegradation may be used according to this invention to degrade toxic organic chemicals from solutions thereof, regardless of the source of the contaminanted solutions. Based upon current knowledge, bioremediation alone is not expected to be able to detoxify all the polycyclic aromatic hydrocarbons, polychlorinated dibenzo-p-dioxins and polychlorinated dibenzofurans. Substantially-complete decontamination of pentachlorophenol-treated poles, desirably includes the SFE treatment of one aspect of this invention followed by the photodegradation according to another aspect of this invention using techniques as described in the present application.
In addition the photodegradation of solutions of such contaminants has also been provided.
CONCLUSION
From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions. Consequently, such changes and modifications are properly, equitably, and "intended" to be, within the full range of equivalence of the following claims. | A process is provided herein for extracting organic toxic contaminants including pentachlorophenol, polychlorinated dibenzo-p-dioxins, and polychlorinated dibenzofurans, from wood, e.g., utility poles, fence posts, or railway ties. The process comprises extracting the wood with a supercritical fluid in conjunction with an entrainer having wood swelling properties and an agent to break the hydrogen bond between the organic toxic contaminants and the wood, at conventional supercritical fluid extraction temperatures and pressures. The process is further improved by exposing, either in a slurry of the wood phase, or in a liquid phase resulting from such extraction, the contaminants to UV, e.g., sunlight, in the presence of a photosensitizer. The present invention also provides for the photodegradation of a solution of organic toxic chemicals including pentachlorophenol, polychlorinated dibenzo-p-dioxins, and polychlorinated dibenzofurans, by exposing such solution to UV, e.g., sunlight, in the presence of a photosensitizer. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Great Britain Patent Application No. 1519195.0, filed Oct. 30, 2015, the entirety of which is incorporated by reference herein.
TECHNICAL FIELD
[0002] This application relates to novel compounds and their use as CGRP receptor antagonists. Compounds described herein may be useful in the treatment or prevention of cerebrovascular or vascular disorders such as migraine. The application is also directed to pharmaceutical compositions comprising these compounds and the manufacture and use of these compounds and compositions in the prevention or treatment of such cerebrovascular or vascular disorders.
BACKGROUND OF THE INVENTION
[0003] Migraine is a highly disabling neurovascular disorder characterized by attacks of moderate to severe headache that are often associated with nausea, vomiting, photophobia, and phonophobia. The attacks can last from 4 to 72 h, and the average attack frequency is 1 or 2 per month. About 20-30% of migraine patients experience transient focal neurologic symptoms known as aura, which are usually visual and can precede or accompany the headache. Migraine afflicts about 11% of adults worldwide and results in a significant socioeconomic burden, in terms of both quality of life and lost productivity.
[0004] Whilst the pathomechanism of migraine is still unclear, one of the leading hypotheses is based on activation of the trigeminovascular system (TS). Several neuropeptides participate in this activation, calcitonin gene-related peptide (CGRP) playing a crucial role among them. CGRP exerts various biological effects through the peripheral and central nervous system (CNS). The functional CGRP-receptor (CGRP-R) complex has been well characterized, and novel therapeutic approaches target CGRP itself and its receptors. This invention relates to the development of CGRP receptor antagonists (CGRP-RA).
[0005] CGRP, a 37-amino acid neuropeptide derived from the gene encoding calcitonin, is formed from the alternative splicing of the calcitonin/CGRP gene located on chromosome 11. In humans, CGRP has two isoforms: α- and β-CGRP. The β-isoform differs from the α-isoform in the amino acids located at positions 3, 22 and 25. The chemical structure of CGRP involves a disulphide bridge between residues 2 and 7 and an amidated C-terminus. The cyclic cysteine2-cysteine7 motif has a basic role in receptor activation. In the human trigeminal ganglia (TRIG), CGRP-immunoreactive neurons account for up to 50% of all neurons. It has been demonstrated through an in situ hybridization technique that 40% of all nerve cell bodies contain CGRP mRNA and CGRP. Double immunostaining has shown that in the human TRIG CGRP is co-localized with nitric oxide synthase, substance P (SP), pituitary adenylate cyclase activating peptide (PACAP) and nociceptin, which may play a role in the pathomechanism of migraine.
[0006] The functional CGRP-R consists of three proteins: i) Calcitonin Receptor Like Receptor (known as CRLR, CALCRL or CLR) is a seven-transmembrane spanning protein, which forms the ligand binding site with; ii) RAMP1, determining the specificity of the receptor; and iii) the CGRP-R component protein (RCP) couples the receptor to intracellular signal transduction pathways and to adenylyl cyclase.
[0007] It is thought that the C-terminal region of CGRP initially binds to the large N-terminal extracellular domain (ECD) of the receptor, likely making interactions with both CLR and RAMP1. This initial binding event greatly increases the local concentration of the N-terminal region of CGRP in the vicinity of the juxtamembrane portion of CLR, allowing their relatively weak interaction to occur and resulting in receptor activation. Since mutagenesis experiments indicated that most small molecule antagonists interacted with the ECD of CLR/RAMP1, it was hypothesized that they bind to this region of the receptor and prevent the initial binding of CGRP to the receptor. A notable exception to this model of peptide binding and small molecule receptor antagonism is the hydroxypyridine class of antagonists, which apparently interact with transmembrane domain 7 (TM7) in CLR and not with the extracellular domain (Bell I M, J. Med. Chem., 2014, 57(19), 7838-58).
[0008] The first clinically tested CGRP-RA, olcegepant, was based on a dipeptide backbone, had high molecular weight, and was not orally bioavailable. Nonetheless, when dosed intravenously, olcegepant proved to be an effective antimigraine agent, and this proof-of-concept study greatly increased interest in the field. Following the success of olcegepant, a number of orally acting CGRP-RAs were advanced to clinical trials. Telcagepant and compounds BI 44370, MK-3207, and BMS-927711 have all been used for acute treatment of migraine as oral agents. Taken together, the results from these clinical studies demonstrate that CGRP-RAs can exhibit similar antimigraine efficacy to the gold standard triptan drugs but with a significantly lower incidence of adverse events than is typically observed with a triptan. It is worth noting that the available data indicate that these CGRP blockers do not cause vasoconstriction and suggest that they may have a superior cardiovascular safety profile to the triptans. One potential concern that has been reported with some CGRP-RAs is the observation of elevated levels of liver transaminases in some patients, and this reportedly led to the discontinuation of MK-3207. Although elevated liver enzymes were also found in a small number of subjects after dosing with telcagepant for an extended period, it is not clear if these findings are in some way mechanism-based or specific to these two compounds. In clinical trials for acute migraine therapy, the CGRP-RAs displayed favorable effects, but their frequent administration was associated with liver toxicity (the elevation of liver transaminases), which limited their clinical use. Hence, there is a need to develop new CGRP-RAs which do not induce liver injury.
SUMMARY OF THE INVENTION
[0009] One possibility to address the risk of liver injury is to target a non-oral route of delivery for a small molecule which will place a lower burden on the liver through first-pass exposure. The compounds of the invention can be used for sub-cutaneous, intravenous and/or intranasal routes of administration. The molecular profile for a CGRP-RA intended for such routes of administration differs from the profile required for an oral molecule: extremely high affinity and functional potency, coupled with extremely high solubility is required. Disclosed herein are novel compounds, and the first medical use of said compounds as CGRP receptor antagonists.
[0010] Compounds of the invention include compounds of formula (I)
[0000]
[0000] or salts thereof, wherein R 1 is selected from
[0000]
[0000] R 2 is H or forms a spirocyclic heterocyclic ring with R 3 ;
R 3 forms a spirocyclic heterocyclic ring with R 2 or is a heterocyclic ring if R 2 is H.
DETAILED DESCRIPTION OF THE INVENTION
[0011] The invention relates to novel compounds. The invention also relates to the use of novel compounds as CGRP receptor antagonists. The invention further relates to the use of compounds in the manufacture of medicaments for use as CGRP receptor antagonists. The invention further relates to compounds, compositions and medicaments for the treatment of cerebrovascular or vascular disorders such as migraine (including subtypes such as: migraine without aura, chronic migraine, pure menstrual migraine, menstrually-related migraine, migraine with aura, familial hemiplegic migraine, sporadic hemiplegic migraine, basilar-type migraine, cyclical vomiting, abdominal migraine, benign paroxysmal vertigo of childhood, retinal migraine), status migrainosus, cluster headache, dialysis headache, paroxysmal hemicrania, osteoarthritis, hot flashes associated with menopause or medically induced menopause due to surgery or drug treatment, hemicrania continua, cyclic vomiting syndrome, allergic rhinitis, or rosacea. The invention further relates to compounds, compositions and medicaments for the treatment of broader pain states and diseases involving neurogenic inflammation including dental pain, earache, middle ear inflammation, sunburn, joint pain associated with osteoarthritis and rheumatoid arthritis, cancer pain, fibromyalgia, diabetic neuropathy, pain associated with inflammatory bowel disease-Crohn's disease, gout, complex regional pain syndrome, Behçet's disease, endometriosis pain, back pain or cough.
[0012] Compounds exemplified herein are based around the structure: formula (I):
[0000]
[0000] wherein R 1 is selected from
[0000]
[0000] R 2 is H or forms a spirocyclic heterocyclic ring with R 3 ;
R 3 forms a spirocyclic heterocyclic ring with R 2 or is a heterocyclic ring if R 2 is H.
[0013] In a more particular embodiment, the substituent for R 1 is
[0000]
[0014] In a particular embodiment, the substituent for R 2 is H and R 3 is selected from:
[0000]
[0000] In a more particular embodiment, R 3 is
[0000]
[0015] In a particular embodiment, R 2 forms a spirocyclic heterocyclic ring with R 3 to form:
[0000]
[0016] Further embodiments of the invention include methods of treatment comprising administering a compound of formulas (I) as a CGRP receptor antagonist. The treatment using a compound of formulas (I) may be in the treatment of cerebrovascular disorders such as migraine (including subtypes such as: migraine without aura, chronic migraine, pure menstrual migraine, menstrually-related migraine, migraine with aura, familial hemiplegic migraine, sporadic hemiplegic migraine, basilar-type migraine, cyclical vomiting, abdominal migraine, benign paroxysmal vertigo of childhood, retinal migraine), status migrainosus, cluster headache, dialysis headache, paroxysmal hemicrania, osteoarthritis, hot flashes associated with menopause or medically induced menopause due to surgery or drug treatment, hemicrania continua, cyclic vomiting syndrome, allergic rhinitis, or rosacea. The invention further relates to compounds, compositions and medicaments for the treatment of broader pain states and diseases involving neurogenic inflammation including dental pain, earache, middle ear inflammation, sunburn, joint pain associated with osteoarthritis and rheumatoid arthritis, cancer pain, fibromyalgia, diabetic neuropathy, pain associated with inflammatory bowel disease—Crohn's disease, gout, complex regional pain syndrome, Behçet's disease, endometriosis pain, back pain or cough.
[0017] Certain novel compounds of the invention show particularly high activities as CGRP receptor antagonists.
[0018] Exemplary compounds include:
[0000]
[0019] The NMR and LCMS properties as well as the biological activities of these compounds are set out in Tables 2 and 3.
[0020] To the extent that any of the compounds described have chiral centres, the present invention extends to all optical isomers of such compounds, whether in the form of racemates or resolved enantiomers. The invention described herein relates to all crystal forms, solvates and hydrates of any of the disclosed compounds however so prepared. To the extent that any of the compounds and intermediates disclosed herein have acid or basic centres such as carboxylates or amino groups, then all salt forms of said compounds are included herein. In the case of pharmaceutical uses, the salt should be seen as being a pharmaceutically acceptable salt.
[0021] Pharmaceutically acceptable salts that may be mentioned include acid addition salts and base addition salts. Such salts may be formed by conventional means, for example by reaction of a free acid or a free base form of a compound with one or more equivalents of an appropriate acid or base, optionally in a solvent, or in a medium in which the salt is insoluble, followed by removal of said solvent, or said medium, using standard techniques (e.g. in vacuo, by freeze-drying or by filtration). Salts may also be prepared by exchanging a counter-ion of a compound in the form of a salt with another counter-ion, for example using a suitable ion exchange resin.
[0022] Examples of pharmaceutically acceptable salts include acid addition salts derived from mineral acids and organic acids, and salts derived from metals such as sodium, magnesium, or preferably, potassium and calcium.
[0023] Examples of acid addition salts include acid addition salts formed with acetic, 2,2-dichloroacetic, adipic, alginic, aryl sulfonic acids (e.g. benzenesulfonic, naphthalene-2-sulfonic, naphthalene-1,5-disulfonic and p-toluenesulfonic), ascorbic (e.g. L-ascorbic), L-aspartic, benzoic, 4-acetamidobenzoic, butanoic, (+)-camphoric, camphor-sulfonic, (+)-(1S)-camphor-10-sulfonic, capric, caproic, caprylic, cinnamic, citric, cyclamic, dodecylsulfuric, ethane-1,2-disulfonic, ethanesulfonic, 2-hydroxyethanesulfonic, formic, fumaric, galactaric, gentisic, glucoheptonic, gluconic (e.g. D-gluconic), glucuronic (e.g. D-glucuronic), glutamic (e.g. L-glutamic), α-oxoglutaric, glycolic, hippuric, hydrobromic, hydrochloric, hydriodic, isethionic, lactic (e.g. (+)-L-lactic and (±)-DL-lactic), lactobionic, maleic, malic (e.g. (−)-L-malic), malonic, (±)-DL-mandelic, metaphosphoric, methanesulfonic, 1-hydroxy-2-naphthoic, nicotinic, nitric, oleic, orotic, oxalic, palmitic, pamoic, phosphoric, propionic, L-pyroglutamic, salicylic, 4-amino-salicylic, sebacic, stearic, succinic, sulfuric, tannic, tartaric (e.g. (+)-L-tartaric), thiocyanic, undecylenic and valeric acids.
[0024] Particular examples of salts are salts derived from mineral acids such as hydrochloric, hydrobromic, phosphoric, metaphosphoric, nitric and sulfuric acids; from organic acids, such as tartaric, acetic, citric, malic, lactic, fumaric, benzoic, glycolic, gluconic, succinic, arylsulfonic, pamoic acids; and from metals such as sodium, magnesium, or preferably, potassium and calcium.
[0025] Also encompassed are any solvates of the compounds and their salts. Preferred solvates are solvates formed by the incorporation into the solid state structure (e.g. crystal structure) of the compounds of the invention of molecules of a non-toxic pharmaceutically acceptable solvent (referred to below as the solvating solvent). Examples of such solvents include water, alcohols (such as ethanol, isopropanol and butanol) and dimethylsulfoxide. Solvates can be prepared by recrystallising the compounds of the invention with a solvent or mixture of solvents containing the solvating solvent. Whether or not a solvate has been formed in any given instance can be determined by subjecting crystals of the compound to analysis using well known and standard techniques such as thermogravimetric analysis (TGE), differential scanning calorimetry (DSC) and X-ray crystallography.
[0026] The solvates can be stoichiometric or non-stoichiometric solvates. Particular solvates may be hydrates, and examples of hydrates include hemihydrates, monohydrates and dihydrates.
[0027] For a more detailed discussion of solvates and the methods used to make and characterise them, see Bryn et al., Solid-State Chemistry of Drugs, Second Edition, published by SSCI, Inc of West Lafayette, Ind., USA, 1999, ISBN 0-967-06710-3.
[0028] “Pharmaceutically functional derivatives” of compounds as defined herein includes ester derivatives and/or derivatives that have, or provide for, the same biological function and/or activity as any relevant compound of the invention. Thus, for the purposes of this invention, the term also includes prodrugs of compounds as defined herein.
[0029] The term “prodrug” of a relevant compound includes any compound that, following oral or parenteral administration, is metabolised in vivo to form that compound in an experimentally-detectable amount, and within a predetermined time (e.g. within a dosing interval of between 6 and 24 hours (i.e. once to four times daily)).
[0030] Prodrugs of compounds may be prepared by modifying functional groups present on the compound in such a way that the modifications are cleaved, in vivo when such prodrug is administered to a mammalian subject. The modifications typically are achieved by synthesizing the parent compound with a prodrug substituent. Prodrugs include compounds wherein a hydroxyl, amino, sulfhydryl, carboxyl or carbonyl group in a compound is bonded to any group that may be cleaved in vivo to regenerate the free hydroxyl, amino, sulfhydryl, carboxyl or carbonyl group, respectively.
[0031] Examples of prodrugs include, but are not limited to, esters and carbamates of hydroxyl functional groups, ester groups of carboxyl functional groups, N-acyl derivatives and N-Mannich bases. General information on prodrugs may be found e.g. in Bundegaard, H. “Design of Prodrugs” p. 1-92, Elsevier, New York-Oxford (1985).
DEFINITIONS
Heterocyclic
[0032] Heterocyclic means a cyclic group which may be aromatic in which at least one ring member is other than carbon. For example, at least one ring member (for example one, two or three ring members) may be selected from nitrogen, oxygen and sulphur. The point of attachment of heteroaryl groups may be via any atom of the ring system. Exemplary heteroaryl groups include pyridyl, indazolyl, 1,4-dihydro-2H-pyrido[2,3-d][1,3]oxazin-2-one, 1,3-dihydro-2H-imidazo[4,5-b]pyridin-2-one, 3,4-dihydroquinazolin-2(1H)-one, quinolin-2(1H)-one, piperidinyl, pyrrolidinyl, 2,8-diazaspiro[4.5]decane and the like.
[0033] The term “pharmaceutical composition” in the context of this invention means a composition comprising an active agent and comprising additionally one or more pharmaceutically acceptable carriers. The composition may further contain ingredients selected from, for example, diluents, adjuvants, excipients, vehicles, preserving agents, fillers, disintegrating agents, wetting agents, emulsifying agents, suspending agents, sweetening agents, flavouring agents, perfuming agents, antibacterial agents, antifungal agents, lubricating agents and dispersing agents, depending on the nature of the mode of administration and dosage forms. The compositions may take the form, for example, of tablets, dragees, powders, elixirs, syrups, liquid preparations including suspensions, sprays, inhalants, tablets, lozenges, emulsions, solutions, cachets, granules, capsules and suppositories, as well as liquid preparations for injections, including liposome preparations.
[0034] The dosages may be varied depending upon the requirements of the patient, the severity of the condition being treated, and the compound being employed. Determination of the proper dosage for a particular situation is within the skill of the art. Generally, treatment is initiated with the smaller dosages which are less than the optimum dose of the compound. Thereafter the dosage is increased by small increments until the optimum effect under the circumstances is reached. For convenience, the total daily dosage may be divided and administered in portions during the day if desired.
[0035] The magnitude of an effective dose of a compound will, of course, vary with the nature of the severity of the condition to be treated and with the particular compound and its route of administration. The selection of appropriate dosages is within the ability of one of ordinary skill in this art, without undue burden. In general, the daily dose range may be from about 10 μg to about 30 mg per kg body weight of a human and non-human animal, preferably from about 50 μg to about 30 mg per kg of body weight of a human and non-human animal, for example from about 50 μg to about 10 mg per kg of body weight of a human and non-human animal, for example from about 100 μg to about 30 mg per kg of body weight of a human and non-human animal, for example from about 100 μg to about 10 mg per kg of body weight of a human and non-human animal and most preferably from about 100 μg to about 1 mg per kg of body weight of a human and non-human animal.
Preparation of the Compounds of the Invention
[0036] Compounds of the invention may be prepared, for example, by routes including those depicted in Scheme 1. Details of many of the standard transformations such as those in the routes below and others which could be used to perform the same transformations can be found in standard reference textbooks such as “Organic Synthesis”, M. B. Smith, McGraw-Hill (1994) or “Advanced Organic Chemistry”, 4 th edition, J. March, John Wiley & Sons (1992).
[0000]
[0037] Urea formations between amino acid intermediates, for example methyl esters of amino acids, and amine intermediates can be formed under conditions using a coupling agent such as DSC in the presence of a base such as triethylamine or DIPEA in solvents such as DMF. The methyl ester portion of the subsequently formed urea derivatives can be saponified using aqueous bases such as lithium hydroxide in a suitable solvent such as THF, MeOH, 1,4-dioxane, EtOAc or a mixture thereof. The acid intermediates thus formed can be converted into amide examples under standard conditions, for example using a coupling agent such as HATU, in the presence of a base such as DIPEA in a suitable solvent such as DMF or DCM. The amine partners for such amide couplings can be prepared using an appropriate combination of standard transformations (for example reductive aminations using an amine, an aldehyde or ketone, and a reducing agent such as sodium triacetoxyborohydride in a solvent such as DCM in the presence of acetic acid; or amide formation under conditions such as those detailed above; or nucleophilic aromatic substitution (S N Ar) reactions). In the synthesis of compounds of the invention S N Ar reactions between an amine and a halogenated heterocycle are typically conducted at 80° C., in a suitable solvent such as MeCN and in the presence of a base such as K 2 CO 3 . Following standard transformations such as the above, or during such a sequence of such transformations, removal of standard protecting groups may be necessary and can be undertaken using conditions which can be found in reference textbooks, for example “Protecting Groups”, 3 rd edition, P. J. Kocieński, Georg Thieme Verlag (2005). One such transformation is the removal of a tert-butoxycarbonyl group (commonly known as a Boc group) from an amine under acidic conditions such as HCl in a solvent such as 1,4-dioxane, MeOH, EtOH, DCM or combinations thereof. It can be appreciated that Boc deprotection of amine intermediates of the invention which possess additional basic centres may result in hydrochloride salts of different stoichiometries. For example the Boc deprotection of an intermediate with one additional basic centre will result in the formation of a new amine intermediate which is for example the mono-hydrochloride or di-hydrochloride salt, which will often be used without neutralisation of the hydrochloride salt to produce the free base of the intermediate, as it can be appreciated that in the subsequent amide formation an excess of a base such as DIPEA or triethylamine is typically used to neutralise the hydrochloride salt. Amine intermediates of the invention formed by Boc-deprotection which are used without neutralisation to the free base are named herein as the hydrochloride (x HCl), and the present invention extends to all salt forms of the said intermediates. Another such protecting group removal is the deprotection of a carbobenzyloxy-protected amine (commonly known as a CBZ or Z group) using reductive conditions such as catalysis by palladium on carbon in a solvent such as EtOH or aqueous EtOH in the presence of gaseous H 2 . Alternative conditions for the removal of a CBZ-protecing group include transfer hydrogenation, for example using a palladium on carbon catalyst in the presence of or ammonium formate in a solvent such as EtOH or aqueous EtOH at an elevated temperature such as 70° C.
General Procedures
[0038] Where no preparative routes are included, the relevant intermediate is commercially available. Commercial reagents were utilized without further purification. Room temperature (rt) refers to approximately 20-27° C. 1 H NMR spectra were recorded at 400 MHz or 600 MHz on Bruker, Varian or JEOL instruments at ambient temperature unless otherwise specified. Chemical shift values are expressed in parts per million (ppm), i.e. (δ)-values. The following abbreviations are used for the multiplicity of the NMR signals: s=singlet, br=broad, d=doublet, t=triplet, q=quartet, quin=quintet, h=heptet, dd=doublet of doublets, dt=double of triplets, m=multiplet. Coupling constants are listed as J values, measured in Hz. NMR and mass spectroscopy results were corrected to account for background peaks. Chromatography refers to column chromatography performed using silica and executed under positive pressure (flash chromatography) conditions. LCMS experiments were carried out using electrospray conditions under the conditions below. LCMS data are given in the format: Mass ion, electrospray mode (positive or negative), retention time (experimental text and Table 1); Mass ion, electrospray mode (positive or negative), retention time, approximate purity (Table 2).
[0039] Method A.
[0040] Instruments: Hewlett Packard 1100 with G1315A DAD, Micromass ZQ; Column: Waters X-Bridge C-18, 2.5 micron, 2.1×20 mm or Phenomenex Gemini-NX C-18, 3 micron, 2.0×30 mm; Gradient [time (min)/solvent D in C (%)]: 0.00/2, 0.10/2, 8.40/95, 10.00/95; Solvents: solvent C=2.5 L H 2 O+2.5 mL 28% ammonia in water solution; solvent D=2.5 L MeCN+135 mL H 2 O+2.5 mL 28% ammonia in water solution; Injection volume 1 μL; UV detection 230 to 400 nM; column temperature 45° C.; Flow rate 1.5 mL/min.
[0041] Method B.
[0042] Instruments: Agilent Technologies 1260 Infinity LC with Chemstation software, Diode Array Detector, Agilent 6120B Single Quadrupole MS with API-ES Source; Column: Phenomenex Gemini-NX C-18, 3 micron, 2.0×30 mm; Gradient [time (min)/solvent D in C (%)]: 0.00/5, 2.00/95, 2.50/95, 2.60/5, 3.00/5; Solvents C and D are as described above in Method A; Injection volume 0.5 μL; UV detection 190 to 400 nM; column temperature 40° C.; Flow rate 1.5 mL/min.
ABBREVIATIONS
[0000]
DCM=dichloromethane
DIPEA=N,N-diisopropylethylamine
DMAC=N,N-dimethylacetamide
DMF=dimethylformamide
DMSO=dimethylsulfoxide
ES=electrospray
EtOAc=ethyl acetate
h=hour(s)
HATU=1-[bis(dimethylamino)methylene]-1H-1,2,3-triazolo[4,5-b]pyridinium 3-oxid hexafluorophosphate
L=litre
LC=liquid chromatography
LCMS=liquid chromatography mass spectrometry
MeCN=acetonitrile
min=minute(s)
MS=mass spectrometry
NMR=nuclear magnetic resonance
rcf=relative centrifugal force
rpm=revolutions per minute
rt=room temperature
s=second(s)
THF=tetrahydrofuran
[0064] Prefixes n-, s-, i-, t- and tert- have their usual meanings: normal, secondary, iso, and tertiary.
Synthesis of Intermediates
Preparation of Carboxylic Acid Intermediates
Typical procedure for the preparation of carboxylic acid intermediates via urea formation and subsequent saponification, as exemplified by the preparation of Intermediate 6, (2R)-3-(7-methyl-1H-indazol-5-yl)-2-{[(2′-oxo-1′,2′-dihydro-1H-spiro[piperidine-4,4′-pyrido[2,3-d][1,3]oxazin]-1-yl)carbonyl]amino}propanoic acid
[0065]
[0066] Step 1) Et 3 N (2.26 mL, 16.3 mmol) was added to a solution of (R)-methyl 2-amino-3-(7-methyl-1H-indazol-5-yl)propanoate dihydrochloride (Intermediate 5, 995 mg, 3.3 mmol) and DSC (917 mg, 3.6 mmol) in DMF (20 mL) and the mixture stirred at rt for 30 min. Spiro[piperidine-4,4′-[4H]pyrido[2,3-d][1,3]oxazin]-2′(1′H)-one (Intermediate 4, 785 mg, 3.6 mmol) was then added portionwise and the reaction mixture stirred at rt for 18 h before concentration in vacuo. The residue was partitioned between H 2 O and MeOH/DCM (1:9), the phases were separated and the aqueous layer was washed with H 2 O. Residual solid from the separation step was dissolved in MeOH and the combined organic layers were concentrated in vacuo and purified by flash chromatography, eluting with EtOAc in MeOH (20:1), to yield methyl (2R)-3-(7-methyl-1H-indazol-5-yl)-2-{[(2′-oxo-1′,2′-dihydro-1H-spiro[piperidine-4,4′-pyrido[2,3-d][1,3]oxazin]-1-yl)carbonyl]amino}propanoate (1.06 g, 2.22 mmol) as a white solid.
[0067] LCMS (Method A): m/z 479.3 (ES+), at 2.61 min, 100%.
[0068] 1 H NMR: (400 MHz, DMSO-d 6 ) δ: 1.59-1.75 (m, 2H), 1.78-1.90 (m, 2H), 2.45 (s, 3H), 2.90-3.08 (m, 4H), 3.59 (s, 3H), 3.86-3.96 (m, 2H), 4.28-4.38 (m, 1H), 6.94-7.06 (m, 3H), 7.32 (dd, J=7.4, 1.2, 1H), 7.39 (s, 1H), 7.95 (s, 1H), 8.18 (dd, J=5.1, 1.6, 1H), 10.79 (s, 1H), 13.04 (s, 1H).
[0069] Step 2) Methyl (2R)-3-(7-methyl-1H-indazol-5-yl)-2-{[(2′-oxo-1′,2′-dihydro-1H-spiro[piperidine-4,4′-pyrido[2,3-d][1,3]oxazin]-1-yl)carbonyl]amino}propanoate (1.06 g, 2.22 mmol) was dissolved in THF (15 mL) and MeOH (3 mL) and an aqueous solution of LiOH (1M, 4.4 mL, 4.4 mmol) was added dropwise. After stirring at rt for 3.5 h further aqueous LiOH (1M, 2.2 mL, 2.2 mmol) was added dropwise and the mixture stirred for 1 h at rt before concentration under a stream of nitrogen. The residue was dissolved in a minimum volume of H 2 O and cooled to 0° C. Aqueous 1M HCl was added dropwise to adjust the pH to ≦3 and the resulting precipitate was isolated by filtration, washed with cold H 2 O and Et 2 O to yield the title compound (877 mg, 1.89 mmol) as a pale yellow solid.
Data in Table 1.
Intermediate 7, (2R)-3-(7-methyl-1H-indazol-5-yl)-2-({[4-(2-oxo-2,3-dihydro-1H-imidazo[4,5-b]pyridin-1-yl)piperidin-1-yl]carbonyl}amino)propanoic acid
[0070]
[0071] The title compound (1.50 g, 3.2 mmol) was prepared over two steps from (R)-methyl 2-amino-3-(7-methyl-1H-indazol-5-yl)propanoate (Intermediate 5, 1.00 g, 4.3 mmol) and 1-(piperidin-4-yl)-1,3-dihydro-2H-imidazo[4,5-b]pyridin-2-one (Intermediate 1, 1.02 g, 4.7 mmol) using the methods of Intermediate 6.
Data in Table 1.
Intermediate 9, (2R)-3-(7-methyl-1H-indazol-5-yl)-2-({[4-(2-oxo-1,4-dihydroquinazolin-3(2H)-yl)piperidin-1-yl]carbonyl}amino)propanoic acid
[0072]
[0073] The title compound (561 mg, 1.18 mmol) was prepared over two steps from (R)-methyl 2-amino-3-(7-methyl-1H-indazol-5-yl)propanoate (Intermediate 5, 917 mg, 3.93 mmol) and 3-(piperidin-4-yl)-3,4-dihydroquinazolin-2(1H)-one (Intermediate 3, 1.00 g, 4.32 mmol) using the methods of Intermediate 6.
Data in Table 1.
Intermediate 8, (2R)-3-(7-methyl-1H-indazol-5-yl)-2-({[4-(2-oxo-1,2-dihydroquinolin-3-yl)piperidin-1-yl]carbonyl}amino)propanoic acid
[0074]
[0075] Step 1) To a solution of (R)-methyl 2-amino-3-(7-methyl-1H-indazol-5-yl) propanoate (Intermediate 5, 6.05 g, 25.9 mmol) in DMF (60 mL) under N 2 at approximately −20° C. was added CDI (8.40 g, 51.8 mmol) and the mixture was stirred for 15 min while keeping the temperature below −10° C. A solution of H 2 O (2.34 mL) in a few mL of DMF was added and stirring continued for 15 min while keeping the temperature below −10° C. 3-(Piperidin-4-yl)quinolin-2(1H)-one (Intermediate 2, 6.99 g, 30.6 mmol), DIPEA (4.93 mL, 28.2 mmol) and DCM (20 mL) were then added in that order and the mixture was heated to 40° C. under N 2 for 12 hrs. After cooling to rt, 2M HCl (aq) (38.7 mL) was added and the mixture was extracted twice with DCM. The combined organic extracts were washed three times with H 2 O, dried (Na 2 SO 4 ) and concentrated in vacuo. Purification by flash chromatography, eluting with MeOH/DCM (5:95), yielded methyl (2R)-3-(7-methyl-1H-indazol-5-yl)-2-({[4-(2-oxo-1,2-dihydroquinolin-3-yl)piperidin-1-yl]carbonyl}amino)propanoate (10.4 g, 21.3 mmol) as a light tan solid.
[0076] 1 H NMR: (400 MHz, CDCl 3 ) δ: 1.40-1.60 (m, 2H), 1.95-1.97 (m, 2H), 2.46 (s, 3H), 2.90-3.00 (m, 2H), 3.11-3.26 (m, 3H), 3.76 (s, 3H), 4.07-4.12 (m, 2H), 4.86-4.91 (m, 1H), 5.18 (d, J=7.6, 1H), 6.93 (s, 1H), 7.17-7.21 (m, 1H), 7.24 (s, 1H), 7.32 (s, 1H), 7.43-7.54 (m, 3H), 7.95 (s, 1H), 10.70 (s, 2H).
[0077] Step 2) To a solution of methyl (2R)-3-(7-methyl-1H-indazol-5-yl)-2-({[4-(2-oxo-1,2-dihydroquinolin-3-yl)piperidin-1-yl]carbonyl}amino)propanoate (9.79 g, 20.1 mmol) in 1,4-dioxane (150 mL) was added a solution of LiOH.H 2 O (1.26 g, 30.0 mmol) in H 2 O (150 mL) and the mixture was stirred at rt for 2 h. The reaction mixture was concentrated in vacuo to near-dryness and re-dissolved in H 2 O before being acidified with aqueous 2M HCl (approximately 15 mL) whilst being rapidly stirred. The resulting thick white precipitate was isolated by filtration and washed with H 2 O until the washings were near neutral pH. Drying in vacuo yielded the title compound (8.11 g, 17.1 mmol) as an off-white solid.
Data in Table 1.
Preparation of Amine Intermediates
Intermediate 12, benzyl 4-(2,8-diazaspiro[4.5]dec-8-yl)piperidine-1-carboxylate hydrochloride
[0078]
[0079] Step 1) A mixture of tert-butyl 2,8-diazaspiro[4.5]decane-2-carboxylate (Intermediate 10, 0.50 g, 2.08 mmol), benzyl 4-oxopiperidine-1-carboxylate (Intermediate 11, 583 mg, 2.50 mmol), acetic acid (143 μL, 2.50 mmol) and sodium triacetoxyborohydride (530 mg, 2.50 mmol) in DCM (10 mL) was stirred at rt overnight. Further benzyl 4-oxopiperidine-1-carboxylate (Intermediate 11, 600 mg, 2.57 mmol) and acetic acid (150 μL, 2.62 mmol) were added and the mixture stirred at rt for 1 h before addition of further sodium triacetoxyborohydride (550 mg, 2.59 mmol). The mixture was stirred at rt overnight before concentration in vacuo and purification by gradient flash chromatography, eluting with 0-10% MeOH in DCM, yielded tert-butyl 8-{1-[(benzyloxy)carbonyf]piperidin-4-yl}-2,8-diazaspiro[4.5]decane-2-carboxylate (620 mg, 1.35 mmol).
[0080] LCMS (Method B): m/z 458.2 (ES+), at 1.70 min.
[0081] 1 H NMR: (400 MHz, CDCl 3 ) δ: ppm 1.45 (s, 9H), 1.48-1.56 (m, 1H), 1.64-1.74 (m, 4H), 1.87-1.96 (m, 2H), 2.51-1.85 (m, 10H), 3.30-3.43 (m, 4H), 4.19-4.32 (m, 2H), 5.11 (s, 2H), 7.30-7.40 (m, 5H).
[0082] Step 2) HCl in 1,4-dioxane (4M, 5.0 mL, 20.0 mmol) was added to a solution of (tert-butyl 8-{1-[(benzyloxy)carbonyf]piperidin-4-yl}-2,8-diazaspiro[4.5]decane-2-carboxylate (310 mg, 0.68 mmol) in MeOH (5 mL). The mixture was stirred at rt for 3 d before concentration in vacuo yielded the title compound (colourless solid, 290 mg).
Data in Table 1.
Intermediate 14, benzyl [(2R)-1-(2,8-diazaspiro[4.5]dec-8-yl)-1-oxopropan-2-yl]methylcarbamate hydrochloride
[0083]
[0084] Step 1) A mixture of tert-butyl 2,8-diazaspiro[4.5]decane-2-carboxylate (Intermediate 10, 865 mg, 3.60 mmol), N-[(benzyloxy)carbonyl]-N-methyl-D-alanine (Intermediate 13, 712 mg, 3.00 mmol), HATU (1.37 g, 3.60 mmol) and DIPEA (2.68 mL, 15.0 mmol) in DCM (25 mL) was stirred at rt overnight. Saturated aqueous NaHCO 3 solution was added, the phases were separated and the organic phases was concentrated in vacuo. Purification by gradient flash chromatography, eluting with 2-10% MeOH in DCM, followed by preparative HPLC (Phenomenex Gemini-NX 5 μm C18 column, 100×30 mm, eluting with 50 to 80% MeCN/Solvent B over 12.5 min at 30 mL/min [where solvent B is 0.2% of (28% NH 3 /H 2 O) in H 2 O], collecting fractions by monitoring at 205 nm), yielded tert-butyl 8-{N-[(benzyloxy)carbonyl]-N-methyl-D-alanyl}-2,8-diazaspiro[4.5]decane-2-carboxylate as a colourless foam (1.08 g, 2.19 mmol).
[0085] LCMS (Method A): m/z 460.5 (ES+), at 4.68 min.
[0086] 1 H NMR: (400 MHz, DMSO-d 6 ) δ: 1.10-1.29 (m, 5H), 1.30-1.47 (m, 1H), 1.39 (s, 9H), 1.52-1.77 (m, 2H), 2.67-2.77 (m, 3H), 2.87-3.12 (m, 3H), 3.12-3.35 (m, 5H), 3.46-3.76 (m, 1H), 4.88-5.09 (m, 2H), 5.12-5.22 (m, 1H), 7.25-7.42 (m, 5H).
[0087] Step 2) The title compound (white foam, 1.08 g) was prepared from Step 1 material (1.08 g, 2.19 mmol) and 4M HCl in 1,4-dioxane (15 mL, 60.0 mmol) in MeOH (15 mL) using the methods of Intermediate 12.
Data in Table 1.
Intermediate 16, 8-(pyridin-4-yl)-2,8-diazaspiro[4.5]decane hydrochloride
[0088]
[0089] Step 1) A mixture of ter t-butyl 2,8-diazaspiro[4.5]decane-2-carboxylate (Intermediate 10, 1.00 g, 4.16 mmol), 4-fluoropyridine hydrochloride (Intermediate 15, 614 mg, 4.60 mmol) and K 2 CO 3 (1.74 g, 12.6 mmol) in MeCN (80 mL) was heated at 80° C. overnight before cooling to rt and concentration in vacuo. The residue was partitioned between EtOAc and H 2 O, the organic phase was washed with brine, dried (MgSO 4 ), and concentrated in vacuo. Purification by gradient flash chromatography, eluting with 0-100% solvent B in DCM (where solvent B is 7N NH 3 in MeOH/DCM, 1:9) yielded tert-butyl 8-(pyridin-4-yl)-2,8-diazaspiro[4.5]decane-2-carboxylate (610 mg, 1.92 mmol) as a brown, viscous oil.
[0090] LCMS (Method B): m/z 318.2 (ES+), at 1.36 min.
[0091] 1 H NMR: (400 MHz, CD 3 OD) δ: 1.46 (s, 9H), 1.63-1.68 (m, 4H), 1.81-1.85 (m, 2H), 3.23 (s 2H), 3.36-3.54 (m, 6H), 6.82-6.83 (m, 2H), 8.07-8.09 (m, 2H).
[0092] Step 2) The title compound (brown oil, 550 mg) was prepared from step 1) material (610 mg, 1.92 mmol) and 4M HCl in 1,4-dioxane (10 mL) using the methods of Intermediate 12, and used without purification in the preparation of Example 7.
Data in Table 1.
[0093]
[0000]
TABLE 1
Intermediate
Name
Data
1
1-(piperidin-4-yl)-1,3-dihydro-2H-
Commercially available, CAS No. 185961-99-3
imidazo[4,5-b]pyridin-2-one
2
3-(piperidin-4-yl)quinolin-2(1H)-
Commercially available, CAS No. 205058-78-2
one
3
3-(piperidin-4-yl)-3,4-
Commercially available, CAS No. 79098-75-2
dihydroquinazolin-2(1H)-one
4
spiro[piperidine-4,4′-[4H]pyrido[2,
Commercially available, CAS No. 753440-87-8
3-d][1,3]oxazin]-2′(1′H)-one
5
(R)-methyl 2-amino-3-(7-methyl-
Commercially available, CAS No. No. 890044-
1H-indazol-5-yl)propanoate
58-3 (free base), CAS No. No. 1414976-14-9
(dihydrochloride salt)
6
(2R)-3-(7-methyl-1H-indazol-5-
LCMS (Method A): m/z 463.5 (ES−),
yl)-2-{[(2′-oxo-1′,2′-dihydro-1H-
465.3 (ES+), at 0.10 min. 1 H NMR (400 MHz, DMSO-
spiro[piperidine-4,4′-pyrido[2,3-
d 6 ) δ: 1.53-1.91 (m, 4H), 2.44 (s, 3H),
d][1,3]oxazin]-1-
2.89-3.14 (m, 5H), 3.89 (t, J = 11.5, 2H), 4.23 (br s, 1H),
yl)carbonyl]amino}propanoic acid
6.73 (d, J = 7.8, 1H), 6.93-7.06 (m, 2H), 7.31 (d,
J = 7.4, 1H), 7.38 (s, 1H), 7.93 (s, 1H), 8.17 (dd,
J = 5.1, 1.2, 1H), 10.78 (s, 1H), 13.00 (br s, 1H)
7
(2R)-3-(7-methyl-1H-indazol-5-
LCMS (Method A): m/z 464.1 (ES+), at 1.14 min.
yl)-2-({[4-(2-oxo-2,3-dihydro-1H-
1 H NMR (400 MHz, DMSO-d 6 ) δ:
imidazo[4,5-b]pyridin-1-
1.62-1.67 (m, 2H), 1.87-2.12 (m, 2H), 2.38-2.52 (m,
yl)piperidin-1-
1H), 2.46 (s, 3H), 2.70-2.80 (m, 2H), 2.98 (dd,
yl]carbonyl}amino)propanoic acid
J = 13.7, 9.8, 1H), 3.09 (dd, J = 13.7, 4.3, 1H),
4.08 (br d, J = 12.9, 2H), 4.20-4.27 (m, 1H),
4.28-4.38 (m, 1H), 6.75 (d, J = 8.2, 1H), 6.88 (dd, J = 7.8,
5.5, 1H), 7.42 (s, 1H), 7.27 (d, J = 7.8, 1H),
7.42 (s, 1H), 7.88 (dd, J = 5.1, 1.2, 1H), 7.96 (s, 1H),
11.54 (br s, 1H), 12.99 (br s, 1H)
8
(2R)-3-(7-methyl-1H-indazol-5-
LCMS (Method A): m/z 474.3 (ES+), at 1.82 min.
yl)-2-({[4-(2-oxo-1,2-
1 H NMR (400 MHz, DMSO-d 6 ) δ:
dihydroquinolin-3-yl)piperidin-1-
1.25-1.36 (m, 2H), 1.72-1.78 (m, 2H), 2.48 (s, 3H),
yl]carbonyl}amino)propanoic acid
2.66-2.78 (m, 2H), 2.88-2.94 (m, 1H),
2.97-3.03 (m, 1H), 3.10 (dd, J = 8.4, 3.4, 1H), 4.08 (d,
J = 12.0, 2H), 4.24-4.30 (m, 1H), 6.57 (d, J = 8.0,
1H), 7.04 (s, 1H), 7.15 (dd, J = 12.4, 1.2, 1H),
7.27 (d, J = 8.4, 1H), 7.41-7.45 (m, 2H), 7.54 (s,
1H), 7.62 (dd, J = 6.8, 1.2, 1H), 7.97 (s, 1H),
11.69 (s, 1H), 12.1-13.1 (br s, 2H)
9
(2R)-3-(7-methyl-1H-indazol-5-
LCMS (Method A): m/z 475.4 (ES−),
yl)-2-({[4-(2-oxo-1,4-
477.3 (ES+), at 0.66 min. 1 H NMR (400 MHz, DMSO-
dihydroquinazolin-3(2H)-
d 6 ) δ: 1.36-1.66 (m, 4H), 2.47 (s, 3H),
yl)piperidin-1-
2.59-2.78 (m, 2H), 2.92-3.14 (m, 3H), 4.00 (t, J = 16.0, 2H),
yl]carbonyl}amino)propanoic acid
4.06-4.20 (m, 2H), 4.20-4.33 (m, 1H), 6.47 (br s,
1H), 6.75 (d, J = 7.8, 1H), 6.86 (t, J = 7.4, 1H),
7.01 (s, 1H), 7.06-7.17 (m, 2H), 7.36 (s, 1H), 7.96 (s,
1H), 9.21 (s, 1H), 12.99 (s, 1H)
10
tert-butyl 2,8-
Commercially available, CAS No. 336191-17-4
diazaspiro[4.5]decane-2-
carboxylate
11
benzyl 4-oxopiperidine-1-
Commercially available, CAS No. 19099-93-5
carboxylate
12
benzyl 4-(2,8-diazaspiro[4.5]dec-8-
LCMS (Method B): m/z 358.2 (ES+), at 1.51 min.
yl)piperidine-1-carboxylate
1 H NMR (400 MHz, DMSO-d 6 ) δ: ppm
1.49-1.59 (m, 2H), 1.74-1.80 (m, 2H),
1.85-1.96 (m, 4H), 2.07-2.10 (m, 2H), 2.88-2.96 (m, 4H),
3.11-3.13 (m 1H), 3.18-3.26 (m, 2H),
3.28-3.34 (m, 4H), 4.09-4.13 (m, 2H), 5.06 (s, 2H),
7.30-7.38 (m, 5H), 9.22-9.33 (m, 2H),
10.38-10.95 (m, 1H)
13
N-[(benzyloxy)carbonyl]-N-methyl-
Commercially available, CAS No. 68223-03-0
D-alanine
14
benzyl [(2R)-1-(2,8-
LCMS (Method A): m/z 360.4 (ES+), at 5.21 min.
diazaspiro[4.5]dec-8-yl)-1-
1 H NMR (400 MHz, DMSO-d 6 ) δ:
oxopropan-2-yl]methylcarbamate
1.09-1.22 (m, 3H), 1.22-1.57 (m, 4H), 1.59-1.87 (m,
2H), 2.68-2.80 (m, 3H), 2.82-3.08 (m, 2H),
3.11-3.33 (m, 4H), 3.56 (s, 3H), 4.86-5.22 (m, 3H),
7.10-7.57 (m, 5H), 9.20 (br s, 2H)
15
4-fluoropyridine hydrochloride
Commercially available, CAS No.
39160-31-1
16
8-(pyridin-4-yl)-2,8-
LCMS (Method B): m/z 218.2 (ES+), at 0.91 min.
diazaspiro[4.5]decane
1 H NMR: (400 MHz, CD 3 OD) δ: 1.81-1.85 (m,
hydrochloride
4H), 2.05-2.09 (m, 2H), 3.23 (s, 2H),
3.43-3.47 (m, 2H), 3.70-3.84 (m, 4H), 7.19-7.21 (m, 2H),
8.11-8.13 (m, 2H) (exchangeable protons not
observed)
SYNTHESIS OF EXAMPLES
[0094] Typical procedures for the preparation of examples via amide coupling, and where appropriate, deprotection, as exemplified by the preparation of the below examples.
Procedure 1
Example 2, N-[(2R)-1-[8-(N-methyl-D-alanyl)-2,8-diazaspiro[4.5]dec-2-yl]-3-(7-methyl-1H-indazol-5-yl)-1-oxopropan-2-yl]-4-(2-oxo-1,2-dihydroquinolin-3-yl)piperidine-1-carboxamide
[0095]
[0096] Step 1) A mixture of (2R)-3-(7-methyl-1H-indazol-5-yl)-2-({[4-(2-oxo-1,2-dihydroquinolin-3-yl)piperidin-1-yl]carbonyl}amino)propanoic acid (Intermediate 8, 100 mg, 0.21 mmol), benzyl [(2R)-1-(2,8-diazaspiro[4.5]dec-8-yl)-1-oxopropan-2-yl]methylcarbamate hydrochloride (Intermediate 14, 99 mg, 0.25 mmol), HATU (96 mg, 0.25 mL) and DIPEA (146 μL, 0.84 mmol) in DMF (5 mL) was stirred at rt overnight before concentration in vacuo. Purification by gradient flash chromatography, eluting with 0-10% MeOH in DCM yielded benzyl methyl[(2R)-1-{2-[(2R)-3-(7-methyl-1H-indazol-5-yl)-2-({[4-(2-oxo-1,2-dihydroquinolin-3-yl)piperidin-1-yl]carbonyl}amino)propanoyl]-2,8-diazaspiro[4.5]dec-8-yl}-1-oxopropan-2-yl]carbamate (160 mg, 0.20 mmol) as a pale yellow solid. LCMS (Method B): m/z 815.2 (ES+), at 1.41 min, 95%.
[0097] Step 2) Ammonium formate (126 mg, 2.0 mmol) was added to a mixture of benzyl methyl[(2R)-1-{2-[(2R)-3-(7-methyl-1H-indazol-5-yl)-2-({[4-(2-oxo-1,2-dihydroquinolin-3-yl)piperidin-1-yl]carbonyl}amino)propanoyl]-2,8-diazaspiro[4.5]dec-8-yl}-1-oxopropan-2-yl]carbamate (160 mg, 0.20 mmol) in EtOH (10 mL) and H 2 O (2 mL). Palladium on carbon (10%, 10 mg) was added and the reaction mixture was heated at 70° C. overnight. After cooling to rt further ammonium formate (126 mg, 2.0 mmol) and palladium on carbon (10%, 10 mg) were added and the mixture heated at 70° C. for 1 h before cooling to rt, filtration through celite, and concentration of the filtrate in vacuo. Purification by gradient flash chromatography eluting with 0-10% MeOH in DCM, followed by preparative HPLC (Phenomenex Gemini-NX 5 μm C18 column, 100×30 mm, eluting with 20 to 40% MeCN/Solvent B over 12.5 min at 30 mL/min [where solvent B is 0.2% of (28% NH 3 /H 2 O) in H 2 O], collecting fractions by monitoring at 205 nm), yielded the title compound (20 mg, 0.03 mmol) as a colourless solid.
Data in Table 2.
Procedure 2
Example 5, N-[(2R)-1-[8-(N-methyl-D-alanyl)-2,8-diazaspiro[4.5]dec-2-yl]-3-(7-methyl-1H-indazol-5-yl)-1-oxopropan-2-yl]-2′-oxo-1′,2′-dihydro-1H-spiro[piperidine-4,4′-pyrido[2,3-d][1,3]oxazine]-1-carboxamide
[0098]
[0099] Step 1) Benzyl methyl[(2R)-1-{2-[(2R)-3-(7-methyl-1H-indazol-5-yl)-2-{[(2′-oxo-1′,2′-dihydro-1H-spiro[piperidine-4,4′-pyrido[2,3-d][1,3]oxazin]-1-yl)carbonyl]amino}propanoyl]-2,8-diazaspiro[4.5]dec-8-yl}-1-oxopropan-2-yl]carbamate (26 mg, 0.03 mg) was prepared from (2R)-3-(7-methyl-1H-indazol-5-yl)-2-{[(2′-oxo-1′,2′-dihydro-1H-spiro[piperidine-4,4′-pyrido[2,3-d][1,3]oxazin]-1-yl)carbonyl]amino}propanoic acid (Intermediate 6, 70 mg, 0.15 mmol), benzyl [(2R)-1-(2,8-diazaspiro[4.5]dec-8-yl)-1-oxopropan-2-yl]methylcarbamate hydrochloride (Intermediate 14, 71 mg, 0.18 mmol), HATU (68 mg, 0.18 mmol) and DIPEA (0.13 mL, 0.18 mmol) in DMF (2 mL) using the methods of Example 2, Step 1.
[0100] LCMS (Method A): m/z 806.7 (ES+), at 3.64 min.
[0101] 1 H NMR: (400 MHz, CD 3 OD) δ: ppm 0.17-1.06 (m, 2H), 1.06-1.47 (m, 7H), 1.47-1.75 (m, 1H), 1.76-1.96 (m, 1H), 2.03 (d, J=5.1, 3H), 2.19-2.43 (m, 1H), 2.52 (s, 3H), 2.69-2.96 (m, 5H), 2.96-3.24 (m, 7H), 3.40-3.55 (m, 1H), 3.55-3.97 (m, 1H), 4.07 (d, J=10.5, 2H), 4.52-4.74 (m, 1H), 4.97-5.12 (m, 1H), 5.13-5.33 (m, 1H), 6.93-7.19 (m, 3H), 7.20-7.65 (m, 9H), 7.89-8.06 (m, 1H), 8.20 (d, J=4.7, 1H).
[0102] Step 2) A mixture of benzyl methyl[(2R)-1-{2-[(2R)-3-(7-methyl-1H-indazol-5-yl)-2-{[(2′-oxo-1′,2′-dihydro-1H-spiro[piperidine-4,4′-pyrido[2,3-d][1,3]oxazin]-1-yl)carbonyl]amino}propanoyl]-2,8-diazaspiro[4.5]dec-8-yl}-1-oxopropan-2-yl]carbamate (26 mg, 0.03 mg) and palladium on carbon (10%, 10 mg) in EtOH (2.5 mL) and H 2 O (0.5 mL) was stirred at rt overnight under an atmosphere of H 2 . After removal of the H 2 atmosphere the mixture was filtered through celite and the filtrate concentrated in vacuo to yield the title compound (22 mg, 0.03 mmol).
Data in Table 2.
[0103] Further examples prepared by the above procedures are detailed in Table 2.
[0000]
TABLE 2
Ex.
Intermediates/
LCMS data
No.
Name
Procedure
1 H NMR
(Method A)
1
N-{(2R)-3-(7-methyl-1H-
7, 12
(400 MHz, CD 3 OD) δ: ppm
m/z 669.4
indazol-5-yl)-1-oxo-1-[8-
Procedure 1
0.42-0.59 (m, 2H), 0.67-0.79 (m, 1H),
(ES + ), at
(piperidin-4-yl)-2,8-
0.87-0.95 (m, 1H), 1.10-1.49 (m, 4H),
1.86 min,
diazaspiro[4.5]dec-2-
1.51-1.60 (m, 1H), 1.63-1.72 (m, 1H),
95%
yl]propan-2-yl}-4-(2-oxo-
1.76-1.89 (m, 3H), 1.91-2.13 (m, 2H),
2,3-dihydro-1H-
2.13-2.43 (m, 4H), 2.52-2.59 (m, 5H),
imidazo[4,5-b]pyridin-1-
2.76-3.00 (m, 5H), 3.04-3.16 (m, 4H),
yl)piperidine-1-
3.53-3.75 (m, 1H), 4.25-4.32 (m, 2H),
carboxamide
4.46-4.53 (m, 1H), 4.59-4.70 (m, 1H),
7.01-7.06 (m, 1H), 7.10-7.16 (m, 1H),
7.46-7.47 (m, 1H), 7.52-7.57 (m, 1H),
7.92-7.94 (m, 1H), 7.98-8.03 (m, 1H) (4
exchangeable protons not observed)
2
N-[(2R)-1-[8-(N-methyl-D-
8, 14
(600 MHz, DMSO-d 6 , spectrum
m/z 681.7
alanyl)-2,8-
Procedure 1
recorded at 353K): δ: ppm
(ES + ), at
diazaspiro[4.5]dec-2-yl]-3-
0.83-0.96 (m, 2H), 1.04 (br s, 2H), 1.05 (br s,
3.33 min,
(7-methyl-1H-indazol-5-
1H), 1.32-1.54 (m, 5H), 1.56-1.67 (m,
100%
yl)-1-oxopropan-2-yl]-4-
1H), 1.75-1.84 (m, 2H), 2.16 (br s, 2H),
(2-oxo-1,2-
2.17 (br s, 1H), 2.49 (s, 3H),
dihydroquinolin-3-
2.70-2.84 (m, 3H), 2.89-2.99 (m, 4H),
yl)piperidine-1-
3.06-3.15 (m, 2H), 3.25-3.35 (m, 1H),
carboxamide
3.36-3.52 (m, 3H), 3.65-3.77 (m, 1H), 4.12 (t,
J = 13.8, 2H), 4.61 (q, J = 7.8, 1H),
6.29 (br s, 1H), 7.01 (s, 1H), 7.13 (ddd,
J = 7.8, 7.0, 1.1, 1H), 7.29 (d, J = 8.3,
1H), 7.38 (s, 1H), 7.41 (ddd, J = 8.3, 7.1,
1.5, 1H), 7.57 (s, 1H), 7.60 (dd, J = 7.8,
1.0, 1H), 7.94 (s, 1H) (3 exchangeable
protons not observed)
3
N-[(2R)-1-[8-(N-methyl-D-
7, 14
(400 MHz, CD 3 OD) δ: ppm
m/z 671.5
alanyl)-2,8-
Procedure 1
0.44-0.72 (m, 1H), 0.77-0.94 (m, 1H),
(ES + ), at
diazaspiro[4.5]dec-2-yl]-3-
1.07-1.20 (m, 3H), 1.34-1.54 (m, 2H),
2.57 min,
(7-methyl-1H-indazol-5-
1.57-1.68 (m, 1H), 1.77-1.89 (m, 2H), 2.20 (s,
95%.
yl)-1-oxopropan-2-yl]-4-
3H), 2.29-2.47 (m, 2H), 2.54 (s, 3H),
(2-oxo-2,3-dihydro-1H-
2.73-2.82 (m, 1H), 2.90-3.02 (m, 2H),
imidazo[4,5-b]pyridin-1-
3.06-3.45 (m, 7H), 3.49-3.59 (m, 3H),
yl)piperidine-1-
3.63-3.81 (m, 1H), 4.25-4.28 (m, 2H),
carboxamide
4.43-4.55 (m, 1H), 4.60-4.71 (m, 1H),
7.00-7.05 (m, 1H), 7.10-7.16 (m, 1H),
7.46-7.55 (m, 2H), 7.90-8.02 (m, 2H)
(4 exchangeable protons not observed)
4
N-{(2R)-3-(7-methyl-1H-
9, 12
(400 MHz, DMSO-d 6 ) δ: ppm
m/z 682.6
indazol-5-yl)-1-oxo-1-[8-
Procedure 2
0.46-0.99 (m, 3H), 1.00-1.27 (m, 2H),
(ES + ), at
(piperidin-4-yl)-2,8-
1.32 (br s, 3H), 1.40-1.66 (m, 7H),
3.33 min,
diazaspiro[4.5]dec-2-
1.89-2.10 (m, 2H), 2.10-2.25 (m, 2H),
99%.
yl]propan-2-yl}-4-(2-oxo-
2.27-2.43 (m, 3H), 2.45 (d, J = 2.3, 3H),
1,4-dihydroquinazolin-
2.57-2.75 (m, 3H), 2.77-3.01 (m, 5H),
3(2H)-yl)piperidine-1-
3.01-3.18 (m, 2H), 3.97-4.20 (m, 4H),
carboxamide
4.44 (quin, J = 7.5, 1H), 6.67-6.90 (m, 3H),
6.98 (d, J = 4.7, 1H), 7.03-7.22 (m, 3H),
7.36 (br s, 1H), 7.96 (s, 1H), 9.21 (s,
1H), 13.02 (d, J = 9.0, 1H)
5
N-[(2R)-1-[8-(N-methyl-D-
6, 14
(400 MHz, CD 3 OD) δ: ppm
m/z 670.6
alanyl)-2,8-
Procedure 2
0.37-0.62 (m, 1H), 0.62-1.01 (m, 1H), 1.13 (t,
(ES − ), 672.6
diazaspiro[4.5]dec-2-yl]-3-
J = 6.2, 3H), 1.28 (s, 1H), 1.34-1.56 (m,
(ES + ), at
(7-methyl-1H-indazol-5-
3H), 1.56-1.77 (m, 1H), 1.81-1.99 (m,
2.60 min,
yl)-1-oxopropan-2-yl]-2′-
1H), 1.99-2.14 (m, 3H), 2.17-2.27 (m,
100%.
oxo-1′,2′-dihydro-1H-
4H), 2.43-2.53 (m, 1H), 2.54 (s, 3H),
spiro[piperidine-4,4′-
2.70-2.94 (m, 1H), 2.95-3.26 (m, 5H),
pyrido[2,3-
3.37-3.81 (m, 4H), 4.07 (d, J = 13.3,
d][1,3]oxazine]-1-
2H), 4.54-4.76 (m, 1H), 6.95-7.21 (m,
carboxamide
2H), 7.37-7.52 (m, 1H), 7.53-7.65 (m,
1H), 8.00 (d, J = 10.2, 1H), 8.21 (d,
J = 4.7, 1H) (4 exchangeable protons not
observed)
6
N-[(2R)-1-[8-(N-methyl-D-
9, 14
(400 MHz, DMSO-d 6 ) δ: ppm
m/z 684.7
alanyl)-2,8-
Procedure 2
0.39-0.94 (m, 2H), 0.98 (br s, 3H),
(ES + ), at
diazaspiro[4.5]dec-2-yl]-3-
1.16-1.41 (m, 3H), 1.41-1.65 (m, 5H),
3.08 min,
(7-methyl-1H-indazol-5-
1.98-2.17 (m, 3H), 2.46 (s, 3H), 2.57-2.80 (m,
100%.
yl)-1-oxopropan-2-yl]-4-
3H), 2.81-3.26 (m, 8H), 3.38-3.58 (m,
(2-oxo-1,4-
2H), 3.61-3.77 (m, 1H), 3.89-4.21 (m,
dihydroquinazolin-3(2H)-
3H), 4.21-4.31 (m, 1H), 4.41-4.51 (m,
yl)piperidine-1-
1H), 6.74 (d, J = 7.8, 1H), 6.85 (t, J = 7.4,
carboxamide
2H), 6.94-7.22 (m, 4H), 7.34-7.43 (m,
1H), 7.98 (d, J = 6.6, 1H), 9.23 (s, 1H),
13.07 (br s, 1H)
7
N-{(2R)-3-(7-methyl-1H-
7, 16
(400 MHz, CD 3 OD) δ: ppm
m/z 663.6
indazol-5-yl)-1-oxo-1-[8-
Procedure 1,
1.48-1.56 (m, 3H), 1.61-1.68 (m, 2H),
(ES + ), at
(pyridin-4-yl)-2,8-
Step 1
1.83-1.84 (m, 2H), 2.22-2.43 (m, 3H),
2.93 min,
diazaspiro[4.5]dec-2-
2.51-2.58 (m, 3H), 2.91-3.13 (m, 7H),
99%.
yl]propan-2-yl}-4-(2-oxo-
3.21-3.27 (m, 1H), 3.37-3.48 (m, 3H),
2,3-dihydro-1H-
3.52-3.63 (m, 1H), 4.23-4.31 (m, 2H),
imidazo[4,5-b]pyridin-1-
4.45-4.51 (m, 1H), 4.67-4.75 (m, 1H),
yl)piperidine-1-
6.66-6.76 (m, 2H), 7.02-7.08 (m, 1H),
carboxamide
7.13-7.17 (m, 1H), 7.49-7.57 (m, 2H),
7.94-7.96 (m, 1H), 8.03-8.10 (m, 3H) (3
exchangeable protons not observed)
Biological Methods
[0104] Cloning, Baculovirus Generation, Large-Scale Infection of Sf21 Cells and Membrane Preparation.
[0105] Human Calcitonin Receptor Like Receptor (CRLR) and human RAMP1 were cloned into Invitrogen's (ThermoFisher Scientific, UK) pFastBac dual expression vector. Transposition of CRLR/RAMP1 DNA was performed using Invitrogen's Bac-to-Bac Baculovirus Expression Systems. P0 baculovirus was generated by transfecting SF9 cells with bacmid DNA using Cellfectin® II transfection reagent (ThermoFisher Scientific, UK, catalog number 10362-100). Following P0 generation P1 virus was then generated ready for large scale infection and membrane preparation. Sf21 cells were grown in expression medium ESF921 (Expression Systems, USA, catalog number 96-001-01) supplemented with 10% heat-inactivated FBS and 1% Pen/Strep and were infected at a cell density of 2.5×10 6 cells/mL and an MOT of 2. Expression was carried out over 48 h in a shaking incubator set at 27° C. The cell culture was centrifuged at 2,500 rcf for 10 min at 4° C. The pellets were resuspended in cold PBS supplemented with Roche's Complete EDTA-free protease inhibitor cocktail tablets (Roche Applied Sciences, catalog number 05056489001), 1 mM PMSF and 1 mM EDTA. The resuspended cell paste was then centrifuged at 3,273 rcf for 12 min at 4° C. The supernatant was discarded and the pellet frozen at −80° C. The cell pellet from a 4 L culture was resuspended in buffer containing 50 mM Hepes pH 7.5, 150 mM NaCl, 8 Roche EDTA-free protease inhibitor cocktail tablets and 1 mM PMSF. The suspension was left stirring at rt for 1 h and then homogenised for 90 s at 9,500 rpm using a VDI 25 (VWR, USA) homogeniser. The cells were then lysed using a Microfluidizer processor M-110L Pneumatic (Microfluidics, USA). After lysis, the mixture was homogenised for 90 s at 9,500 rpm and then centrifuged at 335 rcf for 10 min. The supernatant was then further ultra-centrifuged at 42,000 rpm for 90 min. After ultra-centrifugation, the supernatant was discarded and the pellet was resuspended in 50 mL (25 mL for each 2 L culture) of buffer containing 50 mM Hepes pH 7.5, 150 mM NaCl, 3 Roche EDTA-free protease inhibitor cocktail tablets and 1 mM PMSF. The suspension was then homogenised for 90 s at 9,500 rpm. The resulting membranes were then stored at −80° C.
[0106] Radioligand Binding Assay.
[0107] Human CGRP receptors (consisting of CRLR and RAMP1) expressed in insect Sf21 cell membrane homogenates were re-suspended in the binding buffer (10 mM HEPES, pH 7.4, 5 mM MgCl 2 , 0.2% BSA) to a final assay concentration of 0.6 μg protein per well. Saturation isotherms were determined by the addition of various concentrations of 3 H-telcagepant (Ho et al, The Lancet, 2008, 372, 2115) (in a total reaction volume of 250 μL) for 60 min at rt. At the end of the incubation, membranes were filtered onto a unifilter, a 96-well white microplate with bonded GF/B filter pre-incubated with 0.5% PEI, with a Tomtec cell harvester and washed 5 times with distilled water. Non-specific binding (NSB) was measured in the presence of 10 nM MK-3207 hydrochloride (CAS No. 957116-20-0). Radioactivity on the filter was counted (1 min) on a microbeta counter after addition of 50 μL of scintillation fluid. For inhibition experiments, membranes were incubated with 0.5 nM 3 H-telcagepant and 10 concentrations of the inhibitory compound (0.001-10 μM). IC 50 values were derived from the inhibition curve and the affinity constant (K i ) values were calculated using the Cheng-Prussoff equation (Cheng et al, Biochem. Pharmacol. 1973, 22, 3099-3108). The pK i values (where pK i =−log 10 K i ) of certain compounds of the invention are detailed in Table 3.
[0108] cAMP Functional Assay.
[0109] cAMP production following receptor activation was determined using the Homogeneous Time-Resolved Fluorescence (HTRF) cAMP dynamic-2 assay (Cisbio, France). The human neuroblastoma cell line SK-N-MC endogenously expressing the human CGRP receptor was seeded at a density of 12,500 cells/well in solid walled 96 well half area plates (Costar, Catalog Number 3688, Corning Life Sciences, Germany). After 16 h incubation at 37° C. media was removed and cells were incubated at 37° C. for 30 min in serum free media containing 500 μM IBMX (Tocris, Abingdon, UK, Catalog Number 2845) and increasing concentrations of test antagonist. Following this cells were challenged with an EC 80 concentration of human CGRP (0.3 nM) for a further 30 min at 37° C. and then cAMP production was determined as manufacturer's instructions before plates were read on a PheraStar fluorescence plate reader (BMG LabTech, Germany). IC 50 values were derived from the inhibition curve. The pIC 50 values (where pIC 50 =−log 10 IC 50 ) were converted to a functional pK b value using a modified Cheng-Prussoff equation where K d =agonist EC 50 and L hot=agonist challenge concentration. The pK b values of certain compounds of the invention are detailed in Table 3.
[0000]
TABLE 3
Example
pK i
pK b
No.
Name
Structure
average
average
1
N-{(2R)-3-(7-methyl-1H- indazol-5-yl)-1-oxo-1-[8- (piperidin-4-yl)-2,8- diazaspiro[4.5]dec-2- yl]propan-2-yl}-4-(2-oxo- 2,3-dihydro-1H- imidazo[4,5-b]pyridin-1- yl)piperidine-1-carboxamide
9.8
9.6
2
N-[(2R)-1-[8-(N-methyl-D- alanyl)-2,8- diazaspiro[4.5]dec-2-yl]-3- (7-methyl-1H-indazol-5-yl)- 1-oxopropan-2-yl]-4-(2-oxo- 1,2-dihydroquinolin-3- yl)piperidine-1-carboxamide
9.8
8.9
3
N-[(2R)-1-[8-(N-methyl-D- alanyl)-2,8- diazaspiro[4.5]dec-2-yl]-3- (7-methyl-1H-indazol-5-yl)- 1-oxopropan-2-yl]-4-(2-oxo- 2,3-dihydro-1H- imidazo[4,5-b]pyridin-1- yl)piperidine-1-carboxamide
10.1
9.2
4
N-{(2R)-3-(7-methyl-1H- indazol-5-yl)-1-oxo-1-[8- (piperidin-4-yl)-2,8- diazaspiro[4.5]dec-2- yl]propan-2-yl}-4-(2-oxo- 1,4-dihydroquinazolin- 3(2H)-yl)piperidine-1- carboxamide
10.1
9.1
5
N-[(2R)-1-[8-(N-methyl-D- alanyl)-2,8- diazaspiro[4.5]dec-2-yl]-3- (7-methyl-1H-indazol-5-yl)- 1-oxopropan-2-yl]-2′-oxo- 1′,2′-dihydro-1H- spiro[2,3-d][1,3]oxazine]- 1-carboxamide
10.0
9.3
6
N-[(2R)-3-[8-(N-methyl-D- alanyl)-2,8- diazaspiro[4.5]dec-2-yl]-3- (7-methyl-1H-indazol-5-yl)- 1-oxopropan-2-yl]-4-(2-oxo- 1,4-dihydroquinazolin- 3(2H)-yl)piperidine-1- carboxamide
9.8
9.2
7
N-{(2R)-3-(7-methyl-1H- indazol-5-yl)-1-oxo-1-[8- (pyridin-4-yl)-2,8- diazaspiro[4.5]dec-2- yl]propan-2-yl}-4-(2-oxo- 2,3-dihydro-1H- imidazo[4,5-b]pyridin-1- yl)piperidine-1-carboxamide
10.3
9.4
[0110] Pharmacokinetic Profiling.
[0111] The pharmacokinetic profiles of Examples and reference compounds have been assessed in male Sprague Dawley® rats via intravenous (iv), sub-cutaneous (sc) and intranasal (IN) routes of delivery, and in male Cynomolgus Monkeys via iv and sc routes of delivery. Pharmacokinetic data for Examples of the invention and a reference compound, olcegepant, are detailed in Tables 4 and 5.
[0112] Methods:
[0113] For rat studies, groups of three male Sprague Dawley® rats, typically ranging in weight between 180 and 300 g, were given a single dose of Example or reference compound via one of the following routes: iv, sc or IN, using doses, dose volumes and vehicles specified in Table 4. Prior to IN dosing rats were anaesthetised with an intramuscular dose of 25-30 mg/kg ketamine cocktail (ketamine, xylazine hydrochloride and acepromazine maleate in saline) and the dose is introduced over 20-30 s via a polyethylene PE-10 tube inserted approximately 5 mm into the nasal cavity of the rat.
[0114] For cynomolgus monkey studies, groups of three male monkeys, typically ranging in weight between 3.0 and 4.5 kg, were given a single dose of Example or reference compound via one of the following routes: iv or sc, using doses, dose volumes and vehicles specified in Table 5. Following dosing by the routes above blood samples were taken at several time points (typically pre-dose, 0.083, 0.25, 0.5, 1, 2, 4, 8 and 24 h) via serial tail vein bleeds (rat) or cephalic or saphenous vein (monkey) from the animal and centrifuged to separate plasma for analysis by LC/MS/MS assay. WinNonlin v6.2 statistics software (Pharsight Corporation, California, USA) was used to generate pharmacokinetic parameters using the non-compartmental model.
[0000]
TABLE 4
Rat iv pharmacokinetics
Dose
Dose volume
Clearance
(mg/kg)
(mL/kg)
Vehicle
(mL/min/kg)
olcegepant
5
1
10% DMAC + 10%
18
SolutolHS15 + 80%
Saline
Example 2
2
1
10% DMAC + 10%
7
SolutolHS15 + 80%
Saline
Rat sc pharmacokinetics
Dose
Dose volume
Bioavailability
(mg/kg)
(mL/kg)
Vehicle
(%)
olcegepant
1
5
10% DMAC + 10%
48%
SolutolHS15 + 80%
Saline
Example 2
1
2
Acidified saline
100%
Rat IN pharmacokinetics
Dose
Dose
concentration,
Bioavailability
(mg/kg)
Dose volume
Vehicle
(%)
olcegepant
1.3
6 mg/mL, 50 μL
Acidified saline
8
Example 2
1
12 mg/mL, 25 μL
Acidified saline
20
[0000]
TABLE 5
Cynomolgus monkey iv pharmacokinetics
Dose
Dose volume
Clearance
(mg/kg)
(mL/kg)
Vehicle
(mL/min/kg)
Example 2
1
1
Acidified saline
8
Cynomolgus monkey sc pharmacokinetics
Dose
Dose volume
Bioavailability
(mg/kg)
(mL/kg)
Vehicle
(%)
Example 2
0.5
1
Acidified saline
100
[0115] Thermodynamic Solubility Profiling.
[0116] A 50 mM DMSO stock solution of test compound was prepared, and from this, a working solution of 1 mM was prepared by dilution with DMSO. The UV absorbance of working solution was scanned from 220 nm to 1000 nm to identify the wavelength maxima of test compound. The 1 mM working solution was then serially diluted in DMSO to different concentrations to determine linearity/calibration curve. To ascertain the aqueous thermodynamic solubility of test compound, samples were added to a volume of PBS buffer (pH 7.4) or Sodium Phosphate Buffer (pH 6.0) which was appropriate to generate a final concentration of 1 mg/mL if all test compound dissolved. The resulting solution was then kept on a RotoSpin shaker at 50 rpm for 24 h at rt before the solution was filtered using 0.45 micron PVDF injector filters in order to remove the insoluble fraction of the compound. Subsequently, 150 uL of the filtrate is taken for quantification using a UV spectrophotometer, acquiring the optical density of standard solutions and test compound at the same wavelength maxima. From the optical density of test compound the thermodynamic solubility is calculated using the linearity/calibration curve and expressed as micromolar (μM). Solubility profiles of certain compounds of the invention are detailed in Table 6.
[0000]
TABLE 6
Thermodynamic
Reference Cpd/
solubility (μM)
Example
pH 6
pH 7.4
olcegepant
150
431
Example 1
1029
Not tested
Example 2
1287
800
Example 3
1432
1548
Example 4
1346
1148
Example 5
1575
1458
Example 6
1496
1571
Example 7
3627
2160 | The disclosures herein relate to novel compounds of formula
wherein R 1 , R 2 and R 3 are as defined herein, and their use in treating, preventing, ameliorating, controlling or reducing cerebrovascular or vascular disorders associated with CGRP receptor function. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a division of application Ser. No. 10/819,445, filed Apr. 6, 2004, the contents of which are expressly incorporated herein by reference.
[0002] The rain and storm water filtration systems discussed herein relate to filtration systems that employ screens to filter debris and other unwanted material from water streams and, more specifically, to filtration systems having a screen comprising a plurality of wedge wires or tilted wedge wires for filtering water streams.
BACKGROUND
[0003] Rainwater downspouts, curbside storm water runoff collectors, and similar water conduits share a common purpose: removal of water from where it is undesired, be it the roof of a building, a city street, a storm basin, or the like. All such conduits allow a volume of water to pass therethrough. Leaf litter, sand, dirt, grit, and other debris cam accumulate within such conduits and clog them, rendering them ineffective. Equally bad, the poor design of many water conduits allows debris to pass through to downstream channels and, ultimately, the ocean, with a consequent negative environmental impact.
[0004] Not surprisingly, much effort and money has been spent devising ways to avoid clogged water conduits and contaminated water streams. Patents have been granted for inventions designed to filter water at curbside storm drains (U.S. Pat. No. 6,231,758 to Morris et al.), to treat water in a horizontal passageway (U.S. Pat. No. 6,190,545 to Williamson), to create temporary stream filtration systems (U.S. Pat. No. 4,297,219 to Kirk et al.), to remove downspout debris (U.S. Pat. No. 5,985,158 to Tiderington), and to shield rain gutters on the eaves of a building (U.S. Pat. No. 4,345,925 to Jefferys).
[0005] However, with respect to downspouts and storm water systems, the prior art has several shortcomings. Among other things, it is difficult to devise a system that both operates under high flow and effectively filters out small particulate matter and other debris. This is because a filter element that accommodates large flow must also be designed with large spacing to suit the large flow. However, large spacing allows medium to small particulates and waste to pass through unfiltered. Conversely, a filter element designed to trap small particulate matter typically obstructs flow. An ideal water runoff filter would be both capable of passing high flow therethrough and removing small waste and debris.
[0006] Accordingly, there remains a need for a filter system for removing debris from a water stream using a filter element that is amenable to high volume flow, capable of removing or trapping waste the size of or even smaller than the size of the gap used for the filter and, preferably, self-cleaning.
SUMMARY
[0007] The present invention integrates a Coanda screen (sometimes called “Coanda-effect” screen) into water collection systems such as downspouts, storm runoff collectors, sewer drains, and similar conduits and receptacles. An exemplary embodiment includes retrofitting an existing downspout section (or customizing a new downspout section) with a Coanda screen to provide a downspout with a highly efficient filter for removing debris from a stream of water. Depending on the water flow rate and the size of the debris encountered, different screen sizes and different screen mounting angles may be selected to accommodate the same. Filtered water can pass through the screen, while debris is retained by the Coanda screen and then collected in an optional retaining basket.
[0008] In another embodiment, a curbside inlet to a storm drain is fitted with a Coanda screen. The screen is mounted between a raw inlet basin and an outlet basin. Filtered water is allowed to pass over the screen and then fall through the screen into the outlet basin, which then flows onward via an outlet pipe. Captured debris and waste are allowed to fall into a retention basin. To remove waste and debris more effectively, a retaining basket is used. When full, the basket can be lifted out of the curbside inlet and emptied.
[0009] In yet another embodiment, there is provided a downspout filter assembly comprising a housing comprising an inlet, and outlet, an interior cavity, and an entrance to the interior cavity; a filter comprising a plurality of wedge wires mounted in the interior cavity of the housing having a portion positioned directly subjacent the inlet; and at least one media pad positioned under the filter for scrubbing water before it exits the outlet.
[0010] The present invention may also be practiced by providing a downspout filter assembly comprising a housing comprising an inlet, and outlet, an interior cavity, and at least one surface positioned along a first plane; a Coanda filter positioned inside the interior cavity at an angle to the first plane; one or more media pads positioned in the interior cavity at a position below the Coanda filter.
[0011] In still yet another aspect of the present invention, there is provided a downspout filter assembly comprising a housing comprising an inlet, an outlet, and an interior cavity; a pair of rails attached to two sections of the interior cavity; at least one removable container positioned on the pair of rails; a media pad positioned in the at least one removable container or below the at least one removable container; and a filter comprising a plurality of wedge wires mounted in the interior cavity in a position above the media pad.
[0012] Yet in another aspect of the present invention, there is provided a downspout filter assembly comprising a housing comprising an inlet, and outlet, an interior cavity, and an entrance to the interior cavity; a filter comprising a plurality of wedge wires mounted in the interior cavity of the housing having a portion positioned subjacent the inlet; and at least one media pad positioned subjacent the filter for scrubbing water before it exits the outlet.
[0013] The present invention may also be practiced by incorporating a downspout filter assembly comprising a housing comprising an inlet, and outlet, an interior cavity, and at least one surface positioned along a first plane; a Coanda filter positioned inside the interior cavity at an angle to the first plane; at least one media pad positioned in the interior cavity at a position below the Coanda filter.
[0014] Yet, it is also within the spirit and scope of the present invention to incorporate a downspout filter assembly comprising a housing comprising an inlet, an outlet, and an interior cavity; a pair of rails attached to two sections of the interior cavity; at least one removable container positioned on the pair of rails; a media pad positioned in the at least one removable container or below the at least one removable container; and a filter comprising a plurality of wedge wires mounted in the interior cavity in a position above the media pad.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] These and other features of the invention will be better understood when considered in conjunction with the accompanying drawings, wherein like part numbers denote like or similar elements and features, and wherein:
[0016] FIG. 1 is a side elevation view of a downspout with a Coanda screen in accordance with practice of the present invention;
[0017] FIG. 2 is a front elevation view of the downspout of FIG. 1 ;
[0018] FIG. 2A is a partial cross-sectional view of a deflector plate;
[0019] FIG. 3 is a cross-sectional view of the downspout of FIG. 2 , taken at line 3 - 3 ;
[0020] FIG. 4 is an enlarged view of the Coanda screen attached at its downstream end to the downspout;
[0021] FIG. 5 is another enlarged view of the same Coanda screen attached at its upstream end to the downspout;
[0022] FIG. 6 is an enlarged view of a section of the Coanda screen of FIGS. 4 and 5 ;
[0023] FIG. 6A is a depiction of a concave screen surface;
[0024] FIG. 7 is a side elevation view of a storm drain system in accordance with practice of the present invention;
[0025] FIG. 8 is a top plan view of the storm drain system of FIG. 7 ;
[0026] FIG. 9 is a partial cross-sectional view of the storm drain system of FIG. 7 taken at line A-A;
[0027] FIG. 10 is a front elevation view of an alternative downspout with a Coanda screen;
[0028] FIG. 11 is a side elevation view of the embodiment of FIG. 10 ;
[0029] FIG. 12 is a front elevation view of another alternative downspout embodiment with a Coanda screen;
[0030] FIG. 13 is a side elevation view of the embodiment of FIG. 12 ;
[0031] FIG. 14 is a semi-schematic partial transparent, exploded, and perspective view of an alternative downspout filter assembly provided in accordance with aspects of the present invention comprising a plurality media pads for scrubbing filtered water;
[0032] FIG. 15 is a semi-schematic partial transparent, exploded, and perspective view of the alternative downspout filter assembly of FIG. 14 ; and
[0033] FIG. 16 is a semi-schematic side view and partial cross-sectional view of the alternative downspout filter assembly of FIG. 14 mounted on a structure and assembled to an upper and a lower downspout section.
DETAILED DESCRIPTION
[0034] In accordance with the present invention, a highly effective filter system for a rain water downspout, sewer inlet, curbside storm water drain, or similar water runoff conduit or receptacle is provided. A preferred embodiment of an improved downspout 10 is shown in FIG. 1 . The downspout is mounted to an exterior wall 12 of a building by conventional mounting means (not shown), such as welds, adhesives (e.g., glue, cement, mortar, etc.), mechanical fasteners (e.g., rivets, bolts, screws, clamps, bands, straps. etc.). and other means known in the art. The downspout 10 includes a Coanda screen 20 mounted within a portion 40 of the downspout, referred to herein as an “upgraded downspout portion” or “upgraded downspout section”. The screen is accessible via a downspout opening 60 in the upgraded downspout portion. Water that flows into the downspout from a gutter (not shown) is filtered as it passes through the Coanda screen. Debris caught by the screen can slide out of the downspout opening into an optional retaining basket 80 mounted outside of and below the downspout opening. Effluent from the downspout empties into a splash guard or basin 100 which, preferably, is seated on a concrete slab 102 . Alternatively, the downstream end of the downspout is coupled to an underground header or a drain line (not shown) running to a main sewer or storm drain. The Coanda screen, upgraded downspout portion, retaining basket, and other features are described below in more detail.
[0035] An existing downspout can be upgraded or retrofitted by cutting out or otherwise removing a portion thereof, and installing an upgraded downspout portion or section 40 therein, using a slip joint, welds, adhesives, mechanical fasteners, or other conventional attachment means. Alternatively, an entire downspout can be fabricated as such and installed as part of a rain water removal system that includes one or more gutters and mounting hardware. In either case, the improved downspout provides a path for funneling water from a roof (or a deck, mezzanine, or other surface) to grade (e.g., street level) or to a storm water runoff drain or a main sewer line. Effluent from the downspout eventually flows to a storm drain or sewer system and then to the ocean, in some cases via a water treatment facility.
[0036] The downspout 10 is preferably constructed of stainless steel, galvanized steel, aluminum, plastic, or some other durable and water-resistant material, and has an interior and an exterior, and a cross-sectional shape that is generally rectangular. Alternatively, the downspout can have a generally circular cross-section or other desired geometry. In an exemplary embodiment, the downspout 10 is physically attached to an exterior wall 12 of a house or a building by any conventional means, such as downspout bands (not shown) anchored to the exterior wall. Water falling into the downspout passes into the upgraded downspout section 40 to the Coanda screen 20 . The Coanda screen 20 allows water to pass through, but traps waste and debris behind.
[0037] A Coanda screen acts by a shearing action referred to as the “Coanda effect”, which is discussed below in greater detail. In FIG. 1 , the Coanda screen 20 has an upper surface 22 , a lower or underside surface 24 , a first (upstream) end 26 , a second (downstream) end 28 , and left and right sides, and is made of a plurality of wedge-shaped wires 30 . Additional details of the wires=shape and relative orientation is provided below.
[0038] The Coanda screen 20 is mounted at an angle within the upgraded downspout portion 40 , with the upstream end 26 of the screen elevated relative to the downstream end 28 of the screen. As shown in FIG. 1 , the upgraded downspout portion 40 has four walls—front 46 , back 47 , left 48 , and right 49 B and has substantially the same shape and dimensions as the remainder of the downspout. The Coanda screen is affixed within the upgraded downspout portion by e.g., securing the upstream end 26 of the screen to the back wall 47 of the upgraded downspout portion, and the downstream end 28 of the screen to the front wall 46 of the upgraded downspout portion. So installed, the screen is seen to form an angle θ (theta) with the back wall. In practice, it has been found that best results are achieved when θ has a value of about 15 to 50 degrees, more preferably, about 20 to 45 degrees.
[0039] To ensure that a substantial portion of the water entering the downspout is filtered, it is preferred that the screen have a large enough area to make contact with all four walls 46 - 49 of the interior of the downspout housing. Alternatively (or, in addition). one or more baffles are mounted within the downspout to divert the flow of water toward the screen. In FIG. 1 , two baffles 52 and 54 are shown secured to the front wall 46 and side wall 48 , respectively, of the upgraded downspout portion at a position above the downspout opening 60 , and oriented such that the baffle projects toward the Coanda screen 20 . The side baffle 54 comprises a front plate 58 and a rear plate 59 . The rear plate 59 is attached to the side wall 48 by known methods, including welding, adhesive, mechanical fasteners and the like while the front plate 58 protrudes from the side wall 48 . The front plate 58 protrusion acts as a diverter to divert water that clings to the side wall towards the screen 20 . Similar attachment and configuration is discussed below for a deflector plate ( FIG. 2A ).
[0040] In FIG. 3 , two side baffles 54 and 56 are shown, secured to the left 48 and right 49 side walls of the downspout. Fewer or greater numbers of baffles can be mounted within the downspout to provide optimal diversion of water toward the Coanda screen. For example, the back wall 47 can also be configured to include a baffle. This may be desirable where the upstream end 26 of the screen is not recessed within the surface of the back wall 47 . The presence of such a baffle ensures that water cannot bypass the screen. The baffles can be attached to the inside walls of the downspout using any conventional means, including, without limitation, welding, adhesives, and mechanical fasteners.
[0041] The downspout opening 60 provides access to the Coanda screen for maintenance and cleaning. Although the screen is self-cleaning, occasionally debris may become trapped within the downspout or (rarely) wedged between the wires 30 that form the screen. Access to the screen is facilitated by providing the downspout opening 60 with appropriate dimensions relative to the screen 20 . A preferred downspout opening 60 has a width approximately 50-100% of the interior width of the downspout, and a height approximately 33-75% of the vertical profile of the screen 20 , the latter being measured at the wall opposite the downspout opening (the back wall 47 in FIG. 1 ) The downspout opening 60 is located intermediate the upstream and downstream ends of the downspout 10 , but not necessarily equidistant from both ends.
[0042] A retaining basket 80 to catch debris caught by the Coanda screen is mounted to the downspout just below a debris deflector plate (further discussed below), using conventional means, such as welding, adhesives, mechanical fasteners, and the like. In an exemplary embodiment, the retaining basket 80 comprises a tightly woven screen made of steel, aluminum, or other weather-resistant material. Debris that does not freely fall into the retaining basket 80 (i.e., debris that clings to the filter due to friction) is eventually pushed out the downspout opening 60 by additional water flowing from the gutter. Water clinging to debris caught in the retaining basket 80 can drip onto the splash guard 100 by passing through the holes of the retaining basket 80 . Alternatively, if an underground header is used to connect with the downspout, water that passes through the retaining basket can be caught by a collector (not shown) mounted beneath the retaining basket, and channeled to the header.
[0043] In an exemplary embodiment, the downspout is also equipped with an external debris deflector plate 110 . The debris deflector plate is mounted just below the downspout opening 60 along the external surface of the front wall 46 , just above the retaining basket 80 . The debris deflector plate covers any space between the downspout 10 and the retaining basket 80 , and ensures that debris exiting the downspout opening does not fall between the downspout and the retaining basket.
[0044] In an exemplary embodiment shown in FIG. 2A , the deflector plate 110 includes a front plate section 112 configured to deflect debris into the retaining basket, and a rear plate section 114 configured to be attached to the downspout. In an exemplary embodiment, the deflector plate 110 , like the downspout itself, is made of a durable, weather-resistant material, such as aluminum, plastic (e.g., polyvinyl chloride and unplasticized vinyl), galvanized steel, and the like. The deflector plate can be mounted to the downspout by known methods, including welding, adhesives, mechanical fasteners, and so forth.
[0045] Reference is now made to FIG. 4 , which is an enlarged view of Detail A indicated in FIG. 1 . The downstream end 28 of the Coanda screen is shown secured to the downspout front wall 46 by an upper bracket 70 and a lower bracket 72 , without obstructing the flow of debris from the upper surface of the Coanda screen into the retaining basket. The two brackets are attached to the downspout by conventional means, such as welding, adhesives, mechanical fasteners, and so forth. Preferably, the upper bracket is substantially flush with the outer wall of the downspout housing at the bottom of the downspout opening.
[0046] Similarly, FIG. 5 provides an enlarged view of Detail B indicated in FIG. 1 . The upstream end 26 of the Coanda screen 20 is shown secured to the downspout back wall 47 by upper 74 and lower 76 brackets. However, in addition to securing the upstream end of the screen 20 , the upper bracket 74 also serves to divert water flow along the back wall 47 of the downspout to the screen. Although not shown, similar upper brackets may also be mounted around the entire perimeter of the screen so that any water flow along any of the four downspout walls is diverted toward the screen. The two brackets 74 , 76 are attached to the downspout by conventional means, such as welding adhesives, mechanical fasteners, and so forth.
[0047] FIG. 6 shows an exemplary cross-sectional view of the Coanda-effect screen 20 . The screen comprises a plurality of individual wedge wires 30 which are parallel to one another and separated from each other by a gap or spacing 32 . The individual wedge wires 30 are held together in the indicated arrangement by welding two or more backer rods (not shown) to the base portions 34 of each individual wedge wire 30 . Coanda screens are commercially available in several standard sizes. Generally, the difference in screen selection relates the width, height, and tilt angle 36 of the wedge wires, and the gap spacing 32 between the wedge wires. In addition, the Coanda screen may be ordered with an overall concave shape. As shown in FIG. 6A , the term “concave” implies a curved contour when viewed with respect to the upper surface 22 of the screen 20 . When a concave screen is specified, the concave shape has the effect of increasing the tilt angle of the individual wedge wires. This in turn allows the leading (upstream) edge 38 of the wedge wire to shear a greater amount of the water, provided that all other parameters are unchanged. In an exemplary embodiment, the Coanda screen has a gap spacing of about 0.1 to 1.0 mm and a tilt angle of about 3 to 15 degrees, with a radius (“R”) of concavity of from about 6 inches to infinity (when R=infinity, the screen is flat). Alternatively, other screen parameters may be used, taking into account the size of the debris likely to be encountered, the anticipated water flow rate and volume, and so forth.
[0048] Coanda screens are available from a number of manufacturers and retailers, including on-line retailers such as www.hydroscreen.com, www.johnsonscreens.com, and www.eni.com/norris/default.html. The screen is described in an article entitled “Hydraulic Performance of Coanda-Effect Screens” by Tony Wahl for publication in the Journal of Hydraulic Engineering, Vol. 127, No. 6, June 2001, the entire contents of which are expressly incorporated herein by reference as if set forth in full.
[0049] As explained by Wahl, the Coanda effect is a tendency of a fluid jet to remain attached to a solid flow boundary. As shown in FIG. 6 , when water 130 flows across the screen 20 from the upstream direction, it tends to remain attached to the upper surface of the screen as it travels in the direction of the downgrade 79 . At a given point along the screen, the water has a thickness “X”. As water 130 flows down the screen, its thickness X is sheared by the leading edge 38 of each individual wedge wire 30 . The sheared water is then redirected approximately tangentially 120 to the direction of the original flow due to the contour of the wedge wire 30 . Thus, different wedge wire contour will cause water to be redirected differently. This shearing action is repeated as water traverses down the screen along the direction of the downgrade 79 . Water is sheared as it travels over other wedge wires 30 . After each layer of water is sheared, it is caused to flow along one of several filtered water paths 120 a, 120 b, 120 c, 120 d, etc. The thickness of the water stream gets progressively smaller as the downstream end of the screen is approached, and the flow of water appears to slow to a mere trickle, or even drop off altogether.
[0050] This phenomenon is used to great effect in the present invention. Debris-laden water is effectively filtered at the Coanda screen. Any debris that does not fall into the retaining basket 80 during rainfall eventually dries on the screen, and either falls into the basket later, or can be manually removed via the downspout opening 60 .
[0051] In an alternate embodiment of the invention shown in FIGS. 7-9 , an effective filter system for removing debris from a storm water runoff collector is provided. The runoff collector 200 comprises a Coanda screen 20 installed between a raw inlet basin 210 and an outlet basin 220 . As before, the screen 20 filters incoming water while trapping debris, but the source of water is a raw stream 212 , from an inlet 214 , and the effluent is a discharge stream 222 for an outlet line 224 .
[0052] In an exemplary embodiment, the Coanda screen 20 is mounted between a first weir 230 and a second weir 240 . The screen has a concave surface, with a radius of from about 6 inches to infinity, and is outfitted with an acceleration plate 250 . The acceleration plate 250 is a metal plate of hardened steel, such as stainless steel and the like, mounted to the upstream end 26 of the screen.
[0053] The acceleration plate has a width of approximately 2 inches or higher depending on the size of the storm drain system. When water flows from the raw inlet basin 210 over the weir 230 , it has a relatively low flow velocity. If water is allowed to flow over the screen 20 without first having the necessary flow velocity, the screen=s ability to filter out debris will greatly decrease. The acceleration plate provides a vertical drop of about 2 inches or higher, allowing in-coming water to build up velocity before it contacts the first wedge wire on the screen.
[0054] Debris caught by the Coanda screen can slide into a retention basket 260 located within a retention basin 262 . In an exemplary embodiment, the retention basket 260 is equipped with a handle 264 , which allows the retaining basket to be lifted out of the basin, whereupon the debris can be discarded. The basket 260 may be a conventional basket and may be constructed out of medium to large steel wire mesh. Due to its size, it may be necessary to lift the basket with a crane or a flit truck having a lift.
[0055] In an alternate embodiment of the upgraded downspout 10 shown in FIGS. 10 and 11 , a tapered front wall 46 and a modified back wall 47 having a tapered back wall section 270 is provided. The tapered front wall 46 and tapered back wall section 270 allow the screen 20 to be moved forward in the direction of the retaining basket 80 , and provide clearance for the installation of an acceleration plate 250 . In an exemplary embodiment, additional wall mounted baffles for diverting water toward the screen 20 are not necessary, as the screen is positioned directly below the incoming flow path and even extends past the incoming path. This screen configuration allows all or substantially all of the incoming flow to flow through the screen.
[0056] In another alternate embodiment of the upgraded downspout 10 , shown in FIGS. 12 and 13 , an optional hinged cover 272 is provided over the downspout opening 60 of an enlarged upgraded downspout 10 . The enlarged upgraded downspout 10 is slightly larger than a conventional or existing downspout section. but has a much larger depth (the distance between the front wall 46 and the back wall 47 ), e.g., on the order of about 1.3 to 3 times deeper. This allows the enlarged upgraded downspout to accommodate a much larger screen 20 than a standard size upgraded downspout. This in turn, allows the much larger screen 20 to filter substantially all of the incoming flow without the need for wall mounted baffles. However, in the embodiment of FIGS. 10-13 , wall mounted baffles, such as baffles 52 and 54 , can be used.
[0057] Referring now to FIG. 14 , a semi-schematic partial perspective-partial transparent view of an alternative downspout filter assembly 280 provided in accordance with aspects of the present invention is shown. In one exemplary embodiment, the downspout filter assembly 280 comprises a housing 282 , having a downspout inlet 284 , a downspout outlet 286 , an interior cavity 288 comprising a plurality of filter components, and an optional door cover 290 . The filter assembly 280 is configured for use in a section of a downspout installed on a structure, such as a parking structure, a building, or other structures that require a water gutter system. As readily apparent, a section of a downspout is to be replaced by the downspout filter assembly 280 . When replaced, an upper or upstream section of the downspout is to be coupled to the downspout inlet 284 by conventional means and a lower or downstream section of the downspout is to be coupled to the downspout outlet 286 also by conventional means. Alternatively. the downspout outlet 286 may be coupled directly to a drain or remain opened to drain over a surface drain. The filter assembly 280 is adaptable in that it may be installed in an existing downspout section or be part of a new downspout installation.
[0058] In one exemplary embodiment, the filter components comprise a Coanda filter 20 , a collection container or a debris container 292 , an outlet container 294 , and a filter medium 296 , which may comprise one or more media pads 298 a, 298 b for one or more different filtering functions. Alternatively, a filter comprising a plurality of wedge wires may be used to filter debris and other contaminants, with tilted wedge wires or Coanda screen being more preferred. Screen pith wedge wires are commercially available, for example, through Goel Engineers in India, which has the following website: http://www.goelka.com/wws.htm. The filter components are housed inside the interior cavity 288 of the housing 282 and are closed therein by a door cover 290 abutting the housing flange 300 and a latch 302 , which may embody a key lock or other prior art means for securing the door to the flange. In one exemplary embodiment, the door cover 290 may comprise two or more door sections and may include a gasket 304 for providing a relatively tight seal as compared to when no gasket is used. The gasket may include any prior art gaskets and may adhere to the door cover by adhesive. The door cover 290 is connected to the housing 282 via one or more conventional hinges or fasteners. For venting, one or more vent holes 291 may be incorporated on one or more sides of the housing 282 . If the vent holes 291 are incorporated, they are preferably positioned at a location with minimal water splash.
[0059] The housing 282 may comprise a number of different shaped configuration, such as a rectangular shaped box, a square shaped box, or a cylindrical shaped box, with a rectangular shaped box being more preferred. The housing 282 may be made from a number of metallic sheets, such as stainless steel sheets, tin sheets, sheet metal, and zinc coated sheet metal with stainless steel sheets being more preferred. Alternatively, plastic, fiberglass, or synthetic plastic materials may be used.
[0060] Referring to the referenced length L, height H, and width W of the housing 282 , in a preferred embodiment, the filter assembly 280 is mounted along a lengthwise direction L against a structure 348 ( FIG. 16 ). To facilitate attachment along the lengthwise direction L, the housing 282 includes a pair of mounting flanges 306 a, 306 b, one along the upper housing section and one along the lower housing section. Alternatively, the filter assembly 280 may be mounted along the width direction W by incorporating the two mounting flanges 306 a, 306 b along the width edge of the upper and lower sections of the housing 282 .
[0061] Also shown in FIG. 14 is an optional final treatment filter media 308 . The final filter media 308 , when incorporated, is to be positioned in a sump 310 , which is the space defined by the area under the two containers 292 , 294 and the bottom of the housing 282 . The media pads 298 a, 298 b and the final filter media 308 , when incorporated, are configured to remove organic compounds, toxic metals, particulates, and other undesirable contaminants. The various filter medium may comprise, for examples, e.g., activated carbon, Rubberizer® polymers and particulate products, metal absorbing soy bean hulls, peat, siliceous rocks, activated silica, Miex resins, and potassium permanganate pellets. Depending on the contaminants to be removed, the particular media to be used can be selected accordingly. As an alternative or in addition to the absorbent pads, pelletized hypochlorite or other formulations of chlorine may be used as a media to kill undesirable bacteria, such as E - coli bacteria. Still alternatively, where electricity power is available, the housing may be equipped with UV (ultraviolet) lamps to provide ultraviolet radiation to also kill undesirable bacteria. Conventional mounting means for mounting UV lamps in a wet environment would be required if UV lamps are incorporated.
[0062] Broadly speaking regarding operation of the downspout filter assembly 280 , during a rain storm or cleaning operation in which water is used, water is directed down a downspout, flows through the downspout inlet 284 , is filtered by the Coanda filter 20 , in which solids and other suspended contaminants are filtered by the filter 20 and are trapped along the upper surface of the filter and the passes through to the outlet container 294 . The trapped solids and other suspended contaminants are subsequently collected in the collection container 292 , either by being pushed into the container 292 by later trapped solids, gravity, or by a service technician. The filtered water that passes through the filter 20 is additionally filtered by the filter medium 296 positioned in the outlet container 294 and by the final filter media 308 located in the sump 310 , if incorporated. Water then flows out the filter assembly 280 via the downspout outlet 286 .
[0063] Referring now to FIG. 15 in addition to FIG. 14 , an exploded perspective view of the downspout filter assembly 280 provided in accordance with aspects of the present invention is shown. The filter 20 incorporated herein is similar to the filter described above with reference to FIGS. 1-6A , and, in addition, may include both wedge wires and tilted wedge wires. A baffle or plate 312 , which may embody a rectangular metallic or plastic plate, is connected to the lower edge of the filter 20 with a second plate 314 connected to the filter 20 at its underside to form an inverted “V” shaped ledge 316 . When assembled, the ledge 316 is adapted to receive or rest on the support rim 318 of the collection container 292 and the support rim 320 of the outlet container 294 (See, e.g., FIG. 14 ) while the upper filter section rests against the back wall of the housing 292 . Optionally, latching mechanisms may be used to removably fasten the filter inside the housing using conventional fastening means.
[0064] The containers 292 , 294 incorporated herein may be made of a metallic mesh material for durability, such as a stainless steel mesh material. However, rubber or hard plastic containers may also be incorporated where desired. In one exemplary embodiment, the mesh size for the collection container 292 should be smaller than the mesh size for the outlet container 294 to prevent or minimize small solids collected in the collection container 292 from escaping through the plurality of openings provided by the mesh. Obviously, the mesh size for both containers can be similarly sized for ease of manufacturability. Handles 322 may be added to the containers 292 , 294 for ease of handling the containers during cleaning or other maintenance operation when the containers are removed from the interior cavity 288 .
[0065] The outlet container 294 and the media pads 298 a, 298 b should be sized such that the perimeter of the pads contacts the interior surface of the outlet container 294 when the media pads 298 a, 298 b are placed therein ( FIG. 16 ). As readily apparent, this configuration ensures that water entering the outlet container 294 will pass through the media pads 298 a, 298 b before it exists the downspout outlet 286 . The pads 298 a, 298 b are positioned in the outlet container by stacking and resting them directly on the base of the container 294 . Optionally, a treatment pad separator (not shown) may be placed in the container first before the first media pad is added with additional treatment pads to be placed in between a set of media pads. The overall dimensions of the containers 292 , 294 , media pads 298 a, 298 b, and other components of the filter assembly 280 can vary depending on the volume throughput of the particular downspout, which can vary from installation to installation. In a preferred embodiment, the filter assembly 280 and all its components should be sized to handle about 110% to about 125% of the maximum expected flow rate of the particular downspout section.
[0066] In one exemplary embodiment, an exit flow deflector 324 comprising a base 326 and two side walls 328 each comprising a rail or a flange 330 are incorporated in the filter assembly 280 . The base 326 preferably has a surface that is sloped about 10-30 degrees from the surface of the flanges 330 for directing flow entering the sump area 310 , as further discussed below. The flow deflector 324 should have a length and a width approximately that of the outlet container 294 . The flow deflector 324 is preferably made from a rigid material, such as a sufficiently gauged metallic sheet or a hard plastic.
[0067] In an exemplary embodiment, a main baffle or deflector plate 332 may be incorporated in the filter assembly 280 . As further discussed below, the main baffle 332 , if desired, may be installed subjacent or behind the filter 20 so that as water passes through the filter 20 , it is deflected away from the back side wall 334 of the housing 282 by the main baffle. As readily apparent, this arrangement allows the baffle to direct water away from the housing wall so that the water can then flow through the outlet container 294 where it could be scrubbed or cleaned by the media pads 298 a, 298 b, When installed, the surface of the main baffle 332 should be angled about 5-30 degrees relative to the back sidewall 334 . Rivets, spot welding, brackets, fasteners, or other conventional attachment means may be used to attach the flange section 336 of the main baffle 332 to the back sidewall 334 .
[0068] Two brackets or rails 338 , one on an outside sidewall 340 and one on an inside sidewall 342 , are incorporated for placement of the exit flow deflector 324 and the two containers 292 , 294 thereon. The rails 338 , which resemble right-angle brackets, provide two ledges that protrude from the two sidewalls 340 , 342 . The ledges are configured to support the deflector 324 and the two containers 292 , 294 when the same are placed thereon. More particularly, the rails 338 support the deflector 324 and the two containers 292 , 294 by first placing the two flanges 330 of the deflector 324 on the rails 338 and then placing the containers 292 , 294 over the rails, with the outlet container 294 preferably placed directly over the deflector 324 (See. e.g., FIG. 1 ). The sump 310 is an area defined in part by the base of the containers 292 , 294 when over the same are placed on the rails 338 .
[0069] A containment dam 342 is positioned at the entrance 344 to the interior cavity 288 of the housing 282 . The containment dam 342 preferably contacts and forms a seal with the two side walls 340 , 342 and the base wall 346 of the housing. The containment dam 342 preferably extends about ⅕ to about ⅓ of the height of the entrance 344 , and should at least be level with or rises above the surface of the rails 338 . The containment dam 342 may be attached to the housing using any prior art methods, including forming the dam by bending a portion of one or more of the sidewalls and then using welding or epoxy to seal the seam.
[0070] Referring now to FIG. 16 in addition to FIGS. 14 and 15 , a semi-schematic side view and partial cross-sectional view of the downspout filter assembly 280 is shown mounted on a structure 348 . As previously discussed, the filter assembly 280 may be mounted by fastening the upper and lower mounting flanges 306 a, 306 b to the structure using a plurality of fasteners 350 . The inlet 284 and outlet 286 are strapped or clamped to the upper downspout section 352 and lower downspout section 354 , respectively, using fastening clamps or straps 356 in combination with pliant wrappers 358 . The pliant wrappers can embody rubber sheets or other equivalent materials. However, any prior art coupling means may optionally be used to couple the inlet and outlet of the system 280 to the upper and lower downspout sections.
[0071] As shown when water 360 enters the downspout assembly 280 via the inlet 284 and into the interior cavity 288 , the water makes contact with the filter 20 . As previously discussed, debris and other solids carried by the water 360 are then trapped by the filter 20 along the upper surface 22 of the filter. The solids and the debris are then pushed by the stream of incoming water and incoming solids, and/or by gravity, and fall into the collection container 292 . Water, however, passes through the filter 20 to the underside 24 of the filter in the direction of the main deflector plate 332 . During normal flow, water flows in a downward direction towards the outlet container 294 , where it is then cleaned or scrubbed by the media pads 298 a, 298 b before being deflected again by the exit flow deflector 324 . The exit flow deflector 324 channels the water over the final filter media 308 where it is further cleaned or scrubbed before existing the housing 292 via the outlet 286 .
[0072] As readily apparent, the media pads 298 a, 298 b, 308 may be eliminated, replaced with other media pads, or used in combination with additional media pads depending on the desired outcome and/or on environmental regulations. When media pads are used, treatment pad separators 362 may be used to separate the media pad from an adjacent pad or from a solid surface, such as the bottom of the housing. The separators 362 may be made from nylon or plastic webbing sheets such as spun-bonded webbing sheets, steel mesh, porous media, or other material to provide gaps or passages for the water flow.
[0073] In an exemplary embodiment, a passage 364 is provided internally of the interior cavity 288 for bypassing water 360 around the media pads 298 a, 298 positioned inside the outlet container 294 . This passage 364 is located intermediate the lower edge of the main deflector 332 and the top of the outlet container 294 proximate the back sidewall 334 of the housing 292 . In the event the media pads 298 a, 298 b are clogged and water backs up in the outlet container 294 , water can escape through the passage 364 to then flow out of the housing 292 via the outlet 286 .
[0074] Although the invention has been described with reference to preferred and exemplary embodiments, various modifications can be made without departing from the scope of the invention, and all such changes and modifications are intended to be encompassed by the appended claims. For example, an upgraded downspout section can be manufactured as a separate unit and installed as a new downspout. Other materials than those described herein can be used to make the various components of the apparatus described. Changes to the way the baffles are installed, the way they are shaped, the way the deflector plates are installed, and the way the screens are installed within the housing can be made. Other alterations and modifications may be made by those having ordinary skill in the art, without deviating from the true scope of the invention. | A debris-filtering downspout and other water runoff conduits and receptacles are disclosed, and include a screen mounted within a conduit, a culvert, a storm water conveyance or secured to a water collection basin. The screen provides high water throughput and is self-cleaning while effectively filtering debris contained in an incoming water stream. Optionally, media pads may be included to further scrub the water before it exits the downspout assembly. | 4 |
FIELD OF THE INVENTION
The present invention relates to aircraft avionics and, more particularly, to methods and apparatus for providing aircraft engine thrust ratings to avionic systems.
BACKGROUND OF THE INVENTION
Modern jet aircraft include one or more flight management computers electronically connected to electronic engine controllers that are used to control the engines of the aircraft. The maximum level of thrust that can be provided by modern jet engines varies. Airline companies set limits in the level of thrust an engine is to produce under normal operating conditions. This level of thrust is referred to as the "thrust rating" of the engine. Setting a thrust rating below the maximum available level of thrust decreases fuel consumption, and increases engine life. The thrust rating of an engine is determined by expected operating conditions. Heavier aircraft loads require a higher thrust rating. Takeoffs at higher altitudes generally require a higher thrust rating than takeoffs at or near sea level. The flight management/thrust management computers of aircraft use the thrust rating to develop proper engine control signals.
Currently, in order to change an aircraft engine thrust rating, it is necessary to change program pin wiring connected to the flight management/thrust management computers. Upon power-up, the flight management/thrust management computers are initialized with the thrust rating as determined by the program pins. The ratings are used by the flight management/thrust management computers for the duration of the flight.
Reconfiguration of the program pin wiring is time consuming and costly. It also creates configuration verification difficulties. The present invention is directed to overcoming these disadvantages.
SUMMARY OF THE INVENTION
In accordance with this invention, a method and apparatus for providing engine thrust ratings to aircraft avionic systems is provided. Information pertaining to engine thrust ratings is transmitted from electronic engine controllers of the aircraft to one or more avionic computers of the aircraft via one or more digital data buses. Specifically, an identifier is transmitted, where each identifier corresponds to an engine thrust rating. The engine controllers determine the engine thrust rating identifier by reading the configuration of a set of plugs in the associated engine. This identifier is digitally transmitted to the flight management computer/thrust management computer (FMC/TMC). The FMC/TMC includes a database having entries that correspond to various thrust ratings. The FMC/TMC selects the proper data set for the received specified engine thrust rating upon power-up. More specifically, upon power-up, the FMC/TMC(s) read engine thrust rating identifiers, store them in memory, and use the stored rating identifiers at power-up to establish a performance database. When a particular thrust rating is to be changed, the configuration of the set of plugs in the engine whose rating is to be changed is modified to represent the new thrust rating identifier. As a result, the next time power-up occurs, the thrust rating identifier is updated to reflect the new rating.
In accordance with other aspects of this invention, the FMC/TMC includes volatile memory and nonvolatile memory. The identifier pertaining to the thrust rating of the engine is stored in the nonvolatile memory.
In accordance with still other aspects of this invention, the FMC/TMC periodically receives a thrust rating identifier from the electronic engine controllers, compares the received thrust rating identifier with the stored thrust rating identifier, and updates the stored thrust rating identifier if the received identifier differs from the stored identifier.
In accordance with yet other aspects of this invention, the jet aircraft includes two or more jet engines, each having a thrust rating. The FMC/TMC receives the thrust rating identifier from the electronic controller of each jet engine, compares the thrust ratings of the engines, and reports a fault condition if the thrust ratings of the engines do not match. Preferably, the fault condition is reported by the FMC/TMC only if the jet aircraft is on the ground at the time of the comparison.
In accordance with other further aspects of this invention, the avionic system of the aircraft includes at least two FMC/TMCs connected to a common digital data bus. Both FMC/TMCs receive the same thrust rating identifier, and store the thrust rating identifier in their respective memories.
In accordance with yet still other aspects of this invention, the memory of the FMC/TMC(s) includes a database containing multiple entries, each entry corresponding to an engine thrust rating. The FMC/TMC(s) perform a test to determine if an engine thrust rating database entry corresponding to the received thrust rating identifier exists. The thrust rating identifier is stored in the nonvolatile memory of the FMC/TMC(s) only if a corresponding database entry exists.
As will be readily appreciated from the foregoing description, an avionic system formed in accordance with the invention allows the selected engine thrust rating identifier sent to an FMC/TMC to be changed without having to modify existing wiring. When the thrust rating of a jet engine is changed, the new rating is automatically read and used to update the rating identifier stored in the FMC/TMC. More specifically, the electronic engine controller associated with each engine automatically reads engine thrust rating data defined by the engine plug configuration and sends the identifier to the FMC/TMC. The FMC/TMC determines whether the received thrust rating identifier is valid and, if so, stores the thrust rating identifier in memory, preferably nonvolatile memory. The FMC/TMC periodically processes newly received data pertaining to engine thrust rating, determines the validity of the identifier relative to stored data, and stores the new thrust rating identifier in memory if the identifier is found to be valid and different. If the preferable procedure of storing the thrust rating identifier in nonvolatile memory is employed, the thrust rating identifier will be available after a power-off, power-on cycle. In essence, the invention simplifies the changing of thrust rating data.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of this 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 accompanying drawings, wherein:
FIG. 1 is a block diagram of an avionic system incorporating the present invention;
FIG. 2 is a flow diagram illustrating the periodic process used by the flight management computers shown in FIG. 1 to handle newly received thrust rating data;
FIG. 3 is a flow diagram illustrating the process used by the flight management computers shown in FIG. 1 to determine whether a database entry corresponding to a jet engine thrust rating exists in the memory of the flight management computers/thrust management computers; and
FIG. 4 is a flow diagram illustrating the process used by the flight management computers shown in FIG. 1 for updating the jet engine thrust rating identifier stored in memory and determining whether the jet engine thrust rating identifiers are valid.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a block diagram illustrating the major components of an avionic system 102 incorporating the present invention. It is assumed for purposes of discussion that the jet aircraft with which the present invention is being utilized is a two-engine commercial jet aircraft, such as the model 777 produced by The Boeing Company, Seattle, Wash. If the invention is used with an aircraft that includes one jet engine or more than two jet engines, changes that will be apparent to those skilled in this art, in view of the following, will have to be made. Furthermore, in an aircraft comprising a plurality of jet engines, the present invention may be utilized with any subset of engines included on the aircraft.
The avionic system illustrated in FIG. 1 comprises: a pair of jet engines 104a and 104b, each having an electronic engine controller (EEC) 108a and 108b coupled to the engine; a first avionic computer, specifically a flight management computer/thrust management computer (FMC/TMC) 120a and a second FMC/TMC 120b ; and a communication system 130 for transferring digital data between the electronic engine controllers 108 and the FMC/TMCs 120a and 120b. As illustrated in FIG. 1, a flight management computer and a thrust management computer are physically located together and are hereinafter identified as an FMC/TMC 120. In an alternate configuration, the flight management computer and thrust management computer may be separated from each other. The flight management computer and thrust management computer each employ the same process with regard to the invention as described below.
Each jet engine 104a and 104b includes a set of plugs 106 whose configuration establishes the thrust rating of the jet engine 104. Since plugs 106 and how they are manually configured are well known in this art, such plugs and how they are configured are not described here. As is also well known in this art and, thus, not described here, the EECs 108a and 108b are capable of sensing the configuration of the plugs 106, interpreting the configuration, and producing digital data denoting the thrust rating of the engines 104a and 104b.
The communication system 130 for transferring digital data between the EECs 108a and 108b and the flight management computers 120a and 120b illustrated in FIG. 1 comprises a plurality of digital data buses and an engine data interface unit 112. With reference to the left engine 104a, a first controller data bus 110a carries data from the left engine EEC 108a to the engine data interface unit 112. While the controller digital data bus 110a can be any type of digital data bus, in one actual embodiment of the present invention, the controller digital data bus 110a is an ARINC 429 digital data bus. Since the ARINC 429 digital data bus is capable of carrying digital data in only one direction, such as from the left engine EEC 108a to the engine data interface unit 112, this embodiment requires a second controller digital data bus 110b to carry data in the reverse direction, i.e., from the engine data controller 112 to the left engine EEC 108a. A corresponding pair of controller digital data buses 110c and 110d carry digital data between the right engine EEC 108b and the engine data interface unit 112. In an alternate configuration, single bidirectional digital data buses could be used in place of the pairs of controller digital data buses 110a, 110b, and 110c, 110d.
As illustrated in FIG. 1, a flight management digital data bus 114 electronically connects the engine data interface unit 112 with both of the FMC/TMCs 120a and 120b. In one actual embodiment of the invention, an ARINC 629 digital data bus forms the flight management digital data bus 114. Since the ARINC 629 digital data bus is bidirectional, it is capable of carrying data between the engine data interface unit 112 and the FMC/TMCs 120a and 120b in both directions. This is preferable to an alternate configuration, such as forming the flight management digital data bus 114 from two or more unidirectional digital data buses.
A primary function of the engine data interface unit 112 is to serve as an interface between the controller digital data buses 110a, 110b, 110c, and 110d and the flight management digital data bus 114. Since different types of digital data buses employ different protocols for transferring data, the engine data interface unit 112 translates protocols as well as data between the controller and flight management digital data buses.
As will be readily appreciated by those skilled in this art and others, the communication system 130 illustrated in FIG. 1 for transferring digital data between the electronic engine controllers 108a and 108b and the FMC/TMCs 120a and 120b should be considered as exemplary, not limiting. In an alternative configuration, for example, one or more digital data buses could directly couple the EECs 108a and 108b to the FMC/TMCs 120a and 120b. Such a configuration may consist of a single bidirectional digital data bus, or two unidirectional digital data buses. In such a configuration, the engine data interface unit 112 is not necessary. Instead, the EECs 108a and 108b send data directly to and receive data directly from the FMC/TMCs 120a and 120b. As can be readily appreciated by those skilled in this art and others, on most airplanes, the flight management digital data bus 114 is comprised of a plurality of digital data buses.
The avionic system illustrated in FIG. 1 further includes a second flight management digital data bus 128 for carrying digital data between the left and right FMC/TMCs 120a and 120b. The second flight management digital data bus 128 allows the FMC/TMCs 120a and 120b to compare processing results. Obviously, a single FMC/TMC 120 could be used, if desired.
The FMC/TMCs 120a and 120b, illustrated in FIG. 1, each include a volatile memory 124 and a nonvolatile memory 126. Nonvolatile memory is capable of retaining data in the absence of power; therefore, information stored therein is retained through a computer power-down and power-up cycle. Volatile memory does not retain data stored therein when a computer is powered down. Each FMC/TMC 120a and 120b also includes a database 125, which may be stored in the nonvolatile memory 126, or in a separate (not shown) nonvolatile memory. Each FMC/TMC 120a and 120b also includes a data processor 127. For simplicity of illustration, and since they are not pertinent for the present invention, other well known elements of FMC/TMCs are not illustrated in FIG. 1.
As will be better understood from the following description, the EECs 108a and 108b continuously sense the configuration of the plugs 106 of the engines 104a and 104b, interpret the configurations to determine the current thrust ratings of the engines 104a and 104b, and send a corresponding thrust rating identifier to the engine data interface unit 112 via the controller digital data buses 110a and 110c. The engine data interface unit 112 transforms the data into a form suitable for application to the flight management digital data bus 114, which transfers the data to the FMC/TMCs 120a and 120b on a frequent periodic basis. In one actual embodiment of the invention, a new thrust rating identifier is sent to the FMC/TMCs 120a and 120b about five times per second. As will be readily appreciated by those skilled in this art and others, the thrust rating identifier may be formed in a variety of ways to represent an engine thrust rating.
The process used by the FMC/TMCs to handle newly received thrust rating identifiers from the EECs 108a and 108b is illustrated in FIG. 2. Periodic I/O processing 202 is illustrated as beginning at step 204. Step 204 may be triggered by a clock, for example. Next, at step 206, the associated FMC/TMCs 120a or 120b receive a new thrust rating identifier from the related EEC 108a or 108b. At step 208, the FMC/TMCs 120a and 120b store the newly received thrust rating identifier in volatile memory 124. At step 210, a flag is set to mark the receipt of the thrust rating identifier. At step 212, the periodic I/O processing loop ends, and the process recycles to the beginning (step 204). The effect of the periodic I/O processing 202 is that the FMC/TMCs 120a and 120b receive a new thrust rating almost immediately after the configuration of the plugs is changed in the jet engines 104a and 104b. Periodic I/O processing 202 begins when the FMC/TMCs 120a and 120b are turned on, and continues as long as the FMC/TMCs remain powered up.
FIG. 3 is a flow diagram illustrating a portion of the process 302 used by the FMC/TMCs 120a and 120b (FIG. 1) to determine if the database 125 of the related FMC/TMC includes an entry corresponding to a received thrust rating identifier. The processing 302 illustrated in FIG. 3 begins 304 on power-up. At step 306 a test is made to determine whether an EEC thrust rating identifier is stored in nonvolatile memory 126 (FIG. 1). Because information stored in nonvolatile memory 126 is retained even after power down of the FMC/TMC 120, a negative determination occurs only if a thrust rating has never been stored in the nonvolatile memory 126. If such a negative determination is found, the process branches to step 308, where a test is made to determine whether an engine thrust rating identifier, as reported by one of the EECs 108a and 108b (FIG. 1), has been stored in volatile memory as a result of the periodic I/O processing 202 shown in FIG. 2 and described above. If an engine thrust rating identifier is not stored in volatile memory, the process loops back along path 309 and repeats the determination step 308. The periodic I/O processing 202 (FIG. 2) occurs independently of the processing illustrated in FIG. 3. The continuous looping shown by path 309 is terminated when a new thrust rating identifier is received from one of the EECs (step 206 in FIG. 2), the thrust rating is stored in volatile memory (step 208), and the proper flag is set (step 210).
When the determination step 308 determines that an EEC thrust rating identifier is available in volatile memory, the process proceeds to step 310, where a test is made to determine whether a database entry corresponding to the newly received engine thrust rating identifier exists. More specifically, as briefly described above, the FMC/TMCs 120a and 120b each include a database 125. The databases include information pertaining to the jet engines 104a and 104b and the jet aircraft. Among the information included in the databases 125 is a plurality of entries, each entry corresponding to one or more thrust ratings. These entries are used by the FMC/TMCs 120a and 120b in a variety of ways that are well known to those skilled in this art. Since the uses of the thrust rating database entries are not pertinent to this invention, the use of such entries is not described here.
Step 310 of FIG. 3 is a determination of whether a particular database entry corresponding to the newly reported thrust rating identifier exists in the database 125. If such an entry does not exist, the process loops back to step 308, and the test of whether a new thrust rating identifier has been reported by one of the EECs 108a or 108b is repeated. If so, the test at step 310 is repeated. In this manner, the continuous loop 311 is terminated only when a new and different thrust rating identifier is reported by one of the EECs 108a and 108b and a corresponding database entry exists (step 310). When a corresponding database entry has been found, at step 314 the FMC/TMC 120 saves a pointer value to the database entry corresponding to the new engine thrust rating identifier. The pointer value can be used to quickly access the information in the database 125 corresponding to the reported thrust rating identifier when access is required by the related FMC/TMC 120a or 120b. After a pointer value has been saved, the process cycles to a periodic processing loop 316, illustrated in FIG. 4 and described in detail below.
Returning to step 306, if on power-up a determination is made that a thrust rating identifier is stored in nonvolatile memory 126 (FIG. 1), the process proceeds to step 312, where a test is made to determine whether a database entry exists for the engine thrust rating identifier stored in nonvolatile memory 126. The determination of step 312 is similar to that of step 310, discussed above, except that, in step 310, the engine thrust rating tested comes from the thrust rating identifier stored in volatile memory 124 (FIG. 1), as performed in step 208 of FIG. 2. The test of step 312 tests the thrust rating identifier stored in nonvolatile memory 126, in accordance with FIG. 4 and described below. If the test performed at step 312 is negative, the process cycles to step 308 and enters the decision path of steps 308 and 310 as described above. In contrast, if, at step 312, a corresponding database entry is found for the thrust rating identifier stored in nonvolatile memory 126, the process cycles to step 314 where the pointer to the database entry is saved.
As can be readily understood from the above description, when the periodic processing loop 316 is entered, either an old thrust rating identifier is stored in nonvolatile memory 126 (FIG. 1) or a newly reported thrust rating identifier is stored in volatile memory 124, and a valid corresponding database entry in the database 125 exists. FIG. 4 illustrates the periodic processing loop 316. The periodic processing loop 316 begins at step 402. At step 404, the FMC/TMCs 120a and 120b make a test to determine whether the aircraft is on the ground. In order to ensure that changes to the EEC thrust rating due to failures during flight do not affect aircraft operation, changes in a thrust rating identifier stored in nonvolatile memory are only allowed to take place if the aircraft is on the ground. Thus, a negative determination at step 404 results in a branch to a point in the process immediately prior to the end of periodic processing 416. If the aircraft is on the ground, the processing cycles to step 406.
At step 406 a determination is made of the number of EEC-reported thrust rating identifier stored in volatile memory. If no new EEC thrust rating identifiers are stored in volatile memory, the process branches to the end of the periodic processing 416. If only one thrust rating identifier is stored in volatile memory, the process proceeds to step 408, where a test is made to determine whether the thrust rating identifier stored in volatile memory is the same as the thrust rating identifier stored in nonvolatile memory 126 (FIG. 1). If the determination is negative, at step 414 the FMC/TMC 120 replaces the "old" thrust rating identifier stored in nonvolatile memory 126 with the "new" thrust rating identifier. Following this, the processing proceeds back to the beginning of FIG. 3, and the processing described above reoccurs. Thus, the program proceeds as it does upon power-up of the FMC/TMCs 120a and 120b (FIG. 1). If, at step 408, the thrust rating identifier stored in volatile memory 124 is the same as the thrust rating identifier stored in nonvolatile memory 126, the process cycles to the end of periodic processing 416. This is the most common path, resulting from no change in the plugs that define the thrust rating of the engines 104a and 104b.
If, at step 406, more than one thrust rating identifier is stored in volatile memory, the process branches to step 410, where a test is made to determine whether all of the engine thrust rating identifiers stored in volatile memory match. If they do not match, at step 412 a fault condition is reported, the periodic processing loop 316 terminates, and the program ceases. Operator intervention is required at this point.
If, at step 410, it is determined that the reported thrust rating identifiers from all engines match, the process proceeds to step 408, as it does in the situation where only one thrust rating identifier is reported (step 406). It should be noted that the test at step 410 simplifies thrust rating selection on aircraft having engines whose thrust ratings are all the same. The invention does not require this test to be performed. On an aircraft where differing thrust ratings are allowed among the engines, steps 410 and 412 would be eliminated, and processing would cycle to step 408 whenever one or more EEC-reported ratings are available. In this alternative, the FMC/TMCs 120a and 120b would store a thrust rating identifier in nonvolatile memory 126 for each jet engine 104.
While the presently preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention as defined in the appended claims. For example, the sequence of many of the processing steps depicted in FIGS. 3 and 4 could be changed or the steps carried out in other ways designed to accomplish the same functional result. | An avionic system (102) in which engine thrust rating data is transmitted from electronic engine controllers (108a and 108b) to flight management computer/thrust management computers (120a and 120b) via digital data buses (110a, 110c, and 114) is disclosed. The flight management computer/thrust management computers (120a and 120b) select the proper data set for the specified engine thrust rating upon power-up. If the thrust rating changes, the flight management computer/thrust management computers (120a and 120b) select a new data set corresponding to the new thrust rating as received over the digital data bus (110a, 110c, and 114). This is accomplished without the need to change aircraft wiring. The flight management computer/thrust management computers (120a and 120b) store the thrust rating in nonvolatile memory (126), allowing the flight management computer/thrust management computers (120a and 120b) to use the stored value to initialize relevant settings according to current engine thrust rating. | 6 |
[0001] This application is a continuation of application Ser. No. 08/606,988 filed Feb. 26, 1996.
FIELD OF THE INVENTION
[0002] This invention is in the field of adhesives, and more particularly, acrylic pressure sensitive adhesives which have improved bonding characteristics to low energy surfaces.
BACKGROUND
[0003] As used herein, the term “film” refers to a thin, flexible, single- or multi-layer polymeric sheet. The term is used interchangeably with the terms “backing” and “carrier web”. Graphic marking films or labels formed from vinyl films coated with acrylic pressure sensitive adhesives (PSAs) arc well-known in the art. However, to date, the ability to provide such label and graphic marking film films with high bonding strength, (i.e. non-removal), to low energy surfaces such as high density polyethylene and polypropylene plastics has not been possible without sacrificing important properties of the adhesive such as shear strength and cohesive strength.
[0004] As used herein, the term “low energy surfaces” is intended to mean those surfaces which exhibit low polarity and low critical surface tension (less than about 40 dynes/cm 2 ) characteristics. One example of a low energy surface is the surface of a polyolefin plastic. Among the PSAs, it is known that acrylic-based PSAs exhibit poorer bond characteristics to low surface energy polyolefin plastics than do rubber-based PSAs. This effect results from the greater difference in polarity between the acrylic PSA and the polyolefin surface as compared to that between the rubber PSA and the polyolefin surface. Unfortunately, however, it would be very desirable to use acrylic PSAs in many applications, since acrylic PSAs exhibit excellent outdoor durability, whereas rubber PSAs show poor ultraviolet and oxidative stability due to chemical unsaturation of the hydrocarbon elastomer.
[0005] Common physical methods to obtain high bond strength of pressure sensitive adhesives to polyolefin plastics include flame treating, which oxidizes the surface of the plastic, chemical etching with strong acids to increase polarity of the bonding surface, or the use of a primer or topcoat containing a chlorinated polyolefin. For example, Japanese Patent No. HEI 1(1989)-242676 discusses the use of chlorinated polyolefin resins in connection with pressure sensitive adhesives. One disadvantage of such surface treatment methods that they are inefficient in that they add an additional process step when applying graphic marking films or labels to low energy surfaces. This is less than ideal since industrial consumers of graphic marking films and labels desire that these products can be easily applied in a single step without the need for additional, time consuming surface preparation methods.
[0006] For a permanent graphic marking film or label application, it would be desirable to have bond characteristics similar to those associated with rubber-based PSAs combined with the outdoor durability associated with acrylic PSAs. One method to increase bond strength of acrylic PSAs to low surface energy polyolefin plastics is to incorporate a compatible tackifier such as a rosin ester, a terpene phenolic resin or a hydrocarbon resin into the adhesive. Although the use of a tackifier dramatically improves bond strength as measured by peel force at low speeds, inclusion of these tackifiers raises the glass transition temperature (Tg) of the PSA which results in reduced low temperature performance and also causes a “shocky” or “zippy” peel characteristic at faster peel rates. This “shocky” or “zippy” peel is an undesirable characteristic which can result in easy removal of films and labels, as well as making them less tamper-resistant.
[0007] Additionally, loss in adhesive shear strength and cohesive strength is also observed if large amounts of tackifier or plasticizer are incorporated into the PSA.
[0008] In many applications, it is desirable that graphic marking films or labels be difficult to remove once they are applied to a surface. This may be accomplished by providing the graphic marking film or label film with a means by which attempts to remove it will result in tearing or other damage to the graphic marking film or label. A method to increase the destructibility of PSA coated vinyl labels or graphic marking films is to make the vinyl film backing less elastic or “brittle”. This is achieved by adding a hard acrylic resin and decreasing the plasticizer level of the vinyl film.
[0009] U.S. Pat. No. 5,141,790 (Calhoun et al.) and U.S. Pat. No. 5,296,277 (Wilson et al.) the teachings of both of which are incorporated herein by reference, describe an adhesive film referred to commercially as Controltac Plus™ film (available from Minnesota Mining and Manufacturing Company, hereafter “3M”). The adhesive surface of the Controltac Plus™ film is characterized in that it includes clustered domains of a non-adhesive material, referred to as “pegs” which extend a short distance from the adhesive surface. The patents also describe adhesive films in which the adhesive surface is microtextured or provided with a microtopological structure.
SUMMARY
[0010] The present invention relates to the incorporation of a plasticizer material into a tackified acrylic PSA. The resulting PSA is shown to provide improved bonding of polyvinylchloride graphic marking films and labels to low energy surfaces such as high density polyethylene plastic.
[0011] More specifically, the invention relates to tackified and plasticized acrylic PSA compositions comprising:
[0012] a) about 100 parts by weight of an acrylic copolymer, said acrylic copolymer comprising from about 70-98% by weight of one or more monofunctional acrylates having nontertiary alkyl groups with between 1 and 14 carbon atoms and from about 30-2% by weight of a polar monomer;
[0013] b) about 10-40 parts by weight of a tackifier,
[0014] c) about 3-10 parts by weight of a plasticizer; and
[0015] d) optionally, a crosslinker.
[0016] The invention also relates to films which incorporate such tackified adhesives, and the use of those films as graphic marking films and labels.
[0017] Specific chemical classes of plasticizers, when incorporated into the tackified pressure sensitive acrylic adhesive, improve the bonding characteristics of the adhesive to low energy surfaces. The addition of plasticizer to a tackified acrylic adhesive has been found to improve the wet-out or “quick stick” to low energy surfaces. The addition of plasticizer offsets the increase in glass transition temperature caused by the tackifier and improves bond strength. When incorporated at levels of less than about 10 parts plasticizer per 100 parts adhesive, the presence of the plasticizer results in little effect on shear performance or cohesive strength of the adhesive.
[0018] Among the plasticizers discovered to improve bonding characteristics are polyglycol ethers, polyethylene oxides, phosphate esters, aliphatic carboxylic acid esters, benzoic esters, and combinations thereof. In addition, other plasticizers which improve bonding to low energy surfaces have been identified, however, these have been found to cause some decrease in cohesive strength. These include sulfonamides and aromatic carboxylic acid esters.
[0019] The incorporation of the specified plasticizers along with acrylic-compatible tackifiers allows one to construct an outdoor durable vinyl label or graphic marking film with improved adhesion to low energy surfaces, and in particular, high density polyethylene surfaces, without the need for physical or chemical treatment of the surfaces. In one embodiment, the label or graphic marking film construction may include a destructible vinyl film backing for vandal-resistant applications. In this embodiment, the graphic marking film or label can be die cut with a microperforated or micro-rough steel rule which will initiate tearing when removal is attempted. Removal is further deterred by the improved adhesion characteristics of the graphic marking film or label. Despite these modifications to the film, the article maintains flexibility and fit strength for easy fabrication in graphic marking film or label manufacture.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1 is a schematic representation of the cross-section of a vinyl film label.
[0021] [0021]FIG. 2 is a histogram plotting 180° peel adhesion for various adhesive compositions.
[0022] [0022]FIG. 3 is a histogram plotting film shrinkage for various adhesive compositions.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Acrylic Pressure Sensitive Adhesives
[0024] A variety of acrylic pressure sensitive adhesives commonly used in commercial applications for vinyl decorating graphics films include acrylic copolymers having from about 70-98% by weight of one or more monofunctional acrylates having nontertiary alkyl groups with between 1 and 14 carbon atoms and from about 30-2% by weight of a polar monomer.
[0025] In a preferred embodiment, the acrylic PSA is a copolymer of ethylenically-unsaturated alkyl acrylates (C 1 -C 14 ) such as isooctylacrylate, 2-ethylhexyl acrylate, 2-methylbutylacrylate (MBA), N-butyl acrylate, methylacrylate (MA), ethylacrylate, and isoborinylacrylate (IBA). The polar monomer can comprise ethylenically-unsaturated carboxylic acids such as methacrylic acids, acrylic acids (AA), itaconic acids, β-carboxyethylacrylates, fumaric acid, acrylamides (Acm) or other polar monomers such as n-vinyl pyrrolidone, N-vinyl caprolactam, 2-hydroxyethyl acrylate, and the like.
[0026] This class of adhesives bonds very aggressively to painted substrates and has excellent cohesive strength due, at least in part, to the polar monomer. While the use of polar monomers leads to adhesives with good cohesive strength, the high glass transition temperature contribution of these monomers to the adhesive is a disadvantage when formulating adhesives for “quick wet-out” on low energy surfaces.
[0027] One preferred PSA formulation for low energy surfaces was determined to be a 95/5 ratio isooctylacrylate/acrylic acid. This formulation resulted in a composition which was balanced between too much acrylic acid (which tended to “stiffen” the PSA formulation, leading to poor “wet-out”), and too little acrylic acid (which leads to PSA compositions with poor cohesive strength).
[0028] Several pressure sensitive adhesives having applicability to the present invention are presented in Table I below:
TABLE I Acrylic Pressure Sensitive Adhesives Polymer Chemistry Molecular Weight 90/10 IOA/AA 1.5 × 10 6 93/7 IOA/AA 1 × 10 6 93/7 IOA/AA 5 × 10 5 94/6 IOA/AA 5 × 10 5 95/5 IOA/AA 2 × 10 5 98/2 IOA/AA 1 × 10 5 70/22.5/7.5 IOA/MA/AA 2 × 10 5 96/4 2-MBA/Acm 2 × 10 5 90/10 2-MBA/AA 5 × 10 5 68/28/4 IOA/IBA/AA 2 × 10 5
[0029] Tackifiers
[0030] To obtain high bonding characteristics to low energy surfaces, the most commonly used tackifiers in acrylic pressure sensitive adhesives include terpene phenolics, rosins, rosin esters, esters of hydrogenated rosins, synthetic hydrocarbon resins and combinations thereof. The tackifiers which were evaluated are listed in the following Table II:
TABLE II Common Acrylic PSA Tackifers Company Trade Name Chemical Class Hercules Foral ®85 Hydrogenated Glycerol Ester of Rosin Hercules Hercolyn ®-D Hydrogenated Methyl Ester of Rosin Arizona Chemical Nirez 2019 Terpene Phenolic Resin Union Camp Uni-Tac-70 Tall Oil Rosin Hercules Regalrez 6108 Aromatic Hydrocarbon Resin Exxon ECR-180 Petroleum Hydrocarbon Resin
[0031] Hydrogenated rosin esters are the preferred tackifiers as a result of performance advantages which include: high levels of “tack”, outdoor durability, oxidation resistance, compatibility with hot melt processing, and limited interference in post crosslinking of acrylic PSAs.
[0032] Tackifiers are typically added at a level of about 10-40 parts per 100 parts of dry acrylic PSA to achieve desired “tack”. However, as noted above, the addition of these tackifier types can reduce shear or cohesive strength and raise the Tg of the acrylic PSA which is undesirable.
[0033] Crosslinkers
[0034] In order to increase shear or cohesive strength of acrylic pressure sensitive adhesives, a crosslinking additive is usually incorporated into the PSA. Two main types of crosslinking additives are commonly used. The first crosslinking additive is a thermal crosslinking additive such is a multifunctional aziridine. One example is 1,1′-(1,3-phenylene dicarbonyl)-bis-(2-methylazinidine) (CAS No. 7652 -64-4), referred to herein as “Bisamide”. Such chemical crosslinkers can be added into solvent-based PSAs after polymerization and activated by heat during oven drying of the coated adhesive.
[0035] In another embodiment, chemical crosslinkers which rely upon free radicals to carry out the crosslinking reaction may be employed. Reagents such as, for example, peroxides serve as a precursor source of free radicals. When heated sufficiently, these precursors will generate free radicals which bring about a crosslinking reaction of the polymer chains. A common free radical generating reagent is benzoyl peroxide. Free radical generators are required only in small quantities, but generally require higher temperatures to complete the crosslinking reaction than those required for the bisamide reagent.
[0036] The second type of chemical crosslinker is a photosensitive crosslinker which is activated by high intensity ultraviolet (UV) light. Two common photosensitive crosslinkers used for hot melt acrylic PSAs are benzophenone and 4-acryloxybenzophenone which is copolymerized into the PSA polymer. Another photocrosslinker, which can be post-added to the solution polymer and activated by UV light is a triazine; for example 2,4-bis(trichloromethyl)-6-(4-methoxy-phenyl)-s-triazine. These crosslinkers are activated by UV light generated from artificial sources such as medium pressure mercury lamps. Depending on the type of crosslinker, no more than about 0.5% by weight of chemical crosslinker typically is needed to achieve the desired crosslinking.
[0037] Aside from thermal or photosensitive crosslinkers, crosslinking may also be achieved using high energy electromagnetic radiation such as gamma or e-beam radiation.
[0038] A physical crosslinking agent may also be used. In one embodiment, the physical crosslinking agent is a high T g macromer such as those based upon polystyrene and polymethylmethacrylate which are used at about 2-6 parts by weight per 100 parts by weight dry adhesive.
[0039] Diisocyanates have also been reported as crosslinking agents for adhesives based on copolymers of acrylic acids.
[0040] Other Additives
[0041] Since acrylic pressure sensitive adhesives have excellent oxidative stability, additives such as antioxidant and UV light absorbers are generally not needed. In contrast, rubber-based PSAs typically include such additives.
[0042] Small amounts of heat stabilizer, (less than about 0.3% by weight), can be utilized in hot melt acrylic PSAs to increase thermal stability during processing.
[0043] Although not required, in some special applications, fillers (clay) or colorants (TiO 2 or carbon black) may be used as additives to impart opacity or color to the adhesive, or to make the adhesive system less expensive.
[0044] Backings
[0045] In one embodiment of the present invention, backings of plasticized, flexible polyvinylchloride films are used to form decorative films, labels or graphic marking films. A modified polyvinylchloride film is of interest for destructible or vandal resistant type labels or graphic marking films. This film has been made “brittle” or “tearable” by lowering the plasticizer level and adding a methylacrylate/butylacrylate copolymer resin (Elvacite™ 2013 available from Imperial Chemical Industries, Wilmington, Del.) to the PVC film formulation. These films may be made by casting front organosol solutions or calendered from an extrudable PVC resin.
[0046] Other backings of interest include, but are not limited to, polyesters, polyolefins, papers, foils, polyacrylates, polyurethanes, perfluoropolymers, polycarbonates, ethylene vinyl acetates, and the like. Backings of vinyl films, woven and nonwoven sheets, woven and nonwoven fabrics, papers and retroreflective sheeting are intended to be included.
[0047] Plasticizers
[0048] Plasticizers useful in the invention are selected from a wide variety of commercially available materials. Representative plasticizers are listed in Table III.
TABLE III Acrylic PSA Plasticizers Company Trade Name Chemical Class Chemical Name ICI Pycal 94 Polyethylene Polyoxyethylene Aryl Ether Americas Oxide Monsanto Santicizer Adipic Acid Dialkyl Adipate 97 Ester Monsanto Santicizer Phosphoric 2-Ethylhexyl Diphenyl 141 Acid Ester Phosphate Monsanto Santicizer Phosphoric t-Butylphenyl Diphenyl 154 Acid Ester Phosphate Monsanto DOA Adipic Acid Di(2-Ethylhexyl) Adipate Ester Akzo Ketjenflex 8 Sulfonamide Toluencsulfonamide Nobel Velsicol Benzoflex Benzoic Acid Dipropylene Glycol 9-88 Ester Dibenzoate Velsicol Benzoflex Benzoic Acid Polyethylene Glycol P-200 Ester Dibenzoate Rhone- Alkapol Polypropylene Polyoxypropylene Aryl Ether Poulenc SQR-490 Oxide Sartomer Sartomer Formic Acid Dibutoxyethoxyethyl Formal 660 Ester (Cryoflex) Sartomer Sartomer Adipic Acid Dibutoxyethoxyethyl Adipate 650 Ester (Wareflex)
[0049] In each case, the added plasticizers must be compatible with the acrylic PSA being used in the formulation. The amount of plasticizer added to the PSA formulation is dependent upon the molecular weight of the adhesive. It is preferred that a minimum amount of plasticer be used. Specifically, it is one feature of the invention to obtain improved substrate bonding characteristics without sacrificing cohesive strength or shear strength performance. Typically, as much as about 10 parts by weight plasticizer per 100 parts adhesive can be added without compromising cohesive strength for high molecular weight, (Mw greater than about 1×10 6 ), adhesives. In the case of lower molecular weight, (Mw less than about 3×10 5 ), no more than about 5 parts by weight per 100 parts adhesive is needed.
[0050] Method of Making Plasticized Acrylic PSAs
[0051] Plasticizer can be added to the acrylic pressure sensitive adhesives at numerous points during the adhesive formulation process. For example, the plasticizer may be added to the acrylic copolymer or terpolymer solutions either prior to or following polymerization, it may be blended into the melt for hot-melt acrylic PSAs during coating, it may be added to the monomer syrup of ultraviolet- or thermally- polymerized acrylate PSAs, or it may be added to a water-based acrylate PSA emulsion.
[0052] For these methods, it is preferred that the plasticizer is miscible with the acrylate PSA or its solution, is soluble in any solvents that are present, is thermally stable in hot melt applications, does not substantially interfere with the polymerization reaction or the crosslinking process, and forms a stable emulsion along with the acrylate PSA in water-based adhesive formulations.
[0053] The present invention has particular applicability in connection with vinyl films for graphic marking film and labels. In one embodiment, the vinyl film can be an extendible polyvinylchloride backing for use in decorative labels and graphic marking films. As noted above, a taper-resistant vinyl film may also be made. Such tamper-resistant films have particular applicability for use as warning, instruction or safety labels which break apart when tampered with, making the label difficult or impossible to remove.
[0054] A typical film construction is shown in FIG. 1 which the film 10 comprises a film layer 12 , such as a 2 mil (0.05 mm) vinyl/acrylate film having an acrylic PSA 14 applied to one surface thereof. A release liner 16 such as silicon-coated paper or film is adhered to the PSA until the film is ready to be adhered to a surface.
[0055] The film may be made tamper-resistant by die cutting the film layer 12 with a 60T microperforated steel rule. The “micro-rough” edges imparted to the film enhance its “tear” or “breaking” characteristics.
[0056] Films of the type depicted in FIG. 1 can be applied to low energy plastic surfaces such as high density polypropylene (HDPP) and high density polyethylene (HDPE) parts. Such parts are useful in many outdoor applications including, but not limited to, lawn and garden equipment, recreational vehicles, all-terrain vehicles, snowmobiles, motorcycles and watercraft. The particular parts include, but are not limited to, covers, hoods and fenders which are decorated with films forming vinyl graphic marking films, warning labels and instructional labels.
[0057] For the films of the present invention, measured peel adhesions at a moderate peel rate of about 90 inches (230 cm) per minute should be greater than 4 pounds per inch (18 N/25 mm width) to achieve adequate bonding characteristics to high density polyethylene. Dead load shear performance of 10,000 minutes or greater is desired as measured by the PSTC-7 Static Shear Test (1.6 cm 2 ×1.6 cm 2 /1 kilogram) described below. However, for applications in which vinyl graphic marking film or label films are applied to the parts described above, this level of dead load shear performance is not required. It is preferable, however, that the PSA has sufficient adhesive strength to resist shrinkage forces which may be imparted by the graphic marking film or label film to which the adhesive is applied.
EXAMPLES
[0058] Testing Protocol
[0059] 1. 180° Peel Adhesions PSTC-1: Based on the Pressure Sensitive Tape Counsel (PSTC) test standard, a 1 inch (2.54 cm) wide strip of PSA coated 2 mil (0.05 mm) vinyl film is laminated to a high density polyethylene test panel. The test specimen is backed with a standard 2 mil vinyl film for reinforcement. The applied test specimen is allowed to equilibrate for about 24 hours at about 72° F. (22° C.) and about 50% relative humidity. The test sample is than peeled at an angle of 180° and a speed of about 12 or 90 inches (30 or 230 cm) per minute, using a Lloyd, Instron or IMASS peel test machine. The peel adhesion measurement is reported in pounds per inch width or kilograms per 254 centimeters width.
[0060] 2. Static Shear PSTC-7: A ½ inch square (1.6 cm 2 ) sample PSA coated rigid foil or polyester film is laminated to #304 Stainless Steel to test for holding power or cohesive strength. The sample is allowed to equilibrate for about 24 hours at about 72° F. (22° C.) and about 50% relative humidity before a 1 kilogram weight is applied. The test is run at about 72° F. (22° C.) and about 50% relative humidity conditions. The time to fail, when the sample separates from the panel in minutes is recorded. The failure mechanism is also recorded which is either “pop-off” wherein no adhesive residue remains on the panel or the backing, or “cohesive” wherein adhesive remains on both test panel and test sample.
[0061] 3. Film Shrinkage: This test is an additional test used to measure internal adhesive or shear strength. It relates directly to actual product use conditions. This test measures the ability of the PSA to “hold the vinyl film in place” or to resist the shrinkage forces imparted by the vinyl film. A 2½ inch (6.35 cm) by 4 inch (10.2 cm) PSA coated vinyl film sample is applied to an aluminum panel. The applied vinyl film sample is slit with a razor blade in both the crossweb and machine direction and is conditioned at 150° F. (65.6° C.) for 24 hours. Measurements in one-one thousand inch (mils) increments of the razor cut openings are recorded. The razor slit will tend to separate or widen for adhesives with poor internal or cohesive strength. Generally gap opening of 10 mils or greater indicates that the PSA has poor shear strength while adhesives that have good shear or cohesive strength will show small gap openings, less than 10 mils, and will hold the vinyl film in place.
Example 1
Solution Cast Sample
[0062] A pressure sensitive acrylic adhesive for low energy surfaces was formulated by adding to 100 parts (solids) of a high molecular weight, (Mw greater than 1×10 6 ), 93/7 isooctylacrylatelacrylic acid (IOA/AA) copolymer solution (25% solids in ethyl acetate), 20 parts Foral®, 10 parts Hercolyn®-1), and 10 parts Pycal® 94. To this formulation, 0.6 parts Bisamide crosslinker per 100 parts adhesive (5% solution in toluene) is added. The solution was mixed for 1 minute and rolled for an additional hour to reduce air entrapment. The adhesive composition is coated onto silicone release liner, and then dried in an oven for 5 minutes at a temperature of 200° F. (93.3° C.). A coating weight of 0.6 g/24 in 2 (155 cm 2 ) was targeted.
[0063] The coated pressure sensitive adhesive of this example was laminated to various films to produce labels and graphic marking films. In one embodiment, the film may be a polyvinylchloride film which is made flexible by the presence of a PVC-compatible plasticizer or, alternatively, the film may be a brittle, destructible polyvinylchloride film which contains both a PVC-compatible plasticizer and a copolymer resin, such as a methylacrylate/butylacrylate copolymer resin.
Example 2
Hot Melt Sample
[0064] A pressure sensitive acrylic adhesive coated vinyl graphic marking film for low energy surfaces was made by formulating an adhesive with a composition of 100 parts by weight of a low molecular weight, (Mw less than 3×10 5 ), 95/5/0.4 isooctylacrylate/acrylic acid/4-acryloxybenzophenone terpolymer, 15 parts by weight Foral®85, 5 parts by weight Hercolyn®-1), and 5 parts by weight Pycal® 94.
[0065] This formulation was hot melt coated onto a silicone release liner at a coating weight of 0.6 g/24 in 2 (155 cm 2 ) and exposed to a UV light dose of 525 mj/cm 2 . (National Institute of Standards and Technology in accordance with EIT and MIL-STD 45662A). A pressure sensitive adhesive coated vinyl film was prepared as described in Example 1.
[0066] Performance Data
[0067] The data in FIG. 2 shows the effects that tackifier and plasticizer have on peel adhesion on high density polyethylene plastic. 180° peel adhesion values greater than 17 Newtons per 25 mm width, at a peel rate of 30 cm/minute, are realized when a tackified pressure sensitive adhesive is formulated with Pycal®94 plasticizer. With an increased peel rate of 230 cm/minute, the Pycal®94 plasticized PSA exhibits peel adhesions greater than 20 newtons/25 mm width. These results are unique in that the highest peel adhesions are observed for tackified acrylic PSAs which have been plasticized with Pycal®94. At a fast peel rate of 230 cm/minute, the difference in 180° peel adhesions on high density polyethylene are even greater for Pycal®94 modified acrylic adhesives than those adhesives without plasticizer.
[0068] Internal adhesive strength is another, important performance characteristic. In applications where vinyl graphic films or decals are coated with acrylic PSA, the adhesive must have enough internal strength to resist the inherent tendency of the vinyl to shrink. Adhesive strength is most commonly measured by a dead load or static shear test, as described in PSTC-7. An alternative method for determining adhesive strength is to measure the film shrinkage of the PSA-coated vinyl film.
[0069] The data in FIG. 3 shows how film shrinkage is effected by the addition of the Pycal®94 plasticizer tackified acrylic PSA. The addition of the Pycal®94 to the PSA formulation does cause a minor change in film shrinkage. However, this slight change is negligible in the overall performance of the vinyl coated PSA.
[0070] The data in Table IV shows that different classes of plasticizers may be utilized to achieve the desired performance characteristics. The data includes 180° peel adhesions to high density polyethylene, film shrinkage measurements with and without solvent containing screenprinting inks, and static shear values. The data shows that different classes of plasticizers, when incorporated into the PSA formulation, exhibit peel adhesions over 15 Newtons/25 mm width on high density polyethylene while maintaining film shrinkage performance of less than 0.25 mm.
[0071] Shrinkage measurements for PSA coated vinyl films printed with solvent inks were also recorded in Table IV. The ability of the PSA coated vinyl films to resist the effects of solvent ink printing on film shrinkage is important to product performance. Typically, film shrinkage values of PSA coated vinyl films, printed with solvent inks, are double in comparison to non-screenprinted PSA coated vinyl films. In Table IV, under Film Shrinkage, 3900 Solvent Ink, the film was coated with a screen printing ink and a transparent coating. In the first step of the process, a black solvent ink (Scotchcal™ 3905 available from 3M) is screen printed onto a film using a 225-mesh polyester screen. The printed film is dried in a forced draft oven for 1 hr at 150° F. (66° C.). In the second step of the process, the black-printed film is then overcoated with a clear coat (Scotchcal™ 3920 available from 3M) using the same screen and dried an additional 1 hr at 150° F. (66° C.).
[0072] The static shear data in Table IV correlate with the film shrinkage test results. Those plasticized PSA samples with less than 10,000 minutes of shear exhibit cohesive or internal adhesive failure. These measurements were made at 23° C., using a 1000 gram weight with a sample area of 1.6 cm 2 . Also shown in Table IV are plasticizers with high film shrinkage or low static shear values. Although not wishing to be bound by any particular theory, this may indicate incompatibility of those plasticizers with the acrylic PSA.
[0073] In summary, the data presented in Table IV and FIGS. 2 and 3 shows that increased peel adhesions to low energy surfaces, such as high density polyethylene, can be achieved with addition of tackifiers and specific plasticizers without compromising internal adhesive strength.
TABLE IV 95/5/0.4 IOA/AA/ABP Polymer with 15 Parts Foral ®85 & 5 Parts Hercolyn ®-D Tackifiers STATIC 180° Peel Film SHEAR @ Adhesion Shrinkage (mm) 23° C. (minute) (N/25 mm) 3900 Chromate 30 cm/ 230 cm/ Solvent Primed Plasticizer minute minute No Ink Ink Aluminum 5.0% Pycal 94 19.8 22.9 0.150 0.250 10,000+ 5.0% 11.0 19.4 0.173 10,000+ Santicizer 97 5.0% 15.4 21.6 0.175 0.250 10,000+ Santicizer 141 5.0% 16.3 21.6 0.175 0.275 10,000+ Santicizer 154 Pop-off 5.0% DOA 12.3 0.0 0.173 0.275 10,000+ 5.0% 16.7 18.0 0.250 0.650 80 Ketjenflex 8 Cohesive 5.0% 15.4 21.6 0.175 0.325 1,500 Benzoflex P-200 Cohesive 5.0% 15.4 21.1 0.173 0.375 90 Benzoflex 9-88 Pop-off 5.0% 17.2 20.2 0.200 0.300 10,000 Alkopol SQR-490 Pop-off 5.0% 14.1 22.0 0.200 0.325 10,000+ Sartomer 660 5.0% 12.3 20.7 0.150 0.300 10,000+ Sartomer 650
[0074] The data in Table V, below, represents a diverse range of PSA copolymers and terpolymers that were modified with plasticizer to enhance adhesion to low energy plastics. Pressure sensitive adhesives made from copolymers of isooctylacrylate/acrylic acid (IOA/AA), 2-methylbutylacrylate/acrylic acid (2-MBA/AA) and 2-methylbutylacrylate/acrylamide (2-MBA/Acm) and terpolymers of isooctylacrylate/methylacrylate/acrylic acid (IOA/MA/AA) and isooctylacrylate/isobornylacrylate/acrylic acid (IOA/IBA/AA) were tested. Pressure sensitive adhesive formulations 1-14 were made by bulk solution polymerization. Formulation 15 was made by solventless ultraviolet polymerization. Average molecular weight (M w ) was determined via GPC. Various tackifiers and crosslinking methods were utilized in the PSA formulations.
[0075] 180° peel adhesions to high density polyethylene increase when Pycal®94 plasticizer is added to the PSA. For example, when 5 parts of Pycal®94 is added to 100 parts of a copolymer consisting of 96 parts 2-methylbutylacrylate and 4 parts acrylamide, the adhesion to the high density polyethlylene substrate increases from 2.2 N/25 mm width to 6.6 N/25 mm width at a peel rate of 230 cm/minute. Peel adhesions increased from 4.4 N/25 mm width to 17.2 N/25 mm width at a peel rate of 30 cm/minute when 7.5 parts of Pycal®94 is added to 100 parts of adhesive terpolymer consisting of 76 parts of isooctylacrylate, 215 parts of isobornylacrylate and 2.5 parts of acrylic acid.
TABLE V 180° Peel Adhesion (N/25 mm) Film Shrinkage PSA Formulation Tackifier Plasticizer 30 cm/ 230 cm/ (mm) 100 Parts Crosslinker Parts Parts Mw minute minute No Ink 1 98/2 IOA/AA 0.6% Aziridine 25 Foral ®85 5 Pycal ®94 1 × 10 6 17.2 20.7 0.350 2 95/5 IOA/AA 0.3% ABP 11 Regalrez 6108 5 Pycal ®94 2 × 10 5 13.2 0.125 3 95/5 IOA/AA 0.4% ABP 15 Foral ®85/5 5 Pycal ®94 2 × 10 5 19.8 22.9 0.200 Hercolyn ®-D 4 93/7 IOA/AA 0.6% Aziridine 25 ECR-180/10 10 Pycal ®94 1 × 10 6 15.0 23.3 0.075 Hercolyn ®-D 5 94/6 IOA/AA 1.5% Azirdine 12 Nirez ® 2019/7.5 11 Pycal ®94 5 × 10 5 20.2 0.150 Unitac ®70 6 90/10 2-MBA/AA 1.1% Aziridine None None 5 × 10 5 2.2 0.9 0.125 7 90/10 2-MBA/AA 1.1% Azirdine None 5 Pycal ®94 5 × 10 5 11.0 2.2 0.150 8 96/4 2-MBA/Acm 0.2% ABP None None 2 × 10 5 7.9 2.2 0.175 9 96/4 2-MBA/Acm 0.2% ABP None 7.5 Pycal ®94 2 × 10 5 10.6 6.6 0.300 10 76/21.5/2.5 IOA/IBA/AA 0.6% Aziridine 20 Regalrez ® 6108 None 1 × 10 6 4.4 2.2 0.100 11 76/21.5/2.5 IOA/IBA/AA 0.6% Aziridine 20 Foral ®85 7.5 Pycal ®94 1 × 10 6 17.2 17.6 0.150 12 76/21.5/2.5 IOA/IBA/AA 0.6% Aziridine 20 Regalrez ® 6108 7.5 Pycal ®94 1 × 10 6 17.2 3.5 0.125 13 70/22.5/7.5 IOA/MA/AA 0.15% ABP None 5 Pycal ®94 2 × 10 5 13.6 11.0 0.200 14 85/10/5 IOA/MA/AA 0.4% ABP 15 Foral ®/5 5 Pycal ®94 2 × 10 5 19.4 23.3 0.125 Hercolyn ®-D 15 90/10 IOA/AA 0.2% Trazine None 4 Santicizer ® 141 1.5 × 10 6 6.6 0.250
[0076] Equivalents
[0077] Various modifications and alterations to this invention will become apparent to those skilled in the art without departing from the scope and spirit of this invention. It should be understood that this invention is not intended to be unduly limited by the illustrative embodiments and examples set forth herein and that such examples and embodiments are presented by way of example only with the scope of the invention intended to be limited only by the claims set forth herein as follows. | A vinyl graphic marking film or label coated with a pressure sensitive acrylic adhesive designed to achieve high or permanent adhesion to polymeric low energy surfaces is disclosed. In addition to good adhesion to low energy surfaces, the graphic marking film or label may have microperforated or micro-rough edges which initiate tearing when removal is attempted. The article maintains flexibility and film strength for easy fabrication in graphic marking film or label manufacture. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/131,590 filed on May 26, 2011, which is a national stage entry of PCT Application PCT/US09/06323 filed on Dec. 1, 2009, which claims the benefit of U.S. Provisional Application 61/119,959 filed on Dec. 4, 2008, the full disclosures of which are incorporated herein by reference in their entirety.
TECHNICAL FIELD OF THE INVENTION
[0002] This application relates to technique and system for prevention of a loop condition at a telephone internetwork (ISUP/SIP) interface boundary.
BACKGROUND OF THE INVENTION
[0003] Telephone systems and IP-based mobile systems provide for communication between telephone units, including the use of mobile user equipment on wireless communication networks. Among other elements, the transition of connectivity from one communication network to another network usually involves a transition of communication services. The user equipment, source network, and target network may be called different names depending on the nomenclature used and the base technology used in the particular network configurations or communication systems.
[0004] An IP-based mobile system includes at least one mobile node on a wireless communication system. A “mobile node” is sometimes referred to as user equipment, mobile unit, mobile terminal, mobile device, or similar names depending on the nomenclature adopted by particular system providers. The various components on the system may be called different names depending on the nomenclature used on any particular network configuration or communication system.
[0005] For instance, “mobile node” or “user equipment” encompasses PC's having cabled (e.g., telephone line (“twisted pair”), Ethernet cable, optical cable, and so on) connectivity to the wireless network, as well as wireless connectivity directly to the cellular network, as can be experienced by various makes and models of mobile terminals (“cell phones”) having various features and functionality, such as Internet access, e-mail, messaging services, and the like. The term “mobile node” also includes a mobile communication unit (e.g., mobile terminal, “smart phones,” nomadic devices such as laptop PCs with wireless connectivity).
[0006] According to the RFC 3261, June 2002, SIP is an application layer protocol for establishing, terminating and modifying multimedia sessions. “SIP:Session Initiation Protocol”, RFC 3261, June 2002. SIP communications are typically carried over IP protocols and IP networks. Telephone calls are considered a type of multimedia sessions where just audio is exchanged.
[0007] ISUP is a level 4 protocol used on traditional switched telephone (SS7) networks. ISUP communications are typically carried over MTP, although such communications can also run over an IP network. “Application of the ISDN user part of CCITT signaling system No. 7 for international ISDN interconnections,” ITU-T Q.767 recommendation, February 1991. ISUP is used for controlling telephone calls and for maintenance of the network blocking circuits, resetting circuits, and other network equipment.
[0008] There are several flavors of ISUP. ITU-T Q.767 International ISUP is used through this document; some differences with ANSI ISUP (“Signaling System No. 7; ISDN User Part” T1.113-1995 ANSI, January 1995) and TTC ISUP are outlined. ISUP Q.767 is the least complex of all the ISUP flavors. Due to the small number of fields that map directly from ISUP to SIP, the signaling differences between Q.767 and specific national variants of ISUP will generally have little to no impact on the mapping. It should be noted that the ITU-T has not substantially standarized practices for Local Number Portability since portability tends to be grounded in national numbering plan practices, and that consequently LNP must be described on a virtually per-nation basis.
[0009] The manner of mapping between two signaling protocols: the Session Initiation Protocol (SIP) and the ISDN User Part (ISUP) of SS7 is described in Q.1912.5 Profile C and, RFC 3398, December 2002, which focuses on the translation of ISUP messages into SIP messages, and the mapping of ISUP parameters into SIP headers, and vice versa.
[0010] A module performing the mapping between these two protocols is usually referred to as Media Gateway Controller (MGC), although the terms ‘softswitch’ or ‘call agent’ are also sometimes used. An MGC has logical interfaces facing both networks, the network carrying ISUP and the network carrying SIP. The MGC also has some capabilities for controlling the voice path. There is typically a Media Gateway (MG) with E1/T1 trunking interfaces (voice from PSTN) and with IP interfaces (VoIP). The MGC and the MG can be merged together in one physical box or kept separate.
[0011] The Mapping between SIP headers and ISUP parameters in RFC 3398, December 2002, focuses largely on the mapping between the parameters found in the ISUP Initial Address Message (IAM) and the headers associated with the SIP INVITE message. Both of the IAM and SIP INVITE messages are used in their respective protocols to request the establishment of a call. Once an INVITE has been sent for a particular session, such headers as the To and From field become essentially fixed, and no further translation will be required during subsequent signaling, which is routed in accordance with Via and Route headers. Hence, the problem of parameter-to-header mapping in SIP-T is confined mostly to the IAM and the INVITE. There are other mappings that are important as well such as the mapping of Address Complete Message and Call Progress Messages to SIP 18X response messages. Q.1912.5 defines details on the mapping between ISUP and SIP in various scenarios and configurations.
[0012] The population of parameters in the ISUP ACM and REL messages based on SIP status codes is addressed in RFC 3398, December 2002, which also describes when the media path associated with a SIP call is to be initialized, terminated, modified. This RFC does not, however, go into details about how the initialization is performed or which protocols are used for that purpose.
[0013] A “loop condition” arises during initialization of a call across the ISUP/SIP boundary interface where a telephone call is routed repeatedly between the ISUP and SIP domains with a non-decrementing hop counter. This condition results in the same telephone call being processed indefinitely. If the “loop condition” is not broken, system resources will continue to be consumed on a telephone call that cannot be connected, instead of dropping the attempted telephone connection. What is needed is a method of breaking this “loop condition” and break the cycle of providing the same (or higher) parameter values between networks at the network boundary for an uncompleted telephone connection.
SUMMARY OF THE INVENTION
[0014] The present invention provides a solution to prevent a “loop condition” that can arise at the interface boundary of two telephone networks, known by their standard names ISUP and SIP networks. By adjusting parameter values, known as Hop Counter (ISUP) and Max-Forward (SIP), in a predetermined manner, the present invention prevents the situation where a failed connection continues to be processed because the same parameter values are repeatedly provided between networks at the network boundary interface, also called a “loop condition.”
[0015] The present invention solves the “loop condition” by adjusting the Hop Counter and Max-Forward parameter values in a predetermined manner such that the adjusted parameter values break the cycle of providing the same parameter values between networks at the network boundary for an uncompleted connection, or break an endless “loop condition.”
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Embodiments of the present application will now be described, by way of example only, with reference to the accompanying drawing figures, wherein:
[0017] FIG. 1 is a figure showing the “loop condition” problem with system components,
[0018] FIG. 2 is a figure showing the use of the algorithm in the system components,
[0019] FIG. 3 is a figure showing the avoidance of the “loop condition” problem using the invention on the system components; and,
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The present invention focuses on the adjustment of parameter values used in the transition protocol described in Interworking per ITU-T Recommendation Q.1 912.5. The parameters include the ISUP Hop Counter and the SIP Max-Forwards Header.
[0021] The ISUP Hop Counter is designed for prevention of the loop condition on the SST network. The Hop Counter value is set by the originating exchange to a value of 1 to 31 (there should be a default value, e.g., 20), and it is decremented by 1 by each intermediate exchange unless hop counter is not activated for the outgoing trunk. The Hop Counter value should never increase for a call with each intermediate exchange. Forwarded calls are treated as a new origination and gets a new Hop Counter value, and the terminating office ignores the hop counter since the call is terminated at that location. In the situation where a call goes unconnected to its termination point after the number of Hop Counter reaches zero, the call is cleared from the system.
[0022] The loop condition occurs when a call goes unconnected to its termination point, but the system continues to use system resources to continue to try and indefinitely connect the call by transitioning the call among intermediate nodes on the system. When a call is received by an intermediate node, the node examines the Hop Counter value for the call received by the intermediate node. If the Hop Counter value is a positive number, the call will be transferred (with a Hop Counter decremented by one) to the next node or termination point. If the Hop Counter has reached zero because the call has been transitioned across the Hop Counter number of intermediate nodes without being connected to the intended termination point, the intermediate node will clear the call from the system because it will be considered an unconnectable call.
[0023] Thus, if the Hop Counter value reaches zero from the value it was given by the originating exchange, the system components or intermediate nodes that examine the Hop Counter will assume that the call should be cleared from the system because it is not capable of being connected to its intended termination point within a reasonable number of hops. In this manner, the value set for the Hop Counter value prevents a loop condition by setting an upper limit on the number of intermediate node transitions a call can make before being cleared by the system as an unconnectable call. Loop condition problems are thereby prevented on the ISUP network by the Hop Counter and this upper limit of transitions a call can make on the system.
[0024] The SIP Max-Forward header operates in much the same way to prevent loop conditions. The SIP Max-Forward header is set by an originating UAC (e.g., PSTN GW, or SIP client), and it has a valid value range: 0-255. RFC 3261 recommends a default value of 70. The SIP Max-Forward value is decremented by one at each node in the path.
[0025] The loop condition on the SIP system occurs when a SIP call goes unconnected to its termination point, but the system continues to use system resources to continue to try and indefinitely connect the call by transitioning the call among intermediate nodes on the system. When a call is received by each node on the SIP system, the node examines the Max-Forward value for the call received by the node. If the Max-Forward value is a positive number, the call will be transferred (with a Max-Forward decremented by one) to the next node or termination point. If the Max-Forward value has reached zero because the call has been transitioned across the Max-Forward number of nodes without being connected to the intended termination point, the call will be cleared from the system because it will be considered an unconnectable call.
[0026] Thus, if the Max-Forward value reaches zero from the value it was given by the originating exchange, the system components or intermediate nodes that examine the Max-Forward will assume that the call should be cleared from the system because it is not capable of being connected to its intended termination point within a reasonable number of hops. In this manner, the value set for the Max-Forward value prevents a loop condition by setting an upper limit on the number of intermediate node transitions a call can make before being cleared by the system as an unconnectable call. Loop condition problems are thereby prevented on the SIP network by the Max-Forward and this upper limit of transitions a call can make on the system.
[0027] When a call transitions from the ISUP network to the SIP network, the Hop Count value needs to be mapped over to a Max-Forward value. In like manner, when a call transitions from the SIP network to the ISUP network, the Max-Forward value needs to be mapped over to a Hop Count value. This mapping is governed by Interworking per ITU-T Recommendation Q.1912.5, with preset formulas to make the mapping of these parameter values. For ISUP to SIP, the mapping equation is “Max-Forwards =integer portion of (Factor*Hop-counter)” where Factor is a predetermined number. For SIP to ISUP, the mapping equation is “Hop-counter=integer portion of (Max-Forwards/Factor)” where Factor is a predetermined number. In this manner, a call that is transitioned over an interworking network boundary (ISUP/SIP) will carry with it the necessary Hop Count or Max-Forward value so that the “loop condition” does not occur.
[0028] When the transition occurs and the formulas are applied, an SIP Max-Forward value will be bigger than the ISUP Hop Counter when mapping from ISUP to SIP direction. Also, when the transition occurs and the formulas are applied, the ISUP Hop Counter resulted from mapping equation must not be significantly smaller to a point where the hop counter will lead to calls being frequently cleared due to too many hops. With respect to the Factor used in the mapping equations, the Factor used in the different mapping equations may be different. That is, one proposed mechanism for addressing the mapping equations for the Hop Count to Max Forward, or vice versa, values, is for the ISUP to SIP and SIP to ISUP mapping equations to use two different factors, e.g., a smaller factor for SIP to ISUP direction.
[0029] There is a problem with using the established transition equations, because some originating exchanges sets the initial Hop Counter value to a too small value, which causes call failure when the factor X is set to 1. The root cause of this problem is that the SIP network introduces more hops that a typical TDM network does and the TDM originating switch is not aware of this situation. The typical solution is to compensate for this by multiplying the Hop Counter value with a factor (greater than 1). The SST uses the same factor for both directions to prevent SST from becoming a looping point. If the factor is set to a bigger value, e.g., 2, then the SIP to ISUP direction may have issues since this brings down the Hop Counter value for SIP to ISUP direction significantly.
[0030] This problem is illustrated in the situation shown in FIG. 1 , where a call is transitioned back and forth across the ISUP/SIP network boundary, but the mapping equations prevent to decrement of the Hop Count and Max Forward values with each loop of the call across the interfaces.
[0031] In FIG. 1 , the Core network 100 is coupled to the ISUP SST network 125 , which is coupled to the SIP Proxy network 150 . The mapping equation for SIP to ISUP is “MaxFwd=HC*2,” and the mapping equation for SIP to ISUP is “HC=MaxFwd/1.” The mapping equations are performed at the ISUP and SIP Interworking UNIT SST 125 . Hop Count value of 4 is received in step 110 at the SST 125 , and the mapping equation produces a MaxFwd value of 8, which decremented by 1 because of the intermediate hop counted at the SST 125 .
[0032] This results in the MaxFwd value of 7 shown in 112 , and forwarded to the SIP Proxy network 150 in step 114 . The SIP Proxy network 150 notices that the transitioned call destination has moved to the PSTN network at step 116 , which is back on SST network 125 . So, the MaxFwd value is decremented by one to account for the SIP Proxy network 150 as an intermediate node, and the call is sent back to the SST network 125 with a MaxFwd value of 6 at step 118 .
[0033] The SST network 125 takes the MaxFwd value, decrements it by one to account for the SST network 125 as an intermediate hop, and performs the mapping equation “HC=MaxFwd/1” at step 120 . This mapping equation results in a Hop Count value of 5. The call is transitioned to the Core network 100 in step 122 , where the Core network 100 decrements the Hop Count value by one in step 124 , to produce a Hop Count value of 4.
[0034] Based on the analysis of the call on the Core network 100 , the call is shown to be destined to a location on the SIP Proxy network 150 , so the Core Network 100 routes the call back to the SST network 125 with the Hop Count value of 4 in step 100 . As can be readily recognized, this is the same Hop Count value as the previous step 100 , and even though the call is obviously unconnectable, the mapping equations and transitions over the network interface boundaries is producing an infinite loop condition that will continue to consume network resources without end.
[0035] The present invention prevents this type of interworking loop condition by having an intelligent factor (i.e., an algorithm) that converts the ISUP Hop Counter to SIP Max-Forwards in such a way that the loop condition prevention mechanism is not broken and yet the number of hops/segments a call is allowed to traverse is significantly improved. The algorithm can be tweaked to form different variants (embodiments). The invention allows a bigger “factor” to be applied for ISUP to SIP direction than SIP to ISUP direction.
[0036] The present invention uses one or more mapping equation algorithms on the system components to produce a high “gain” when converting between ISUP Hop Counter and SIP Max-Forward so as to minimize the chances of calls failing when transitioning between ISUP and SIP. And, the present invention uses one or more mapping equation algorithms on the system components that have an intelligent factor that will guarantee the Hop Counter, or Max-Forwards value, will always decrease by at least one, even if taking the shortest possible loop back to the other network so as to guarantee that we will never have infinite loops.
[0037] The present invention uses one or more mapping equation algorithms on the system components to calculate the maximum value for the SIP Max-Forwards based on ISUP Hop Counter, ISUP to SIP conversion factor, and SIP to ISUP conversion factor in such a way that if the call would loop back from the SIP to ISUP, the resulting ISUP hop counter to the interworking unit would be at least one less than the original hop counter value hence preventing an infinite loop. The present invention uses mapping equation algorithms that calculates the Max-Forward value by taking the reverse mapping factor into consideration.
[0038] The present invention uses one or more mapping equation algorithms on the system components that calculate the Max-Forward value by giving a constant gain for one direction. For example, in the ISUP to SIP direction, the mapping equations used on the system components adds an incremental 4 to the resulted Max-Forwards value, and decrements the Max-Forward value by 4 before converting to ISUP Hop Counter for SIP to ISUP direction. The idea of combining the various aspects discussed above into one set of mapping algorithms to be used on the system components results in artificially decrementing a number of hops from the Hop Counter after applying the SIP to ISUP conversion factor so that the equal amount of hops can be added to the ISUP to SIP conversion direction, which addresses the typical issue of the SIP Max-Forwards value being too low when the incoming Hop Counter value is too small.
[0039] The present invention uses one or more mapping equation algorithms on the system components to customize the algorithm based on certain known facts such as the next node will not loop back immediately hence the maximum value of the SIP Max-Forwards value can be bigger. The idea of calculating the maximum Max-Forwards value by first figuring out the minimal Max-Forwards value that would cause a loop and then output the max-forwards value being (the minimal max-forwards value−1). The present invention uses one or more mapping equation algorithms on the system components to use the same algorithm for all the interworking units in the network, as well as activate an algorithm for all the Interworking units in the network at once to minimize failures. Ultimately, the goal is to produce a bigger Max-Forwards value if the next node will not loop back or to calculate the Max-Forwards value by taking the minimal loop length into consideration, but achieve a Max-Forwards value that will allow an unconnectable call to terminate based on the use of an intelligent mapping equation.
[0040] On top of the known mapping equations, the present invention uses the following equation to produce a bigger Max-Forward value and make sure the Max-Forward value does not drop below a predetermined small value. The present invention uses the following equation for the ISUP to SIP direction:
[0000] Max-Forwards−MIN(255, MINWHCI+1)* F 2+2)−1), ( F 1*HCI−1))+ G )
[0000] where:
[0041] HCl is the incoming Hop Counter value to the interworking unit,
[0042] F2 is the factor used to calculate the ISUP hop counter based on SIP max-forwards value,
[0043] F1 is the factor used to calculate the SIP Max-Forwards value based on ISUP Hop Counter,
[0044] G is a predetermined directional gain factor added to the second part of the equation.
[0045] The directional gain G is a factor between 0 to 5, which provides adjustment of the algorithm based on deployment needs. A bigger G value produces bigger SIP Max-forwards value for ISUP to SIP direction but produces smaller value for HC for the SIP to ISUP direction.
[0046] In an example shown in FIG. 2 , the F1 factor is 2 and the F2 factor is 1. In FIG. 2 , the Core network 200 is coupled to the SST network 225 , which is coupled to the SIP Proxy network 250 . The mapping equation for SIP to ISUP is shown above using the minimum of the ((HCl+1)*F2+2)−1) or (F1*HCl−1). The mapping equations are performed at the SST network 225 . The first part of the minimum equation is (((4+1)*1)+2)−1), or (((5*1)+2)−1), or (7−1), or 6. The second part of the minimum is (2*4)−1, or 8−1, or 7. The minimum of 6 and 7 is 6. As such, a Hop Count HCl value of 4 received in step 210 at the SST network 225 , results in a mapping equation Minimum MaxFwd value of 6 at step 212 , which forwarded to the SST network 225 in step 214 .
[0047] This results in the MaxFwd value of 6 shown in 212 , and forwarded to the SIP Proxy network 250 in step 214 . The SIP Proxy network 250 notices that the transitioned call destination has moved to the PSTN network at step 216 , which is back on SST network 225 . So, the MaxFwd value is decremented by one to account for the SIP Proxy network 250 as an intermediate node, and the call is sent back to the SST network 225 with a MaxFwd value of 5 at step 218 .
[0048] The SST network 225 takes the MaxFwd value of 5, decrements it by one to account for the SST network 225 as an intermediate hop, and performs the mapping equation “HC=MaxFwd/1” or “4/1 ” at step 220 . This mapping equation results in a Hop Count value of 4. The call is transitioned to the Core network 200 in step 222 , where the Core network 200 decrements the Hop Count value by one in step 224 , to produce a Hop Count value of 3.
[0049] Based on the analysis of the call on the Core network 200 , the call is shown to be destined to a location on the SIP Proxy network 250 , so the Core Network 200 routes the call back to the SST network 225 , but this time with the Hop Count value of 3 in step 310 shown in FIG. 3 sent from Core Network 300 . This is a smaller Hop Count value than was sent out in FIG. 2 at step 210 , which means the Hop Count value is decreasing.
[0050] As shown in FIG. 3 on the next loop, the Minimum mapping equation for SIP to ISUP using HCl=3 and the mapping equation shown above will produce the minimum of the ((HCl+1)*F2+2)−1) or (F1*HCl−1). The mapping equations are performed at the SST network 225 . The first part of the minimum equation is (((3+1)*1)+2)− 1 ), or (((4*1)+2)−1), or (6−1), or 5. The second part of the minimum is (2*3)−1, or 6−1, or 5. The minimum of 5 and 5 is 5. As such, a Hop Count HCl value of 3 received in step 310 at the SST network 325 , results in a mapping equation Minimum MaxFwd value of 5 in step 312 , which is forwarded to the SST network 325 in step 314 .
[0051] This results in the MaxFwd value of 5 shown in 312 , and forwarded to the SIP Proxy network 350 in step 314 . The SIP Proxy network 350 notices that the transitioned call destination has moved to the PSTN network at step 316 , which is back on SST network 325 . So, the MaxFwd value is decremented by one to account for the SIP Proxy network 350 as an intermediate node, and the call is sent back to the SST network 325 with a MaxFwd value of 4 at step 318 .
[0052] The SST network 325 takes the MaxFwd value of 4, decrements it by one to account for the SST network 325 as an intermediate hop, and performs the mapping equation “HC=MaxFwd/1” or “3/1” at step 220 . This mapping equation results in a Hop Count value of 3. The call is transitioned to the Core network 300 in step 322 , where the Core network 300 decrements the Hop Count value by one in step 324 , to produce a Hop Count value of 2 that is transitioned back to the SST network 325 . This is a smaller Hop Count value than was sent out in FIG. 2 at step 210 , which means the Hop Count value is decreasing—and will continue to decrease until it reaches zero and the call is cleared from the system as being unconnectable. In this manner, any loop condition arising at the network interface boundary will be broken by the present invention, and system resources will be conserved over prior art systems.
[0053] The present invention uses the following equation for the SIP to ISUP mapping direction:
[0000] Hop Count=MIN(31, INT(MAX(0,( MF 2−1− G ))/ F 2)) where:
[0054] MF2 is the incoming MaxForward value from the SIP network,
[0055] F2 is the factor used to calculate the ISUP hop counter based on SIP max-forwards value,
[0056] G is a predetermined directional gain factor added to the second part of the equation.
[0057] This equation will also assist with breaking any loop condition by reducing the Hop Count value with each successive loop in a transition of calls over the interworking network boundary interface. Ultimately, the goal is to reduce the Hop Count value to zero in this condition, so that the unconnectable call can be cleared from the system.
[0058] The above-described embodiments of the present application are intended to be examples only. Those of skill in the art may effect alterations, modifications and variations to the particular embodiments without departing from the scope of the application. In the foregoing description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these details. While the invention has been disclosed 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 such modifications and variations as fall within the true spirit and scope of the invention. | The present invention provides a solution to maximize the chance of completion for an ISUP to SIP direction call by enabling a bigger factor for converting ISUP hop counter to SIP Max-Forwards value than the reverse direction thus enabling more hops in the SIP network. Enabling a bigger factor for ISUP to SIP direction can cause loops without special considerations. This invention provides an algorithm that prevents a “loop condition” that can arise at the interface boundary of two telephone networks, known by their standard names 1SUP and SIP networks. The present invention solves the “loop condition” problem by adjusting the Hop Counter and Max-Forward parameter values in a predetermined manner such that the adjusted parameter values break the cycle of providing the same parameter values between networks at the network boundary for an uncompleted connection, or break an endless “loop condition”. | 7 |
FIELD OF THE INVENTION
The present invention relates to a process for the synthesis of racemic nerol oxide i.e. 3,6-dihydro-4-methyl-2-[2-methyl-1-propenyl)-2H-pyran from monoterpene alcohol nerol i.e. cis-3,7-dimethylocta-2,6-diene-1-ol. The present invention particularly relates to a process for the preparation of racemic nerol oxide of formula 1 from nerol of formula 2 comprising addition of a halogenating agent to monoterpene nerol of formula 2 in an anhydrous alcoholic solvent to produce 7-alkoxy-3,7-dimethyl-6-halo-2-octenol of formula 3 where R represents the alkyl group such as methyl, ethyl, n-propyl and n-butyl and the like and X represents a halogen such as chloro, bromo-, iodo, thereafter dehydrohalogenation of the compound of formula 3 with a strong base or an alkali furnishing 7-alkoxy-3,7-dimethyl-octa-2,5-dien-1-ol derivative of formula 4 and finally converting the octadienol of formula 4 to produce racemic nerol oxide of formula 1 using dilute mineral acid, Lewis acid or an acidic resin.
BACKGROUND OF THE INVENTION
Nerol oxide is a valuable base material in perfumery and occur naturally as an ingredient of Bulgarian rose oil (0.038%) and grape juice. It exists naturally as a racemic mixture of (R and S) isomers of 3,6-dihydro-4-methyl-2-(2-methyl-1-propenyl)-2H pyran. The olfactory properties of racemic nerol oxide are comparable to those of diastereoisomeric rose oxides as regards totality and strength and is dominated by a powerful greenish-spicy note of the geranium type corresponding to the odour of (−)-cis-rose oxide.
Nerol and geraniol are the monoterpenic constituents of Cymbopogon spp. (lemon grass) These are the geometrical (cis and trans) isomers and can also be easily obtained by chemical reduction or catalytic hydrogenation of citral, another very common monoterpenic constituent of lemon grass.
Ohloff prepared the intermediate 3,7-dimethyl-octa-2,5-dien-1,7-diol from nerol by its photosensitized air oxidation followed by reduction and cyclisation with an acid to obtain racemic nerol oxide [G. Ohloff, K. H. Schulte-Elite & B. Willhalm Helv. Chim. Acta. 47, 602, 1964]. In another publication nerol was first subjected to epoxidation at C 6 –C 7 double bond and the epoxy derivative so obtained was heated in dimethyl amine at 150° to give 3,7-dimethyl-6-dimethyl amino-2-octen-1,7-diol which on oxidation with hydrogen peroxide and pyrolysis at 180° C. gave a diol intermediate that on acid catalysed cyclisation led to the formation of nerol oxide [G. Ohloff & B. Lienhard Helv. Chim. Acta. 48, 182, 1965].
Tyman and Willis reported the total synthesis of nerol oxide by reaction of 3-methyl-2-butenal and 3-methyl-3-butenol in presence of an acid. [J. H. P. Tyman & B. J. Willis Tet. Lett. 4507, 1970]. Hasegawa T. Co Ltd. Japan in 1980 disclosed that 3,7-diethyl-1-octen-3-ol-5-one on reduction with Lithium aluminium hydride (LAH) followed by its cyclisation producing nerol oxide [Hasegawa T. Co Ltd. Japan, Chem. Abstracts, 93, 239702, 1980].
In another publication Ohloff et al. in 1980 described the synthesis of optically active nerol oxide from (−)-(R)-linalool in a nine step reaction sequence which is more of academic interest [G. Obloff, W. Giersch, K. M. Schulte-Elite, P. Enggist & E. Demole Helv. Chim. Acta. 63, 1582, 1980]. Thus the methodologies or processes reported in prior art are generally are of academic interest, non-ecnomical as well as cumbersome. The overall yield of the final product nerol oxide is also low.
OBJECTS OF THE INVENTION
The main objective of the present invention is to develop a novel, simple and economically viable process for the preparation of racemic nerol oxide.
Another objective of the invention is to develop a process from commercially available monoterpene alcohol nerol utilizng the cheap and recoverable reagents in the process that may be capable of facile up scaling.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides a process for the preparation of racemic nerol oxide of formula 1 from monoterpene nerol of formula 2, the process comprising:
(i) haloalkoxylating monoterpene nerol of formula 2 with a halogenating agent and in a solvent to produce 7-alkoxy-3,7-dimethyl-6-halo-2-octenol of formula 3 where R is alkyl and X is halo;
(ii) dehydrohalogenating the compound of formula 3 to obtain a 7-alkoxy-3,7-dimethyl-2,5-dien-1-ol derivative of formula 4 where R is as stated above; and
(iii) converting the octadienol of formula 4 to produce racemic nerol oxide of formula 1.
In one embodiment of the invention, R is selected from the group consisting of methyl, ethyl, -propyl and n-butyl.
In another embodiment of the invention X is selected from the group consisting of chloro, bromo- and iodo.
In a further embodiment of the invention, the dehydrohalogenation of compound of formula 3 is carried out with a strong base or an alkali;
In yet another embodiment of the invention, the compound of formula 4 is converted into racemic nerol of formula 1 using dilute mineral acid, lewis acid or an acidic resin.
In another embodiment of the invention, the halogenating agent is selected from the group consisting of N-halogenated compounds selected in turn from the group consisting of N-chlorosuccinimide, N-bromosuccinimide and N-iodosuccinimide, 1,3-dibromo-5,5-dimethylhydantoin (DDH), halogen selected in turn from bromine and iodine, and halogenated salt selected in turn from iodine monochloride and potassium iodate.
In another embodiment of the invention, the solvent used in haloalkoxylation reaction is an alcoholic solvent selected from the group consisting of methanol, ethanol and propanol, or water or any mixture thereof.
In yet another embodiment of the invention, the haloalkoxylation reaction is effected at a temperature in the range of 0–50° C.
In another embodiment of the invention, the base used for dehydrohalogenation is an inorganic base selected from the group consisting of sodium carbonate, potassium carbonate, lithium carbonate, sodium hydroxide, potassium hydroxide and barium hydroxide.
In another embodiment of the invention, the base used for dehydrohalogenation is an organic base selected from the group consisting of diethyl amine, triethyl amine, 1,8-diaza [5,4,0] undec-7-en (DBU), pyridine and collidine.
In another embodiment of the invention, dehydrohalogenation in step (ii) is carried out in the presence of a solvent selected from non-polar and polar solvents.
In another embodiment of the invention, the solvent is selected from the group consisting of hexane, toluene, dioxane, dimethoxy ethane, methanol, ethanol, dimethyl formamide, water and any mixture thereof.
In another embodiment of the invention, dehydrohalogenation is effected at ambient to reflux temperature of the solvent used.
In another embodiment of the invention, cyclisation of the intermediate octadienol of formula 4 to produce racemic nerol oxide is effected in the presence of an organic solvent, an aqueous solvent or an aqueous alcoholic solvent.
In another embodiment of the invention, the dehydrohalogenation is effected at a temperature in the range of 0–20° C.
In another embodiment of the invention the mineral acid is dilute sulphuric acid.
In another embodiment of the invention step (iii) is carried out at a temperature in the range of 0–50° C. preferably 0–15° C.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a novel process for the preparation of racemic nerol oxide of formula (1) above from a monoterpene nerol of formula (2) above. The process comprises addition of halogenating reagent in presence of an alcohol to the monoterpene nerol of formula 2 to produce 7-alkoxy-3,7-dimethy-6-halo-2-octenol of formula 3 where R represents an alkyl group and X represents a halogen. The halogenated product is subsequently dehydrohalogenated using a strong base or an alkali to give 7-alkoxy-3,7-dimethyl-octa-2,5-dien-1-ol of formula 4. The compound of the formula 4 is easily cyclised when stirred with an acid or an acidic resin or Lewis acid to produce racemic nerol oxide of formula 1. The halo alkoxylation reaction of monoterpenic alcohol nerol of the formula 2 is preferably effected by N-halogenated succinimide selected from N-chlorosuccinimide, N-bromosuccinimide, N-iodosuccinimide or N, N-dihalogenated dimethyl hydantoin such as 1,3-dibromo-5,5-dimethyl hydantoin (DDH) or a halogen or halogenated salts such as bromine, iodine, iodine monochloride, potassium iodate and the like but more preferably 1,3-dibromo-5,5-dimethyl hydantoin (DDH) in a polar anhydrous alcoholic solvent such as methanol, ethanol, propanol and the like but more preferably methanol. The cohalogenation is effected at a temperature at 0–50° C., more preferably at 0–20° C. The base used for dehydrohalogenation of the halogenated product of formula 3 is preferably selected from inorganic bases such as sodium hydroxide, potassium hydroxide or barium hydroxide, sodium carbonate and the like or it may be selected from the organic bases such as diethyl amine, triethyl amine, 1,8-diazabicyclo [5,4,0]-undec-7-en (DBU), pyridine, collidine and the like but more preferably an inorganic base to produce 7-alkoxy-3,7-dimethyl-octa-2,5-dien-1-ol of formula 4. Dehydrohalogenation reaction is effected in a polar or medium polar solvents such as water, ethanol, methanol, dioxane, dimethoxy ethane and the like or the mixture thereof at ambient to reflux temperature of the solvent. Cyclisation of compound of formula 4 is effected using acidic reagents such as an acidic resin or dilute mineral acid and the like or a Lewis acid, more preferably a dilute mineral acid such as sulphuric acid in an organic solvent or aqueous or aqueous alcoholic solution at a temperature 0–50° C. preferably 0–15° C.
The invention is described with reference to examples given below. These examples should not be construed as to restrict the scope of reaction.
EXAMPLE 1
Step-1; Preparation of 6-bromo-3,7-dimethyl-7-methoxy-2-octenol of formula 3, where R═CH 3 and X═Br
Commercial nerol (50.0 g, 0.324 mol, 95% purity) is dissolved in anhydrous methanol (150 mL) in a flask fitted with a thermometer, a dropping funnel and a nitrogen inlet. 1,3-Dibromo-5,5-dimethylhydantoin (DDH) (50.0 g, 0.174 mol) is added slowly in small proportions with vigorous stirring at a temperature of 10° C. in nitrogen atmosphere. The temperature during the addition of DDH is maintained between 10–15° C. After the complete addition of DDH the reaction mixture is further stirred for one hr. On completion of the reaction, the mixture is poured in cold water in a separating funnel and extracted with ethyl acetate (3×50 mL). The combined layer of the solvent is washed with 5% sodium carbonate solution (3×25 mL) and then with water (3×30 mL) to neutral pH. Finally the solvent layer is dried over anhydrous sodium sulphate and concentrated on a thin film evaporator at reduced pressure to give colourless oil which is identified as 6-bromo-3,7-dimethyl-7-methoxy-2-octenol of formula 3 (73.12 g, 85.32%) identified by spectral data.
1 HNMR CDCl 3 , δ: 1.27 & 1.32 (6H, 2xS, 2xCH 3 ), 1.74 (3H, S, CH 3 ), 3.23 (3H, S, OCH 3 ), 3.89(2H, d, J=11.6 Hz, CHBr), 4.19(2H, d, J=7 Hz; CH 2 OH), 5.51(1H, t, J=6 Hz, ═CH).
13 CNMR, CDCl 3 , δ: 20.89, 22.86, 23.09, 29.83, 31.03, 49.22, 58.42, 62.84, 76.09, 125.58, 137.29.
MS:M + at m/z 264, 266.
Step-2: Preparation of 3,7dimethyl-7-methoxy-octa-2,5-dien-1-ol of formula 4, where R═CH 3 .
Crude 6-bromo-3,7-dimethyl-7-methoxy-2-octenol (70.0 g, 0.265 mol.) of formula 3 is dissolved in methanol (200 ml) containing potassium hydroxide (35.0 g) and reaction mixture refluxed at 65–70° C. on a water bath for five hours. After the reaction is complete as monitored by TLC,/GLC, the excess solvent is removed by distillation at reduced pressure bringing the total volume to one fourth. The reaction contents are then poured in cold water in a separating funnel and extracted with chloroform (4×50 ml). The solvent layer is washed with water (3×50 ml) to neutral pH. Finally chloroform layer is dried over anhydrous sodium sulphate and concentrated under reduced pressure to produce a pale yellow oily substance which is identified as 3,7-dimethyl-7-methoxy-octa-2,5-dien-1-ol of formula 4 (43.69 g, 89.56%) from its spectral data.
1 HNMR CDCl 3 , δ: 1.25 (6H, 2xS, 2xCH 3 ), 1.73 (3H, S, CH 3 ), 3.14 (3H, S, OCH 3 ), 4.14 (2H, d, J=7 Hz, CH 2 OH), 5.47–5.55 (3H, m, ═CH).
13 CNMR, CDCl 3 , δ: 23.0, 25.25, 25.44, 34.60, 49.70, 58.34, 74.37, 124.67, 126.79, 136.16, 136.84. MS: M + at m/z 184.
Step-3: Preparation of (±)-nerol oxides of formula 1
The compound 3.7-dimethyl-7-methoxy-octa-2,5-dien-1-ol of formula 4 prepared in step 2 above (40.0 g, 0.217 mol) was dissolved in n-hexane (100 ml) in a round bottom flask and to this added hydrochloric acid (5%, 15 mL) at 0° C. and stirred the mire for 2 hours.
After the reaction is complete, the solvent layer was separated and washed with 5% sodium bicarbonate solution (3×20 ml) and then with water (3×30 ml) to neutral pH. Finally the solvent layer is dried over anhydrous sodium sulphate and concentrated under vacuo and finally distilled at reduced pressure to give a colour less oil with specific pungent green and rosacious odour of of racemic nerol oxide of formula 1 (29.47 g, 89.30%) that is also confirmed by spectral analysis.
1 HNMR, CDCl 3 , δ: 1.69 (6H, 2xS, 2xCH 3 ), 1.74 (3H, S, CH 3 ), 4.23 (3H, m, CH 2 OH & CHOH), 5.22 (1H, d, J=7 Hz, ═CH), 5.41 (1H, m, ═CH). 13 CNMR, CDCl 3 , δ: 19.60, 23.90. 26.98, 37.19, 66.79, 71.92, 120.92, 126.94, 133.08, 137.28. MS:M + at m/z 152.
EXAMPLE 2
Step-1: Preparation of 6-bromo-3,7-dimethyl-7-etboxy-2-octenol of formula 3, where R═C 2 H 5 and X═Br
N-bromosuccinimide (60.0 g, 0.337 mol) dissolved in anhydrous ethanol (150 mL) is placed in a flask fitted with a therrometer, a dropping funnel and a nitrogen inlet. Commercial nerol (50.0 g, 0.324 mol, 95% purirty) is taken in the dropping funnel and added slowly with vigorous stirring at a temperature of 5–20° C. in nitrogen atmosphere. The temperature during the addition of nerol is maintained between 10–20° C. After the completion of reaction, the reaction mixture is poured in cold water in a separating funnel and exacted with n-hexane (3×100 mL). The n-hexane extract is washed with 5% sodium carbonate solution (3×25 mL) and then with water to neutral pH. The solvent layer is finally dried over anhydrous sodium sulphate and removed under reduced pressure to give a pale yellow oil identified as 6-bromo-3,7-dimethyl-7-ethoxy-2-octenol of formula 3 (76.63 g 84.95%).
Step-2: Preparation of 3,7-dimethyl-7-ethoxy-octa-2,5dien-1-ol of formula 4 where R═C 2 H 5 .
Crude 6-bromo-3,7-dimethyl-7-ethoxy-2octenol of the formula 3 (70.0 g, 0.251 mol) obtained from step 1 above is dissolved in ethanol (200 mL) in a flask fitted with a condenser. Sodium hydroxide (30.0 gm) is added in the flask and the contents refluxed for 10 hours. After the reaction is complete, solvent is removed by distillation at reduced pressure to bring the total volume to one fourth. The reaction mixture is poured in cold water (200 ml) then extracted with ethyl acetate (3×100 mL). The solvent layer is washed with water to neutral pH. The solvent is finally dried over sodium sulphate and removed under vacuo to give a colourless oil identified as 3,7-dimethyl-7-ethoxy-octa-2,5-dien-1-ol of formula 4 (44.76 g, 89.78%) by spectral studies.
Step-3: Preparation of racemic nerol oxide of formula 1
The compound 3,7-dimethyl-7-ethoxy-octa-2,5-dien-1-ol of formula 4, (40.0 g, 0.20 mol) obtained from step 2 above without purification was dissolved in acetone (100 mL) in a round bottom flask. The resin amberlite plus 120 (15.0 gms) is added in the flask and the reaction mixture is stirred at a temperature 10° C. for 2 hours. After the completion of the reaction as monitored by TLC, the resin is removed by filtration and the solvent layer is distilled under vacuo to produce the crude nerol oxide which thus obtained is purified by steam distillation to furnish pure nerol oxide of formula 1 (27.30 g, 88.98%) and its identity confirmed by spectal studies.
Advantages:
The advantages of the process are as under:
1. The process is novel, and facile and requiring only a three step reaction sequence using monoterpenic alcohol nerol as the starting material. 2. The process is high yielding and yield in each step is betwreen 80–90%. 3. The over all yield of the fumal product i.e. nerol oxide is 55–65%. 4. The reagents used are commercially available, cheap and after recovery may be reutilized after reconversion to the corresponding halo derivatives. 5. The process can be easily up scaled for commercial production. | The present invention relates to a process for the synthesis of racemic nerol oxide i.e. 3,6-dihydro-4-methyl-2-[2-methyl-1-propenyl)-2H-pyran from monoterpene alcohol nerol i.e. cis-3,7-dimethylocta-2,6-diene-1-ol. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 236,170, filed Feb. 20, 1981, which is a continuation of application Ser. No. 927,928, filed July 25, 1978, now issued as U.S. Pat. No. 4,258,630.
BACKGROUND OF THE INVENTION
It has long been recognized that the heating of food within an oven enclosure will be more uniform throughout the food product if it is rotated during the heating process. This is particularly desirable where the product is baked such as cakes, breads or the like.
Early recognition of this concept is found in U.S. Pat. No. 416,839 to Howard and U.S. Pat. No. 557,344 to Shaw.
With the advent of microwave cooking the principle involved became even more important due to the rapidity of baking or cooking the finished product. Accordingly, others have invented structures specifically designed for microwave ovens. Examples are U.S. Pat. Nos. 2,632,838 to Schroeder and 3,177,335 to Fitzmayer et al., both of which show the use of turntables within an oven utilizing ultra-high frequency electromagnetic wave energy (hereinafter referred to as "microwave") for cooking the product within the oven.
In microwave cooking the inner and outer portions of the product within the oven are both heated simultaneously and quickly to a normal cooking temperature. However, the microwave energies are not uniformly distributed within the oven enclosure resulting in unevenness in cooking throughout the body of the food product. It is accordingly even more desirable that the food product be slowly rotated during baking within a microwave oven. As the product is rotated the food passes through uneven microwave patterns to create an even cooking effect eliminating any so-called "hot spots" in the product mass.
While the latter two of the aforementioned patents do disclose turntable mechanisms for rotating a food product container during the cooking process in a microwave oven, they are built into the oven itself thus allowing the driving motor to be disposed outside of the oven interior. These structures are accordingly expensive and are not adapted for use with ovens not so equipped by the original manufacturer.
It is accordingly desirable that a turntable construction be provided in the way of a portable accessory that can be used only when necessary or desirable within a microwave oven.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide a self-enclosed and motorized turntable which may be energized and placed within an oven to serve as a base for a container of a food product cooked therein and gradually rotate the container during the cooking process.
Another object of the invention is to provide a portable rotary stand or turntable which may be used in microwave ovens with no arcing between the turntable drive mechanism and the oven.
Still another object of the invention is to provide a portable rotary turntable for use in microwave ovens which is durable, economical to manufacture, and relatively easy to operate, keep clean and store.
Yet another object of the invention is to provide a portable rotary turntable for use in microwave ovens which is powered by a spring motor with an improved centrifugal governor employing a disc with a tab or tabs.
With these and other objects in view the invention broadly comprises a rotary turntable having a pan shaped base with an annular side wall, a cover member, of similar diameter and positioned in covering relation over the pan, a motor housing of metallic material disposed within and secured to the pan, a spring motor with an improved governor mounted within the housing, means for energizing the motor, drive means acting between the motor and cover whereby as the motor is energized the cover will be rotated relative to the base.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate a complete embodiment of the invention, together with alternatives thereto, according to the best mode so far devised for the practical application of the principles thereof, and in which:
FIG. 1 is a front elevation of a conventional microwave oven with a transparent window in the front door showing the portable turntable positioned on the bottom or bottom shelf of the oven supporting a container for a food product being cooked in the oven.
FIG. 2 is an enlarged side elevation of the turntable unit.
FIG. 3 is a horizontal section through the upper portion of the unit taken on line 3--3 of FIG. 2.
FIG. 4 is a vertical section through the turntable unit taken on line 4--4 of FIG. 2 but showing portions of the motor in elevation.
FIG. 5 is a vertical section through the turntable unit taken on line 4--4 of FIG. 2 showing portions of the motor in elevation and illustrating the improved governor structure.
FIG. 6 is a top view taken on line 6--6 of FIG. 5 showing the governor structure.
FIG. 7 is a top view taken on line 6--6 of FIG. 5 showing the governor in operation.
FIG. 8 is a view similar to that of FIG. 6 showing a cylindrical brake element.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more particularly to the drawings reference numerals will be used to denote like parts or structural features in the different views. The numeral 10 denotes generally a conventional microwave oven of boxlike configuration with controls 11, and hinged front door 12 having a transparent window 14 mounted therein. The bottom of the oven upon which the turntable unit rests is shown at 15 in FIG. 2 and a container C is shown positioned on the turntable within the oven in FIG. 1.
The turntable unit itself forming the subject of the present invention is designated generally by the numeral 20. It has a vertically shallow cylindrical overall shape and the construction thereof will best be understood by reference to FIG. 4.
A bottom turntable base 21 is pan shaped with a flat bottom adapted to rest upon the oven bottom 15 and having an annular side wall which terminates in an outwardly extending flange 22 around the upper edge. Flange 22 has apertures 23 spaced therearound.
Base 21 is formed of a material which is transparent to microwaves, having a low dielectric constant and having a low dissipation factor. This material will hereafter be referred to merely as "dielectric material."
A rotatable turntable cover 24, also of said dielectric material, is horizontally circular and adapted to mate with and cover base 21. Cover 24 has a terminal annular flange 25 which has the same diameter as the inner portion of flange 22. Clips 26 circumferentially spaced about the turntable each have a pair of resilient prongs 27 adapted to slip through an aperture 23 to interlock with flange 22. Each clip 26 also has a projection 28 extending inwardly over the cover flange 25 to loosely retain the cover 24 against upward removal from the base 21.
A motor housing 29 of metal material is disposed within the turntable enclosure between the base 21 and cover 24. This housing has an upwardly opening circular pan 30 with apertures, no larger than 12 millimeters in diameter, in the bottom thereof which are in fixed engagement with projections 31 integrally formed on the bottom of turntable base 21. The motor housing 29 also includes a cover 32 which completely covers the top of pan 30 with a turnover flange providing a secure interlock 34 between the cover and pan. It is particularly important that the exposed edges on the interlock 34 be as smooth or rounded as possible. The minimization of any sharp edges on the exterior surface of the motor housing 29 is very important. However, it will be understood that the members 30 and 32 jointly form a rigid exteriorly smooth housing for the motor housed therewithin.
Cover 24 is provided with an annular upwardly opening raceway 35 which is concentric with the center of the cover. Raceway 35 carries a plurality of ball bearings 40 which may freely roll therein. The underside of cover 24 has an annular raceway 41 molded therein which opens downwardly in vertically opposing relation to raceway 35 in topwise engagement with the bearings 40. Bearings 40 are preferably formed of glass or other dielectric material and are disposed between the raceways 35 and 41.
The diameter of bearings 40 is sufficient to support cover 24 above the turntable base 21 in a slightly elevated position with respect to base 21 so that the flange 25 is spaced slightly above flange 22 yet connected loosely thereto by clips 26.
The numeral 38 denotes an annular roller case plate of dielectric material which has a series of apertures 39 spaced therearound for loosely receiving the ball bearings 40 and retaining them in spaced relation. It has been found, however, that in practice of the invention the retainer 38 may be provided with a near continuous groove. In a still further alternative the plate 38 may be eliminated entirely, with a loosely spaced but continuous series of bearings 40 supporting the cover 24.
A stub shaft 42 is integrally formed with and on the underside of cover 24 at the center thereof. The lower portion of shaft 42 may be, for reasons of durability, formed or lined with metal material which must be spaced at least 3 millimeters from the cover. In the disclosed embodiment of the invention shaft 42 has a squared internal socket 44 formed therein.
A generally U-shaped mounting bracket 45 is secured to the underside of the pan cover 32 as by rivets 46. The purpose of bracket 45 is to mount the motor, designated generally by the numeral 50, within the motor housing 29. Bracket 45 has pairs of opposing arms 51 depending from each end thereof to jointly support a motor mount having a center bar or plate 52 connected to arms 51, and upper and lower elongated plates, denoted respectively at 54 and 55, and suitably connected at their ends to the center plate 52. Plates 52, 54 and 55 lie on parallel planes.
The motor here shown is of the wind-up type. A square shaft 56 extends through and is journaled in the members 45, 52, 54 and 55 and is held against upward displacement by a cross pin 57 in its lower end. Shaft 56 carries a main gear 58 held in place by spacers 59 between the members 52 and 54. A coil spring 60 has its inner end connected to the shaft 56 and its outer end 61 suitably retained in a slot in the leg supporting one end of plate 55. The upper end of shaft 56 fits within the opening 44 in the stub shaft 42 whereby when the cover 24 is turned in a clockwise direction, as viewed from the top, the spring 60 will be wound.
Also within motor 50 there is a braking or timing gear mechanism to restrict the speed of rotation imparted by the spring 60 to the output shaft 56. This mechanism includes a series of spaced parallel upright shafts 64, 65 and 66 having their ends journaled in the plates 52 and 54. Shaft 64 is mounted in slots 68 (FIG. 3) which are generally tangential with respect to the axis of shaft 56 allowing movement of the shaft between idler and operative positions.
While shaft 56 is being wound the shaft 64 will slide forwardly, as viewed in FIG. 4, in the slot 68. Shaft 64 carries a pinion gear 70, which meshes with main gear 58, and much larger gear 71 at its upper end. Shaft 65 carries a pinion gear 72, which meshes with gear 71, and also carries a larger gear 74. The upper portion of shaft 66 has peripheral gear segments at 76 which mesh with gear 74. In the first alternative shown in FIGS. 3 and 4 the shaft 66 also has a star gear 77 fixed thereto which engages central portions of a braking member 78 vertically journaled in the plates 52 and 54 for limited oscillating movement.
A second alternative speed control for the spring motor is shown in FIGS. 5-7. The shaft 66 in this alternative has no star gear 77 nor braking member 78 but instead has a disc 90 mounted axially on shaft 66.
Disc 90 has one or more resilient tabs 93 about its periphery. In the preferred embodiment shown in FIGS. 5-7, the tabs 93 are integral with disc 90 being defined by slits 91 about the periphery of disc 90 which slits 91 extend inwardly at an angle from the peripheral edge 92 of disc 90 along a chord to a point within the disc 90 but does not extend completely across disc 90, all as shown in FIG. 6.
The tabs 93 thus formed are continuous with the remainder of the disc 90 but have some freedom of movement with respect to the remainder of the disc 90 due to the resilient nature of the disc 90, and said tabs 93 may be displaced from the rest position shown in FIG. 6 by application of centrifugal force the positions shown in FIG. 7.
Adjacent to the edge 92 or periphery of disc 90 is a fixed brake element 95, shown in FIGS. 5-7 as a vertically extending strip of metal, but may also be in the form of a cylinder encircling disc 90 like a brake drum as is shown in FIG. 8.
Disc 90 has very low abrasion properties but sufficient friction property to slow disc 90 and hence motor 50 to a fixed speed when the tab members 93 brush against the stationary element 95. Preferred materials for disc 90 are the group of silicone, polyurethane, plastic and rubber having the desired friction, abrasion and resilience. Disc 90 acts as a governor embodying weights, pivots and spring to provide centripetal restraining force all in a single piece. The result is an extremely efficient, compact and economical to manufacture governor structure. It provides constant speed control in a small reliable structure.
When the shaft 56 is being wound the shaft 64 will also be wound while in its forward or idler position, the other portions of the mechanism remaining motionless. When holding pressure is removed from shaft 56, the gear 58 through engagement with gear 70 will move shaft 64 to its rear or operative position. This places gear 71 in engagement with pinion 72.
In the first alternative speed control mechanism shown in FIG. 4, as the unwinding force of spring 60 is exerted upon the shaft 56, such force will be transmitted through the gears 58, 70, 71, 72, 74, 76, and 77 to the member 78. The limited oscillating movement of member 78 and the speed reduction of the gear mechanism will allow shaft 56 to revolve at a very slow speed. The motor mechanism involved is well known in the art.
In the second alternative speed control mechanism shown in FIGS. 5-7, the unwinding force of spring 60 is exerted upon shaft 56, such force being transmitted by means of the gear train through gears 58, 70, 71, 72, 74 and 76 to shaft 66. Disc 90 is mounted on shaft 66 and receives the force causing it to rotate with shaft 66. As disc 90 rotates, tabs 93 are pulled by centrifugal force outwardly from the center of disc 90.
Due to the gearing between shaft 56 and shaft 66, shaft 66 rotates much more rapidly than shaft 56 or, conversely, the output shaft 56 rotates more slowly. As the rotational velocity of shaft 66 and disc 90 increases, tabs 93, and particularly the outer ends of tabs 93, are pulled further outwardly until they encounter brake element 95 as shown in FIG. 7. At this point, tabs 93 wipe across brake element 95. The drag or friction produced between tab 93 and brake element 95 acts to slow or retard the velocity of rotation of disc 90, which serves to govern the rotation at a fairly constant limiting velocity. For purposes of illustration, three tabs 93 are shown, but one single tab 93 would also serve the same function.
The motor used in the assembly may also be battery operated utilizing a suitable gear assembly from the battery operated motor to the shaft 56. Still another alternative is to use suitable motor means within a housing 29 to drive or rotate the cover 21 through a driving connection with the rim or flange portion 25 of the cover, rather than the center stub shaft 42.
In the embodiment herein shown and described, it will be understood that, prior to use, the cover 24 will be manually rotated to wind the spring 60. The turntable is then inserted into the oven onto the oven bottom 15 and the container C is placed upon the cover member 24. The slow unwinding bias of the spring 60 will cause a very slow rotation of the container C and the food product contained therein during the cooking or baking process.
The center aperture 36 in the pan cover 32 should closely receive shaft 42 while yet permitting rotation of the shaft therein. It has been found that for maximum performance the diameter of the aperture 36 should be twelve millimeters or less, allowing reception of a stub shaft 42 of sufficient strength to support the cover while eliminating microwave energy from entering the motor housing 29. The same dimensions are critical where rechargeable batteries might be used to drive the motor, requiring both rechargeable connection and switch openings in the housing 29.
The invention accordingly economically and effectively carries out the aforementioned objectives. | A portable turntable apparatus for use in microwave ovens which is used as a supporting base for a container of food which is cooked within the oven and adapted to gradually rotate the same, the apparatus including a motor including metallic materials which motor is mounted in and enclosed by a metal housing and an outer enclosure comprising a cover and base of non-metallic material to prohibit electrical arcing between the motor and the oven walls. The housing is provided with smooth outer surfaces and a minimal sized aperture opening to allow a driving connection between the motor and the enclosure cover. The motor is a spring motor having an improved centrifugal governor. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a motor driven, hybrid compressor for use in an air conditioner for vehicles, and more specifically, relates to a structure of the compressor for preventing leakage current.
2. Description of Related Art
In a motor driven compressor having a motor for driving a compression mechanism, a high-voltage motor frequently is used. Therefore, the structure between terminal portion of the motor and the motor housing or the compressor housing (e.g., the body portion of the compressor) is insulated for safety. A structure which does not leak current is desired. In such motor driven compressors, liquid refrigerant (i.e., the liquid state of refrigerant gas) and oil with high electric conductivity suspended in the liquid refrigerant are considered to be causes of leakage current. When the liquid refrigerant and the oil enter into the motor side of the compressor, there is the possibility of leakage current. In a known motor driven compressor, a terminal portion of the motor of the motor driven compressor is positioned within uppermost portion of the motor driven compressor. Nevertheless, when the liquid refrigerant is collected on the motor-side of the motor driven compressor, because the distance between the terminal portion and the liquid level may be relatively small, the terminal portion may become submerged in the liquid refrigerant, thereby causing leakage current.
A connecting portion between an external terminal for supplying electricity to the motor of the compressor and a wire end portion of a stator of the motor of the compressor may considered to leak current readily. In known motor driven compressors, no measures appear to have been taken against such leakage current. In order to maintain a high degree of insulation, a connecting portion, which is separated or isolated from the liquid refrigerant and oil, is required. Nevertheless, if the connecting portion and the liquid refrigerant are separated mechanically by a seal mechanism or the like, the internal structure of the compressor may become complicated, and assembly and manipulation of the connecting portion become remarkably difficult.
A hybrid compressor for use in an air conditioner for vehicles and capable of being driven by an engine of a vehicle (e.g., an internal combustion engine of a vehicle or an electric motor of a vehicle) or a motor (e.g., a motor contained within the housing of the compressor) is described in Japanese Utility Model No. 6-87678. A hybrid compressor also is disclosed in Japanese Patent Application Nos. JP A 2001-280630 (JP-A-2002-031664) This hybrid compressor comprises a first compression mechanism of a scroll-type, compressor which is driven exclusively by an engine of a vehicle (e.g., an internal combustion engine of a vehicle or an electric motor of a vehicle) and a second compression mechanism of a scroll-type compressor, which is driven exclusively by a motor contained within the housing of the hybrid compressor. The fixed scrolls of each of the first and second compression mechanism are disposed back-to-back, e.g., extend in opposite directions from a common or shared valve plate, and are integrally formed with each other. In such a hybrid compressor, because the first compression mechanism and the second compression mechanism are driven selectively or simultaneously, improved compressor efficiency may be obtained.
Nevertheless, the hybrid compressor contains the motor, and a liquid refrigerant may enter into the second compression mechanism (i.e., the motor driven compression mechanism). In such a hybrid compressor, high electric conductivity is required to deliver electricity to operate the motor driven compression mechanism. When the amount of liquid refrigerant is increased in the motor driven compression mechanism, leakage current may occur readily.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a motor driven hybrid compressor, which has an uncomplicated structure and may more completely avoid leakage current by providing insulation between a terminal portion of the motor and the housing of the compressor.
To achieve the foregoing and other objects, a motor driven compressor according to the present invention is provided. The motor driven compressor having a motor for driving a compression mechanism comprises a connecting portion for connecting between an external terminal for supplying electricity to the motor and a wire end portion of a stator of the motor. The connecting portion is located above the motor and the compression mechanism.
In the motor driven compressor, the connecting portion is formed in a housing which accommodates the motor and in which the stator is fixed, and the connecting portion is positioned in a hollow projection portion which extends upward. The hollow projection portion is substantially sealed from the exterior of the motor driven compressor.
In the motor driven compressor of the present invention, a motor driven compressor may contain and use a motor for driving a single compression mechanism. Further, the motor driven compressor of the present invention may be a hybrid compressor which comprises a first compression mechanism, which is driven by a first drive source different from the motor, and a second compression mechanism, which is driven by the motor as a second drive source. In the hybrid compressor, each of the first and second compression mechanisms may be a scroll-type compression mechanism, a first fixed scroll of the first compression mechanism and a second fixed scroll of the second compression mechanism are disposed back-to-back e.g., to extend in opposite directions from a common valve plate. In addition, the first fixed scroll and the second fixed scroll are formed integrally. When the hybrid compressor is mounted in a vehicle, the first drive source may comprise an engine for driving the vehicle. The engine of a vehicle for use in driving the first compression mechanism may comprise an internal combustion engine or an electric motor for driving a vehicle.
In the motor driven compressor according to the present invention, because a connecting portion for connecting between an external terminal for supplying electricity to the motor and a wire end portion of a stator of the motor is above the motor and the compression mechanism, if a liquid refrigerant containing oil collects in the second compression mechanism (e.g., the motor driven compression mechanism), the liquid level of the refrigerant does not readily contact the connecting portion; therefore, the connecting portion may maintain high insulation performance.
In particular, because the connecting portion is formed in a housing, which accommodates the motor and in which the stator is fixed, and is disposed in a hollow projection portion which is extends upward from the stator housing. When the inside of the stator housing is filled with liquid refrigerant, the connecting portion does not readily contact the liquid refrigerant; therefore, the connecting portion may maintain high insulation performance. Further, because the hollow projection portion is substantially sealed to the exterior of compressor, when the inside of the stator housing is filled with the liquid refrigerant, the liquid level is prevented from rising into the hollow projection portion by a gaseous body (i.e., refrigerant gas) trapped inside of hollow projection portion. Therefore, the connecting portion may maintain high insulation performance.
As a result, leakage current from the connecting portion to the stator housing of compressor may be reduced or avoided, and the motor driven compressor may operate stably and safely. Particularly, in hybrid compressors, as described above, because operating rate of the second compression mechanism (e.g., the motor driven compression mechanism) generally is lower than that of the first compression mechanism (e.g., the engine driven compression mechanism); thus, liquid refrigerant collects in the second compression mechanism matter than first compression mechanism. Therefore, the present invention is suitable for the hybrid compressor, and may avoid leakage current.
Other objects, features, and advantages will be apparent to persons of ordinary skill in the art in view of the following detailed description of the invention and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention now are described with reference to the accompanying figures, which are given by way of example only, and are not intended to limit the present invention.
FIG. 1 is a vertical, cross-sectional view of a hybrid compressor, according to an embodiment of the present invention.
FIG. 2 is an enlarged, partial cross-sectional view of a motor and stator housing of the hybrid compressor of FIG. 1 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2 , a preferred embodiment of the present invention is depicted. FIG. 1 depicts a hybrid compressor according to an embodiment of the present invention. FIG. 2 depicts a motor and a stator housing of the compressor of FIG. 1 .
With reference to FIG. 1 , a hybrid compressor 1 comprises a first compression mechanism 2 and a second compression mechanism 3 . First compression mechanism 2 comprises a first fixed scroll 10 ; a first orbital scroll 11 , which engages first fixed scroll 10 to form a first plurality of pairs of fluid pockets 12 ; a drive shaft 13 , which engages first orbital scroll 11 and imparts an orbital movement to orbital scroll 11 ; an electromagnetic clutch 15 for engaging and disengaging drive shaft 13 ; and a pulley 14 , which is connected to an engine or electric motor (not shown) of a vehicle via a belt (not shown). A first rotation prevention device 16 prevents the rotation of first orbital scroll 11 . A first inlet port 18 is formed through a compressor housing 17 . Refrigerant gas introduced from first inlet port 18 to first inlet chamber 20 through a first inlet path 19 , flows into fluid pockets 12 . Fluid pockets 12 move toward the center of first fixed scroll 10 while being reduced in volume. Consequently, the refrigerant gas in fluid pockets 12 is compressed. The compressed refrigerant gas is discharged into a first discharge path 22 through a first discharge port 21 formed within a valve plate of the fixed scroll 10 . The discharged refrigerant then flows out to a high pressure side of an external refrigerant circuit through outlet port (not shown).
In contrast, second compression mechanism 3 comprises a second fixed scroll 30 ; a second orbital scroll 31 , which engages second fixed scroll 10 to form a second plurality of pairs of fluid pockets 32 ; a drive shaft 33 , which engages second orbital scroll 31 and imparts an orbital movement to orbital scroll 31 ; and a second rotation prevention device 34 for preventing the rotation of second scroll 31 . An electric motor 35 is provided for driving second drive shaft 33 of second compression mechanism 3 . Electric motor 35 has a rotor 36 , which is fixed to second drive shaft 33 , and a stator 37 . Stator 37 is disposed within stator housing 38 , and motor 35 also is accommodated within stator housing 38 . In second compression mechanism 3 , refrigerant gas is introduced from inlet port 18 to first inlet chamber 20 and flows into a second inlet chamber 40 of second compressing mechanism 3 through a communicating path 39 . Refrigerant gas then is introduced to second fluid pockets 32 of second compression mechanism 3 . Fluid pockets 32 move toward the center of second fixed scroll 30 , while being reduced in volume. Consequently, the refrigerant gas in fluid pockets 32 is compressed. The compressed refrigerant gas is discharged into a second discharge path 42 through a second discharge port 41 formed within a valve plate of the fixed scroll 30 . The discharged refrigerant then flows out to a high pressure side of an external refrigerant circuit through outlet port 23 .
In a preferred embodiment of the present invention, first fixed scroll 10 of first compression mechanism 2 and second fixed scroll 30 of first compression mechanism 3 are disposed back-to-back, e.g., extend in opposite directions from a common valve plate, and the fixed scrolls are formed integrally. Thus, fixed scrolls 10 and 30 form an integral, fixed scroll member 43 .
When hybrid compressor 1 is driven exclusively by an engine, electromagnetic clutch 15 is activated. The rotational output of the engine is transmitted to first drive shaft 13 of the first compression mechanism 2 , and first orbital scroll 11 is driven in its orbital movement by first drive shaft 13 . When driven in this matter, electricity need not be, and generally is not, supplied to electric motor 35 provided for driving second compression mechanism 3 . Consequently, electric motor 35 does not rotate. Therefore, second compression mechanism 3 does not operate.
When hybrid compressor 1 is driven exclusively by an electric motor 35 , electric motor 35 is activated. The rotational output of the electric motor 35 is transmitted to second drive shaft 33 of second compression mechanism 3 , and second orbital scroll 31 is driven in its orbital movement by second drive shaft 33 . When driven in this manner, electricity is not supplied to electromagnetic clutch 15 of first compression mechanism 2 , and the rotational output of the engine of a vehicle is not transmitted to first compression mechanism 2 . Therefore, first compression mechanism 2 does not operate.
When hybrid compressor 1 is driven simultaneously by an engine and electric motor 35 , the rotational output of the engine is transmitted to first drive shaft 13 of first compression mechanism 2 , and electric motor 35 is activated. The rotational output of electric motor 35 is transmitted to second drive shaft 33 of second compression mechanism 3 .
In hybrid compressor 1 , described above, refrigerant gas and oil contained in the refrigerant gas is introduced to second inlet chamber 40 of second compression mechanism 3 driven by electric motor 35 and enters into stator housing 38 (e.g., motor housing) via rotation prevention device 34 portion and bearing portion 44 . Therefore, because the operating ratio of second compression mechanism 3 is lower than first compression mechanism 2 , liquid refrigerant collects more readily in second compression mechanism 3 than first compression mechanism 1 , and similarly, the liquid refrigerant collects in stator housing 38 .
FIG. 1 and FIG. 2 depict hybrid compressor 1 mounted on a vehicle, and a terminal portion 50 of motor 35 is disposed in an upper portion of hybrid compressor 1 . Terminal portion 50 has a connecting portion 53 for connecting an external terminal 51 for supplying electricity to electric motor 35 and a wire 52 of stator 37 of motor 35 . Connecting portion 53 is positioned above motor 35 and second compression mechanism 3 . In this preferred embodiment, hollow projection portion 54 is formed on an upper portion of stator housing 38 . Hollow projection portion 54 extends upward from stator housing and has a chimney pipe shape. Connecting portion 53 is disposed inside of hollow projection portion 54 . Hollow projection portion 54 is substantially sealed to the exterior of compressor by seal member 55 , and the lower end of hollow projection portion 54 is open to stator housing 38 , such that wire 52 may be readily connected to stator 37 .
In hybrid compressor 1 , described above, because connecting portion 53 for connecting external terminal 51 for supplying electricity to motor 35 and wire 52 of stator 37 of motor 35 . Connecting portion 53 is positioned above motor 35 and second compression mechanism 3 . If liquid refrigerant collects in second compression mechanism 3 , the level of liquid refrigerant does not readily contact with connecting portion 53 . Therefore, connecting portion 53 is not submerged in the liquid refrigerant, and connecting portion 53 may maintain high insulation performance.
In this preferred embodiment of the present invention, because hollow projection portion 54 is formed on the upper portion of stator housing 38 and connecting portion 53 is disposed inside of hollow projection portion 54 , when the inside of stator housing 54 is filled with liquid refrigerant connection portion 53 of terminal portion 50 does not readily contact with the liquid refrigerant, and, therefore, connecting portion 53 may maintain high insulation performance. Referring to FIG. 2 , a liquid level 56 of the refrigerant in stator housing 38 is below hollow projection portion 54 . Further, because hollow projection portion 54 is substantially sealed to the exterior of compressor 1 , when the inside of stator housing 38 is filled with the liquid refrigerant, the liquid level is prevented from rising into hollow projection portion 54 by a gaseous body (e.g., refrigerant gas) trapped inside of hollow projection portion 54 .
The motor driven compressor of the present invention is not limited to hybrid-type compressors, but may be employed in a general, motor driven compressor having a single compression mechanism driven by a motor.
Although preferred embodiments of the present invention have been described in detail herein, the scope of the invention is not limited thereto. It will be appreciated by those skilled in the art that various modifications may be made without departing from the scope of the invention. Accordingly, the embodiments disclosed herein are only exemplary. It is to be understood that the scope of the invention is not to be limited thereby, but is to be determined by the claims which follow. | A motor driven compressor having a motor for driving a compression mechanism includes a connecting portion for connecting between an external terminal for supplying electricity to the motor and a wire end portion of a stator of the motor. The connecting portion is located above the motor and the compression mechanism. Further, the connecting portion is formed on the stator housing which accommodates the motor and the stator. The connecting portion is disposed in a hollow projection portion, which extends upward from the housing. Accordingly, the motor driven compressor which is readily manufactured, may avoid a leakage current by insulating a terminal portion of the motor from the housing of compressor. | 5 |
BACKGROUND OF THE INVENTION
This invention concerns a device to capture the relative position of a component of which the position can change relative to a reference component of a washing handling device, in particular a washing machine or drier, and a corresponding washing handling device.
Such devices are known in various forms from the prior art. Thus the document DE 101 04 682 A1 shows a capacitive sensor, with which the axial distance of a tub relative to the housing of a washing machine is provided for the purpose of determining an imbalance, deflection in operation and the present loading of the washing drum. This solution has the disadvantage that capacitive sensors, in the context of the distances to be measured, are relatively difficult to evaluate, and are also subject to electromagnetic interference effects of the environment.
Another arrangement is known from the document DE 103 34 572 B3. In the case of the arrangement described in this document, a coil-based electromagnetic travel sensor is used to capture the deflection of the tub relative to the housing. Such electromagnetic travel sensors too are subject to interference effects and wear problems.
The document DE 698 07 055 T3 describes a washing machine where the present drum deflection and loading are determined using a Hall element and a magnet body associated with it. In this case, there is the problem that Hall sensors too are subject to electromagnetic interference, and to obtain sufficiently good measurement results, large, homogeneous magnets are required. Use of Hall sensors also has the disadvantage that to determine the present position in space, 3 field vectors are always required. Use of a single dipole magnet is not enough, since its field component is not biunique.
In the document DE 199 60 847 A1, the possibility of using strain gauges to determine the position of the tub in the housing of a washing machine is described. To evaluate the signals provided by strain gauges, relatively expensive and sensitive amplifier and compensation circuits are required.
The document DE 10 2004 043 752 B4 describes a measuring device with optical sensors to determine the present deflection of an axis of rotation of a washing drum relative to the tub of a washing machine. The optical system described in it has the disadvantage that it must be integrated into the bearing arrangement of the drum, and this is structurally expensive.
SUMMARY OF THE INVENTION
In contrast, it is the object of this invention to provide a device which is of the type described above, is structurally simple, is insensitive to external influences in operation, and has high measurement precision.
This object is achieved by a device to capture the relative position of a component of which the position can change relative to a reference component of a washing handling device, in particular a washing machine or drier, comprising:
at least one light source, at least one light receiver, a light-reflecting surface, which reflects light which the light source emits to the light receiver,
the device being designed to capture the present relative position, or the distance of the changeable-position component, relative to the reference component, according to the reflected light which the light receiver captures.
According to the invention, the position of the changeable-position component, e.g. the tub of the washing handling device, relative to the reference component, e.g. the housing of the washing handling device or a component which is arranged in a fixed position in the washing handling device, is determined purely optically on the basis of the light reflection and the light intensity which is captured from it. The reflecting surface can be a surface of a separate component, or be integrated into an existing component, e.g. a tub. Such optical determination of position is possible using relatively inexpensively available components. It is not subject to any electromagnetic interference effects. No mechanical components which are moved relative to each other, and can be subject to wear, are required. By suitable formation of the beam path or reflection path or reflecting surfaces, permanently reliable results can be achieved. Thus reflection patterns, e.g. a kind of reflection grid of reflecting and non-reflecting areas, can be used. It is also possible to use convexly or concavely curved reflecting surfaces, in particular spherically curved reflecting surfaces. Similarly, it is also possible to use stepped reflecting surfaces, or ones which are alternately convexly and concavely curved in sub-regions, e.g. for generating Fresnel structures, which make distance measurement easier.
A further development of the invention provides that the reflecting surface is in the form of a scattering reflecting surface, which reflects and scatters the light which the light source emits.
According to the invention, it can also be provided that the light source is in the form of a light-emitting diode (LED), a laser diode or an infrared light source or similar. It is also possible to arrange the light source at a greater distance from the measuring point, and to guide the light to the measuring point via an optical waveguide. According to the invention, it can also be provided that the light receiver is in the form of a phototransistor, photodiode, photoresistor, passively operated LED or similar. Such light sources and light receivers are available inexpensively.
By pulsed control of the light source and/or light receiver, interference effects by external light can be determined and filtered out. Polarised light can also be used.
To simplify the structure of the solution according to the invention, it can be provided that at least one pair of light source and light receiver are combined next to each other in one module. Here it must be stated that the measured distance is always greater than the distance of light source and light receiver which are arranged next to each other.
In relation to this, according to a further development of the invention, it can be provided that at least two pairs of light source and light receiver, which are arranged at different alignments to each other, are arranged. It is thus possible to arrange such modules of pairs of light source and light receiver at different positions or/and with different alignment in the washing handling device, and thus to capture reliably relative movements between the changeable-position component and the reference component, in particular with reference to the housing, along different spatial axes.
According to the invention, it can also be provided that around a light source, multiple receivers are arranged, e.g. on two sides of the light source, or at regular angular distances around the light source, e.g. at an angular distance of 120°. In this way it is possible to improve the determination of position, e.g. by capturing a relative tilt. It is also possible to compensate for measurement errors. In this way, positions can also be captured more easily in three dimensions.
According to the invention, it can also be provided that the light-reflecting surfaces are arranged at an angle to each other. It is thus possible to provide two or three pairs of light source and light receiver, in a perpendicular arrangement to each other, and fixed in the housing, and to assign reflecting surfaces which are correspondingly perpendicularly aligned to each other to them. In this way, movements which are orthogonal to the reflecting surfaces can be determined.
Additionally, according to a further development of the invention, it can be provided that the distance of the pairs of light source and light receiver relative to the light-reflecting surface assigned to them is different. In other words, a pair of light source and light receiver can be arranged in an initial state at a first distance from the light-reflecting surface assigned to them, and another pair of light source and light receiver can be arranged in an initial state at a second distance from the light-reflecting surface assigned to them, the two light-reflecting surfaces being coupled to each other. In this way, when the light reflection which the two light receivers determine is evaluated, on the basis of the known difference of distance between the first and second distances, a plausibility check and compensation of the measurement result can be carried out. Preferably, the orientations of the two pairs of light source and light receiver are essentially aligned.
An alternative version of the invention provides that instead of using multiple light sources, the light which a single light source emits is divided via a beam splitter, e.g. a prism or double-hole screen, into multiple light beams or pencils of rays, and radiated onto different light-reflecting surfaces at different distances or/and different alignments to the light source. The evaluation can then take place via corresponding light receivers, in the manner described above, and with the advantages described above.
To measure pressure or force in a washing handling device, according to the invention a spring arrangement, which is arranged so that it prestresses at least one pair of light source and light receiver and the light-reflecting surface into a predetermined initial position relative to each other, and is deformed on deflection, can also be provided. On the basis of the captured pressure or captured force and of the distance which changes depending on the pressure or force, for example the fullness of a washing drum with water can be determined.
On the basis of the captured force (weight) which is exerted by a load of washing on a drum or tub or its suspension, for example the quantity or mass of introduced washing can also be determined.
The invention also concerns a washing handling device, in particular a washing machine or drier, comprising:
a housing, a changeable-position component, which is carried movably in the housing, and a device of the kind described above,
wherein on one component out of housing or changeable-position component, a sensor arrangement with at least one pair of light source and light receiver is arranged, and on the other component out of housing and changeable-position component, the light-reflecting surface is arranged, and the present relative position of the changeable-position component relative to the housing can be determined according to the light reflection which the light receiver captures.
The light-reflecting surface can be in the form of a surface of a separate component, or in the form of an integrated surface of a component of the washing handling device, e.g. the tub. As the housing, for example the housing of the washing handling device, or a component arranged within the washing handling device, can be used. It is also possible to attach the sensor arrangement to the tub, and the light-reflecting surface to the housing of the washing handling device.
According to the invention, it can also be provided that the changeable-position component is a tub in which a washing drum is rotatably carried, the tub being suspended in the housing so that its position can change. In relation to this, according to the invention it is possible that the tub is carried in the housing by means of at least one passive or actively controllable damper, and in the latter case the damper characteristic can be adjusted according to the captured relative position of the drum receptacle in the housing.
Alternatively, according to the invention, it can be provided that the changeable-position component is a membrane which is prestressed by a spring and can be shifted in a housing, and which closes and seals a pressure chamber in the housing, it being possible to capture the relative position of the membrane relative to the housing according to the captured light reflection, taking account of the compression state of the spring. According to the present pressure in the pressure chamber, the membrane is deflected to a greater or lesser extent against the spring force, compared with a pressure-free initial state. This deflection is captured on the basis of the light reflection. Taking account of the spring characteristic, in particular the spring constant, and the known area of the membrane, conclusions can thus be drawn about the pressure in the pressure chamber. This pressure can give information about the present fullness of the tub with water or lye, for example.
According to another embodiment of the invention, it can be provided that the changeable-position component is a force sensor which is prestressed by a spring. Again, on the basis of the captured light reflection and the compression of the spring associated with it, and taking account of the spring characteristic, conclusions can be drawn about the force acting on the spring. In this way, for example, it is possible to determine what quantity of washing was introduced into the drum, and/or how much water or lye is in the tub.
According to the magnitudes which are captured using the device according to the invention, the operating mode, e.g. the spin speed, the quantity of water to be fed in, the damper characteristic of the actively controllable damper, etc. of the washing handling device can be adjusted.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained using an example, on the basis of the attached figures, of which:
FIG. 1 is a schematic drawing of a washing machine according to the invention;
FIG. 2 is an enlarged schematic view of the measuring device according to FIG. 1 ;
FIG. 3 is an enlarged view of a measuring device according to the invention, to capture pressure;
FIG. 4 is an enlarged view of a measuring device according to the invention, to capture force;
FIG. 5 is a diagram to explain the operation of the force measuring device according to FIG. 4 , and
FIG. 6 is a schematic representation to explain the measuring process with an embodiment according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 , a washing machine according to the invention is shown schematically, and identified as a whole by 10 . This comprises a housing 12 , in which a tub 14 is displaceably suspended. For suspension, four springs 16 , 18 , 20 , 22 , which hold the tub 14 elastically in the upper housing region, are used. The tub 14 is carried by four dampers 24 , 26 , 28 , 30 in the lower housing region. The dampers 24 , 26 , 28 , 30 can be passive or actively controllable, and in the latter case, of active control, their damper characteristic can be changed.
The washing machine 10 also comprises a measuring device 32 to capture the position of the tub 14 relative to the housing 12 . This measuring device 32 is shown enlarged in FIG. 2 .
It comprises three pairs of light source and light receiver, namely a first pair 34 , 36 , a second pair 38 , 40 and a third pair 42 , 44 . Each of the light sources 34 , 38 , 42 emits a light beam 46 , 48 . These light beams are scattered and reflected at the scattering reflecting surfaces 50 , 52 facing the pairs of light source and light receiver, so that depending on the present distance between the scattering reflecting surface and the light receiver 36 , 40 , 44 , at each light receiver 36 , 40 , 44 reflected (scattered) light can be captured with a definite intensity which represents the present distance. The third scattering reflecting surface, facing the pair 42 , 44 , is not shown in the figure. If the distance between light receiver 36 , 40 , 44 and associated scattering reflecting surface changes, the light intensity which the light receiver 36 , 40 , 44 captures also changes.
With the measuring arrangement 32 , any deflections of the tub 14 , the scattering reflecting surfaces 50 , 52 and the third scattering reflecting surface (not drawn) which are permanently coupled to it relative to the module 60 , which is fixed in position and carries the pairs of light source and light receiver, can be captured in real time. In other words, with the measuring arrangement 32 the present position (along all three spatial axes) of the tub 14 in the housing 12 of the washing machine 10 can be captured. This optical capture is to a large extent free of interference effects such as mechanical wear, electromagnetic interference fields, etc. If necessary, the deflection along the spatial axes X, Y and Z shown in FIG. 2 can be measured sequentially, i.e. in a time sequence, so that even mutual interference effects of the individual pairs of light source and light receiver can be prevented. Alternatively, light which is polarised specifically for each measurement direction can be used.
To improve the measurement result, according to the invention optical components such as lenses, screens or filters can be used.
FIG. 3 shows the principle of the measuring device according to the invention, as used with a pressure sensor 62 . The pressure sensor 62 comprises a housing 64 with a pressure connection, inlet and/or outlet 66 . In the housing 64 , a movable membrane 68 , which has an area 70 of which the shape is stable, said area 70 being attached to the housing 64 via flexible areas 72 , 74 so that it is sealed but displaceable, is arranged. The membrane 68 delimits a pressure chamber 76 . The membrane 68 is prestressed into an initial position via a compression spring 78 into the pressure chamber 76 . On its side facing away from the pressure chamber 76 , it has a scattering reflecting surface 78 .
On the side of the membrane 68 facing away from the pressure chamber 76 , on the housing 64 a module 80 with a pair of light source and light receiver is arranged, and as described in relation to FIG. 2 , it emits a light beam to the membrane, and receives scattered reflected light from the membrane. The distance d, which is given by the measurement result which the module 80 determines regarding the light intensity, describes the present compression state of the compression spring 78 relative to an initial state D. From this, taking account of the known spring constant c of the compression spring 78 , according to Hooke's Law (F=c*[D−d]) the spring force F which is exerted on the compression spring 78 can be calculated directly.
Once the movable area A of the membrane 68 is also known, the pressure p in the pressure chamber 76 can be calculated directly from the determined spring force F and the relation p=F/A.
With the solution according to the invention shown in FIG. 3 , a contactless pressure sensor, which can be used inexpensively in washing handling devices such as washing machines or driers, can be implemented in a technically simple way.
FIG. 4 shows another embodiment of the invention, but implemented as a force sensor. In a housing 82 , a measuring rod 84 is displaceably received. In the housing 82 , fixed in the housing, a first measuring sensor 86 and a second measuring sensor 88 are attached, each measuring sensor having a pair of light source and light receiver. A reflecting surface carrier 90 , which has two reflecting surfaces 92 , 94 , is coupled to the measuring rod 84 . They are essentially parallel to each other, but offset by a distance x. The reflecting surface carrier 90 is prestressed via a compression spring 96 into an initial position. Depending on the deflection of the reflecting surface carrier 90 relative to the housing 82 , the result at the measuring sensors 86 , 88 is different intensities of the reflected light at the reflecting surfaces 92 , 94 , so that conclusions can be drawn about the present position of the reflecting surface carrier 90 and thus of the measuring rod 84 .
Again, on the basis of Hooke's Law (F=c*[D−d]) the spring force F which is exerted on the compression spring 96 can be calculated directly. For example, if the measuring rod 84 is coupled to the tub 14 , it is possible to determine from this with what quantity/mass of washing or/and lye the tub 14 is filled.
On the basis of the reflecting surfaces 92 , 94 , which are offset from each other, the result is two different curves K 1 , K 2 for the intensities I of reflected light, as measured by the measuring sensors 86 , 88 . This provides the possibility of a plausibility check, since the measurement results can always be compared with each other. This also provides the possibility of calibration and compensation of the measuring system taking account of the known offset x, e.g. by coefficient formation and/or normalisation. The evaluation can also be simplified in this way. The light intensity I, as is known, falls with the square of the travelled distance x (I˜1/x 2 ). In the case of quotient formation, instead of quadratic relations linear ones are obtained, which simplifies the computational evaluation.
Finally, FIG. 6 shows a possible arrangement of a measuring device 100 according to the invention in a washing machine, for 2 axes. A reflecting surface carrier 102 , with reflecting surfaces 104 , 106 arranged perpendicularly to each other, is attached in a way not shown to a tub, via fixing strips 108 , 110 . A measuring sensor arrangement 112 , with two measuring sensors 114 , 116 arranged orthogonally to each other, emits a pencil of rays 118 . This is reflected and scattered at the reflecting surface 104 , as shown by the pencil of rays 120 . Depending on the distance d, the result is a light intensity, which is captured by the sensor arrangement 114 . In this way, the present relative position between the fixed measuring sensor arrangement 112 and the reflecting surface carrier 102 , which is movable with the tub, can be determined. This measuring principle can be extended directly for the third spatial axis.
Although the preferred embodiments of the present invention have been described herein, the above description is merely illustrative. Further modification of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention as defined by the appended claims. | A sensor device to measure a force or pressure in a washing handling apparatus includes a light source, a light receiver, a light-reflecting surface that reflects light emitted by the light source toward the light receiver, and one or more spring elements that biases the light-reflecting surface into a predefined initial position with respect to the light source and the light receiver where the light-reflecting surface is disposed to be displaceable with respect to the light source and the light receiver in response to application of an external force or pressure against a resetting force of the one or more spring elements. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to electron beam lithography, and more particularly, to a method of compensating for pattern dimension variation caused by a re-scattering effect of the electron beam occurring when a resist is exposed to the electron beam.
[0003] 2. Description of the Related Art
[0004] Electron beam lithography is a technique used in patterning a material layer formed on a substrate in a desired pattern. This entails the process of coating an electron beam resist on a material layer; writing a desired pattern with an electron beam (referred to in the art as an “exposure”); developing the electron beam resist; and etching the material layer by using the electron beam resist pattern formed using the desired pattern as a mask. Electron beam lithography can be used to form a predetermined material layer pattern directly forming an integrated circuit on the substrate, however, in general, electron beam lithography is used to fabricate a photomask for use in photolithography.
[0005] Referring to FIG. 1, the process for fabricating the photomask will be described in greater detail. The process comprises the steps of: coating an electron beam resist 130 on an opaque film 120 (in the case of a phase shift mask, a phase shifting layer is available, hereinafter described simply as an opaque film) formed on a transparent substrate 110 ; writing a desired pattern with an electron beam 150 ; developing the electron beam resist 130 by using a difference of solubility depending on writing of the electron beam; and etching the opaque film 120 by using the formed resist pattern as a mask.
[0006] However, the electron beam 150 does not only expose the desired portion of the electron beam resist 130 , as the electron beam 150 is reflected on the surface of the opaque film 120 or scattered by collisions with atoms of a resist material in the electron beam resist 130 as marked 170 in FIG. 1. Also, the electron beam 150 is reflected in the electron beam resist 130 or on the surface of the electron beam resist 130 and at the lower plane of an objective lens 140 of an electron beam writer and, as a consequence, the electron beam 150 exposes an undesired portion of the electron beam resist 130 as marked 160 in FIG. 1.
[0007] A quantity (a dose) by which the electron beam resist 130 is exposed an extra amount by scattering of the electron beam 150 as described above, is shown in FIG. 2. As shown in FIG. 2, the electron beam resist can be additionally exposed from a region in which a pattern is written with the electron beam, that is, from an edge of the pattern to a maximum distance of 10 cm. Close to the edge of the pattern, the dose can be as high as 25% of the original exposure dose. In FIG. 2, an additional exposure 210 affecting from the region in which a pattern is written with the electron beam, to approximately 10 μm, is caused by forward scattering and backward scattering of the electron beam indicated by reference numeral 170 in FIG. 1, and an additional exposure 220 affecting to approximately 10 cm is caused by re-scattering of the electron beam indicated by reference numeral 160 in FIG. 1. In conclusion, these additional exposures deteriorate the accuracy of the opaque film pattern, and cause a critical dimension (CD) error. The pattern dimension variation caused by the former additional exposure 210 is referred to as a proximity effect, and the pattern dimension variation caused by the latter additional exposure 220 is referred to as a re-scattering effect (multiple scattering effect or a fogging effect) of the electron beam.
[0008] The re-scattering effect of the electron beam affects a wide range (Considering the integration of a current integrated circuit, 10 cm is a very wide range.), and since a dose caused by the additional exposure 220 is relatively small, the effect has not been ascertained, and no compensation method is well-known. However, the pattern dimension variation of the photomask caused by the re-scattering effect of the electron beam is estimated to be about 10˜20 nm when an electron beam dose is 8 μ C/cm 2 at an accelerating voltage of 10 keV, and the pattern dimension variation of the photomask greatly affects the manufacture of more highly-integrated circuits.
[0009] On the other hand, the re-scattering effect of the electron beam is introduced, and a method for forming the lower plane of the objective lens in which the re-scattered electron beam is reflected, of a material with a low atomic number, as a method for reducing this effect is disclosed in, Norio Saitou et al., “Multiple Scattered E-beam Effect in Electron Beam Lithography”, SPIE Vol. 1465, pp.185 - p.191, 1991. That is, it is reported in the paper that an additional dose caused by the re-scattering effect of the electron beam when the lower plane of the objective lens is formed of copper, aluminum, and carbon, respectively, was measured, and the re-scattering effect of the electron beam was lowest when carbon was adopted. However, it is shown in FIG. 2 that the re-scattering effect is not remarkably reduced even if carbon is adopted. In FIG. 2, the chart of symbol “◯” applies to the case where aluminum is adopted, and the chart of symbol “□” applies to the case where carbon is adopted.
[0010] Also, a method for reducing the re-scattering effect by absorbing the re-scattered electron beam by attaching an absorber plate in which a honeycomb groove is formed at the lower plane of the objective lens, is disclosed in Naoharu Shimomura et al., “Reduction of Fogging Effect caused by Scattered Electron in an Electron Beam System”, SPIE Vol. 3748, pp.125 - p.132, 1999. However, it is also not possible for all re-scattered electrons to be absorbed by this method, and there is a limitation in reducing the re-scattering effect.
SUMMARY OF THE INVENTION
[0011] To address the above limitation, it is an object of the present invention to provide a method of compensating for pattern dimension variation caused by a re-scattering effect of an electron beam.
[0012] Accordingly, to achieve the above object, there is provided a method of compensating for pattern dimension variation caused by a re-scattered electron beam, the method comprising the steps of: dividing original exposure patterns into square sections; determining a dose of additional exposure (referred to herein as a “supplemental exposure dose”) to the re-scattered electron beam for each section; and compensating the electron beam resist so that the supplemental exposure dose may be the same for all sections. That is, the method of compensating for pattern dimension variation caused by a re-scattered electron beam comprises the steps of: dividing original exposure pattens into square sections; determining a dose of supplemental exposure to the re-scattered electron beam when adjacent sections are exposed, for each section; determining a compensation exposure dose for each section by deducting supplemental exposure doses of each section from a predetermined reference value; and compensation-exposing the electron beam resist according to the compensation exposure dose of each section.
[0013] The method of compensating for pattern dimension variation caused by a re-scattering effect of an electron beam according to the present invention can be provided in the form of a recording medium on which a program to be read and performed by a commercial computer is recorded. That is, a recording medium on which a program for obtaining compensation exposure data for compensating pattern dimension variation is recorded includes a program module for dividing original exposure patterns into square sections and determining a dose of supplemental exposure to the re-scattered electron beam when adjacent sections are exposed, for each section, a program module for determining a compensation exposure dose for each section by deducting the supplemental exposure dose of each section from a predetermined reference value, and a program module for setting-up compensation exposure patterns for each section with predetermined compensation exposure patterns so as to expose an area proportional to the compensation exposure dose for each section.
[0014] According to the present invention, pattern dimension variation caused by a re-scattering effect of an electron beam can be compensated for, thereby uniformly forming a fine pattern of a more highly-integrated circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The above object and advantages of the present invention will become more apparent by describing in detail preferred embodiments thereof with reference to the attached drawings in which:
[0016] [0016]FIG. 1 is a sectional view illustrating a scattering phenomenon of an electron beam when the electron beam is incident on an electron beam resist;
[0017] [0017]FIG. 2 is a graph of dose of supplemental exposure to a scattered electron beam versus distance from the edge of a pattern;
[0018] [0018]FIG. 3 is a flow chart illustrating steps of compensating for pattern dimension variation caused by a re-scattered electron beam, according to an embodiment of the present invention;
[0019] [0019]FIG. 4 is a layout diagram illustrating steps of dividing predetermined exposure patterns into sections according to an embodiment of the present invention;
[0020] [0020]FIG. 5 is a graph illustrating the manner in which compensation exposure dose to compensate for pattern dimension variation caused by a re-scattered electron beam is determined, according to an embodiment of the present invention;
[0021] [0021]FIG. 6 and FIG. 7 illustrate examples of compensation exposure patterns according to an embodiment of the present invention;
[0022] [0022]FIG. 8 illustrates the size of an electron beam spot when compensation exposing according to an embodiment of the present invention;
[0023] [0023]FIG. 9 is a layout diagram illustrating exposure patterns used for an experiment in compensating for pattern dimension variation caused by the re-scattered electron beam, according to an embodiment of the present invention;
[0024] [0024]FIG. 10 and FIG. 11 are graphs of a line width before compensating for pattern dimension variation and a line width after compensating for pattern dimension variation according to the present invention, versus distance from the edge of a pattern, respectively.
DETAILED DESCRIPTION OF THE INVENTION
[0025] [0025]FIG. 3 is a flow chart illustrating steps of compensating for pattern dimension variation caused by a re-scattered electron beam, according to the present invention. First, an electron beam resist is exposed to an electron beam according to predetermined exposure patterns (step 310 ). Referring back to FIG. 1, an electron beam resist 130 is coated on an opaque film 120 formed on a transparent substrate 110 , and a desired pattern is written with the electron beam. In other words, the electron beam exposure of the step 310 corresponds to a general exposure step, and here, a region not to be exposed to the electron beam is additionally exposed. Here, the desired pattern, for example, may be predetermined material layer patterns as shown in FIG. 4, and the layout of the desired pattern is converted into data form suitable for an electron beam exposure, and is supplied to an electron beam writer. In FIG. 4, the material layer patterns to be actually formed by a follow-up photolithographic process correspond to oblique-lined portions, and a portion exposed by the electron beam corresponds to the oblique-lined portions of FIG. 4 when a photoresist to be used in the follow-up photolithographic process is a negative-type photoresist and in case of a positive-type photoresist, the portion corresponds to a portion excluding the oblique-lined portions of FIG. 4. Hereinafter, for convenience of explanation, it is assumed that the resists to be used as the electron beam resist and in the follow-up photolithographic process are both positive-type resists.
[0026] Returning to FIG. 3, during step 320 exposure patterns, such as those shown in FIG. 4, are divided into square sections 410 . In step 330 , a supplemental exposure dose caused by the re-scattered electron beam is calculated when adjacent sections are exposed, for each section 410 . The step of calculating the supplemental exposure dose for each section 410 can be subdivided as described below.
[0027] First, an exposure pattern density is calculated for each section. As described above, in a case where the photoresist to be used in the follow-up photolithographic process is a positive-type photoresist, the portion exposed by the electron beam to actually fabricate the photomask corresponds to a portion excluding the oblique-lined portions of FIG. 4, and in a case where no oblique-lined portions are included in a section 410 , the exposure pattern density of the section is 1, and on the contrary, in a case where a section is formed of the oblique-lined portions, the exposure pattern density of the section is 0. That is, the exposure pattern density of each section is the fraction of the area of a section not occupied by oblique-lined portions.
[0028] The supplemental exposure doses are calculated for each section using the following equation after the exposure pattern density is calculated for each section:
δ i , j = ∑ x = - ξ ξ ∑ y = - ξ ξ D i + x , j + y - x 2 + y 2 ξ 2 ( 1 )
[0029] wherein δ i,j is a supplemental exposure dose of a section with x-coordinate i and y-coordinate j, ξ is a re-scattering range, and D i,j is an exposure pattern density of the section with x-coordinate i and y-coordinate j.
[0030] The above equation 1 will be described in detail below. For example, in a case where the re-scattered electron beam affects the edge of a window 420 indicated by a thick solid line when a portion of the most centered section 410 in FIG. 4 is exposed, the re-scattering range ξ is 2, and in order to calculate the supplemental exposure dose of the most centered section 410 , the supplemental exposure doses caused by the re-scattering effect of the electron beam when each section contained in the window 420 is exposed, are added. Also, the supplemental exposure dose of each section caused by the re-scattering effect when exposing are proportional to the exposure pattern density of the section and inversely proportional to the distance from the most centered section 410 .
[0031] Returning to FIG. 3, after obtaining the supplemental exposure doses with respect to all sections, compensation exposure doses are calculated for each section (step 340 ). The compensation exposure doses are doses that compensate such that the supplemental exposure dose caused by the re-scattering effect of the electron beam may be constant with respect to all sections. The supplemental exposure dose of each section are deducted from a predetermined reference value. Here, the predetermined reference value may be a maximum value of the supplemental exposure dose with respect to all sections, calculated in the step 330 , or the predetermined reference value may be otherwise appropriately designated. That is, as shown in FIG. 2, since the supplemental exposure doses caused by the re-scattering effect of the electron beam are approximately less than 6% when carbon is used for the lower plane material of an objective lens, a maximum supplemental exposure dose may be set up as 6% of the original exposure (step 310 ) dose. Meanwhile, in a case where the reference value is the maximum value of the supplemental exposure dose, as shown in FIG. 5, the compensation exposure dose of a section x is obtained by deducting the supplemental exposure doses of the section from the maximum supplemental exposure dose 510 .
[0032] Subsequently, a compensation exposure is performed according to the compensation exposure dose obtained for each section. In detail, a predetermined compensation exposure pattern is selected according to the compensation exposure dose for each section (step 350 ), and compensation exposure data are established by gathering the selected compensation exposure pattern for each section, and the electron beam resist is exposed by the electron beam according to these compensation exposure data (step 360 ).
[0033] In FIGS. 6 and 7, which illustrate examples of compensation exposure patterns which can be selected, oblique-lined portions 603 and 703 of FIGS. 6 and 7 denote portions compensation-exposed by the electron beam. In the compensation exposure patterns, portions exposed according to the compensation exposure dose of each section become stepwise broad, and the compensation exposure patterns of FIG. 6 are classified into 11 stages, and those of FIG. 7 into 10 stages. The selection of the compensation exposure patterns of FIGS. 6 and 7 according to the compensation exposure dose for each section is done according to tables 1 and 2, respectively: In tables 1 and 2, δ′ i,j is a compensation exposure dose of a section with x-coordinate i and y-coordinate j, and δ max is the above-mentioned maximum supplemental exposure dose.
TABLE 1 Open ratio of Compensation compensation exposure exposure Compensation exposure dose pattern (%) pattern δ′ i,j < 0.05 δ max 0 610 0.05 δ max ≦ δ′ i,j < 0.15 δ max 10 615 0.15 δ max ≦ δ′ i,j < 0.25 δ max 20 620 0.25 δ max ≦ δ′ i,j < 0.35 δ max 30 625 0.35 δ max ≦ δ′ i,j < 0.45 δ max 40 630 0.45 δ max ≦ δ′ i,j < 0.55 δ max 50 635 0.55 δ max ≦ δ′ i,j < 0.65 δ max 60 640 0.65 δ max ≦ δ′ i,j < 0.75 δ max 70 645 0.75 δ max ≦ δ′ i,j < 0.85 δ max 80 650 0.85 δ max ≦ δ′ i,j < 0.95 δ max 90 655 0.95 δ max ≦ δ′ i,j < 1.0 δ max 100 660
[0034] [0034] TABLE 2 Open ratio of Compensation compensation exposure exposure Compensation exposure dose pattern pattern δ′ i,j < 0.5 0 710 0.05 δ max ≦ δ′ i,j < 0.16 δ max 1/9 715 0.16 δ max ≦ δ′ i,j < 0.27 δ max 2/9 720 0.27 δ max ≦ δ′ i,j < 0.38 δ max 3/9 725 0.38 δ max ≦ δ′ i,j < 0.49 δ max 4/9 730 0.49 δ max ≦ δ′ i,j < 0.60 δ max 5/9 735 0.60 δ max ≦ δ′ i,j < 0.71 δ max 6/9 740 0.71 δ max ≦ δ′ i,j < 0.82 δ max 7/9 745 0.82 δ max ≦ δ′ i,j < 0.93 δ max 8/9 750 0.93 δ max ≦ δ′ i,j < 1.0 δ max 1 755
[0035] The maximum dose during compensation-exposing (step 360 ) is preferably a sufficiently small value (for example, less than 6%) compared to that at the original exposure (step 310 ), preferably, however, the compensation exposure time is comparatively short, for example less than 30 minutes (exposure time at the original exposure is generally several hours.), so that the compensation exposure patterns of FIGS. 6 and 7 are not actually formed on the photomask.
[0036] Also, as shown in FIG. 8, preferably, a spot size 810 of the electron beam when compensation-exposing is several times greater than a line width of the compensation exposure patterns 603 so that the spot 810 overlaps unexposed portions 605 .
[0037] When the compensation exposure is performed in this way, the supplemental exposure dose caused by the re-scattering effect of the electron beam at each section becomes constant, thereby the pattern dimension variation of the photomask is prevented.
[0038] In the above-mentioned embodiment, the method according to the present invention is applied to the fabrication of the photomask. However, in alternative embodiments, the method of the present invention can be applied to the patterning of a predetermined material layer formed on a substrate so as to construct an integrated circuit.
[0039] Hereinafter, experimental examples in which the pattern line width variation when the compensation exposure is performed according to the method of the present invention will be described, in comparison to an example in which the compensation exposure is not performed.
[0040] First, as shown in FIG. 9, an exposure pattern 910 of a 70 mm×70 mm size in which a test pattern 940 , in which linear patterns 950 having a predetermined line width are arranged is formed, is provided. In FIG. 9, oblique-lined regions 930 and 950 correspond to an opaque film pattern, and a blank region 920 corresponds to a portion exposed to the electron beam.
[0041] [0041]FIG. 10 is a graph in which a line width of the test pattern 910 (see FIG. 9) is measured, following a general exposure to the electron beam (step 310 ). In the graph of FIG. 10, the horizontal axis denotes distance to an unexposed area 930 from a boundary between a 100% exposed area (the non-oblique-lined area 920 of FIG. 9) and the unexposed area (the oblique-lined area 930 ), and the vertical axis denotes a measured line width of the test pattern. Reference numeral 1010 denotes a line width when exposing at an accelerating voltage of 50 keV and a dose of 32 μ C/cm 2 , and reference numeral 1020 denotes a line width when exposing at an accelerating voltage of 10 keV and a dose of 8 μ C/cm 2 . Also, reference numeral 1030 denotes a line width when exposing at an accelerating voltage of 10 keV and a dose of 8 μ C/cm 2 and converting the 100% exposed area 920 of FIG. 9 into an area having an average exposure pattern density of 70% with a similar level to that of a conventional integrated circuit device.
[0042] Referring to FIG. 10, variation widths of line widths, that is, differences in a maximum line width and a minimum line width are 53 nm( 1010 ), 15 nm( 1020 ), and 10 nm( 1030 ), respectively. Also, the variation of the line widths including the variation of the line widths at the test pattern 940 of the 100% exposed area 920 , are measured as 87 nm( 1010 ), 22 nm( 1020 ), and 15 nm( 1030 ), respectively.
[0043] Following this, the compensation exposure was performed according to the method of compensating for pattern dimension variation caused by the re-scattered electron beam of the present invention. That is, the exposure pattern 910 of, for example, 70 nm×70 nm of FIG. 9 is divided into the sections of, for example, 1 mm×1 mm, and the exposure pattern density and the supplemental exposure dose with respect to each section are determined.
[0044] Here, the re-scattering range ξ is set up as 8 mm, and the maximum supplemental exposure dose value δ max is set up as 3.5% of the original exposure dose. After obtaining the compensation exposure dose for each section, the line widths of the test pattern formed by the compensation exposure according to the compensation exposure doses are measured.
[0045] Referring to FIG. 11, a graph illustrating the above measured results, the horizontal and vertical axes are the same as those of FIG. 10, and reference numerals 1110 , 1120 , and 1130 denote measured line widths corresponding to 1010 , 1020 , and 1030 of FIG. 10, respectively. In FIG. 11, in the cases of 1110 , 1120 , and 1130 , the variation widths of the line widths are remarkably reduced compared to those of FIG. 10. The variation widths of the line width including the variation of the line widths at the test pattern 940 of the 100% exposed area 920 , are measured as 23 nm( 1110 ), 6 nm( 1120 ), and 4 nm( 1130 ), respectively.
[0046] Meanwhile, the method of compensating for a pattern dimension variation caused by the re-scattered electron beam of the present invention may be realized by a software program, and the program may be provided on computer readable media. Therefore, the method of compensating for pattern dimension variation of the present invention can be performed by a general-purpose digital computer. The media can include storage media such as magnetic media (for example, a read-only memory (ROM), a floppy disk, and a hard disk etc.), optical media (for example, CD-ROM and a digital versatile-disc (DVD) etc.), and carrier waves (for example, transfer via Internet).
[0047] In general, the exposure patterns as shown in FIG. 4 are converted into exposure data for writing with an electron beam and supplied to the electron beam writer, the compensation exposure patterns of FIGS. 6 or 7 obtained by the method of the present invention are also supplied to the electron beam writer as the compensation exposure data. In particular, all steps of the method of the present invention, that is, the steps of: dividing original exposure patterns (FIG. 4) into predetermined-size sections and determining a dose of supplemental exposure by the re-scattered electron beam for each section; obtaining a compensation exposure dose for each section; and selecting predetermined compensation exposure patterns according to the compensation exposure dose for each section and establishing compensation exposure data with respect to entire exposure patterns, can be essentially realized by modules of a computer program, and it is also preferable for the steps to be realized by the computer program. Here, codes and code segments of a functional program, in which each program module is actually coded, can be readily implemented by a skilled computer programmer.
[0048] As described above, according to the present invention, the exposure patterns are preferably divided into square sections, and the supplemental exposure dose caused by the re-scattering effect of the electron beam and the compensation exposure dose are determined for each section. The electron beam resist is compensation-exposed according to predetermined compensation exposure patterns according to the compensation exposure dose for each section, thereby minimizing the pattern dimension variation caused by the re-scattering effect of the electron beam.
[0049] The method of compensating for pattern dimension variation caused by the re-scattering effect of the electron beam of the present invention can be realized by a computer program and performed in a general-purpose digital computer, thereby minimizing the pattern dimension variation caused by the re-scattered electron beam in an electron beam exposure system. | The present invention relates to electron beam lithography, and is directed to a method of compensating for pattern dimension variation caused by a re-scattered electron beam when an electron beam resist is exposed to the electron beam. The method of compensating for pattern dimension variation caused by a re-scattered electron beam comprises the steps of: dividing original exposure pattens into square sections; obtaining a dose of supplemental exposure to the re-scattered electron beam; and compensation-exposing the electron beam resist so that the supplemental exposure dose may be the same for all sections. According to the present invention, the pattern dimension variation can be compensated for a re-scattering effect of the electron beam, thereby uniformly forming a fine pattern width of a more highly-integrated circuit. | 8 |
CROSS REFERENCE
This application is related to, and claims the benefit of U.S. Provisional Application Ser. No. 60/717,487, which was filed on Sep. 14, 2005 entitled “METHOD FOR OPTIMIZING UP-LINK TRANSMIT POWER FOR A WIRELESS BROADBAND TERMINAL IN A MULTI-CARRIER SYSTEM”.
BACKGROUND
The present disclosure generally relates to a wireless telecommunications, and more particularly to a method for optimizing up-link transmission power of a wireless terminal in a multi-carrier system.
One of the features of new generation wireless devices is the faster data transfer rate. For example, in 3G systems, wireless devices are required to have a data transfer rate up to 10 Mb/s, and in future 4G systems, wireless devices may be required to have a data transfer rate up to 1,000 Mb/s. In order to support such a fast rate of data transfer, these wireless communication devices are often designed with broadband capabilities.
As wireless broadband technology advances, many restrictions and limitations are put in place to regulate the use of frequencies. In the United States, the Federal Communications Commission (FCC) puts in place certain regulations that regulate how signals may be transmitted over a spectrum of frequency. For example, FCC has regulations to control the out-of-band spurious emission power in license bands, such as the multipoint multi-channel distribution system (MMDS) and the wireless communication service (WCS) bands. The out-of-band spurious emissions are unwanted frequencies that are outside a designated bandwidth. The out-of-band spurious emissions near a band edge are commonly caused by the inter-modulation distortions from a transmitter. The out-of-band emissions away from the band edge are commonly caused by the noise floor of the transmitter or the combination of the noise floor and the inter-modulation distortions of the transmitter. These regulations limit the allowable output power of the transmitter to a maximum level, in order to ensure the interoperability of various systems in neighboring bands.
There are several conventional solutions for wireless system operators to meet the FCC regulations. The first conventional solution uses a high power linear amplifier to minimize inter-modulation distortions. Advantages of this solution include a higher transmitting power and a lower system link budget. However, the disadvantages of the solution include higher costs, higher power consumption, and a larger size of equipment for sinking heat. This conventional solution is particularly not suitable for a wireless terminal that requires a small size and low manufacturing cost.
The second conventional solution is to use a channel filter for a wireless system to filter out inter-modulation distortions, and to reduce the out-of-band noise floor. This allows the system to have lower out-of-band spurious emissions, but could lead to problems such as high costs, low transmitter power, and fixed frequency channels. In addition, the system may not be able to reduce the out-of-band spurious emissions near the band edge. Thus, this conventional solution is not suitable for a terminal that requires the ability to communicate with various base transceiver stations (BTS) using different frequency channels.
The third conventional solution is to add an extra guard band to the band edge. This allows the system to have a high transmitting power. However, this solution leads to an inefficient use of frequency spectrum, reduction in signal capacity, and an increase in overall system costs.
As such, what is needed in the art of wireless telecommunications technology is a method for optimizing the transmission power for a wireless terminal in a multi-carrier system.
SUMMARY
Described herein are a method for optimizing up-link transmission power from a wireless terminal to a base transceiver station in a multi-carrier system. In one embodiment, the method includes steps of: determining a pathloss between the wireless terminal and the base transceiver station; assigning at least one sub-carrier to the wireless terminal based on the pathloss between the wireless terminal and the base transceiver station; and sending a power cap command signal from the base transceiver station to the wireless terminal for limiting a maximum allowable power transmitted by the wireless terminal to a predetermined level based on the proximity of the sub-carrier to an edge of a frequency band, over which the wireless terminal transmits and receives signals.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A illustrates a down-link signal comprised of a plurality of sub-carriers in a multi-carrier system in accordance with one embodiment.
FIG. 1B illustrates various up-link signals, each of which is comprised of one or more sub-carriers, in a multi-carrier system in accordance with one embodiment.
FIG. 2A illustrates a diagram showing up-link transmission power of a wireless terminal at a sub-carrier near a band edge in a multi-carrier system in accordance with one embodiment.
FIG. 2B illustrates a diagram showing up-link transmission power of a wireless terminal at a sub-carrier away from a band edge in a multi-carrier system in accordance with one embodiment.
FIG. 3 illustrates a flowchart showing a method for optimizing up-link transmission power from a wireless terminal to a BTS in a multi-carrier system in accordance with one embodiment.
FIG. 4 illustrates an operator owned frequency band in accordance with one embodiment.
FIG. 5 illustrates a spectral density profile over a frequency band in accordance with one embodiment.
DESCRIPTION
FIG. 1A illustrates a down-link signal comprised of a plurality of sub-carriers in a multi-carrier system in accordance with one embodiment. The multi-carrier system includes at least one BTS and at least one wireless terminal, such as customer premise equipment (CPE), a Personal Computer Memory Card International Association (PCMCIA) card, or other wireless devices, for exchanging information there between over a wireless channel. The signal transmitted by the wireless terminal and received by the BTS is referred to as an up-link signal, whereas the signal transmitted by the BTS and received by the wireless terminal is referred to as a downlink signal. In this embodiment, the down-link signal contains ten sub-carriers CO, C 1 , C 2 . . . C 9 , each of which is 0.5 MHz wide. As a result, the total width of the signal is 5 MHz.
FIG. 1B illustrates various up-link signals, each of which is comprised of one or more sub-carriers, from the wireless terminal to the BTS in the multi-carrier system in accordance with the embodiment. Diagrams 102 , 104 , and 106 show three examples of up-link signals with various numbers of sub-carriers. The diagram 102 shows an up-link signal with one sub-carrier, thereby forming a 0.5 MHz wide signal. In the diagram 104 , the up-link signal contains two sub-carriers, thereby forming a 1 MHz wide signal. In the diagram 106 , the up-link signal includes four 0.5 MHz sub-carriers, thereby forming a 2 MHz wide signal. In the multi-carrier system, the width of the up-link signal can be varied depending on the needs of the wireless terminal, as the bandwidth of a signal transmitted by the wireless terminal can be variable or fixed over a period of time.
It is noted that the width of each sub-carrier and the number of sub-carriers each up-link or down-link signal has are not limited to those disclosed in the above embodiment. It is understood that a person skilled in the art can implement a multi-carrier system with a sub-carrier of a different size, and signals with a different number of sub-carriers, without departing from the principles described herein.
FIG. 2A illustrates a diagram 200 showing up-link transmission power of a wireless terminal at a sub-carrier near a band edge in a multi-carrier system in accordance with one embodiment. As shown in FIG. 2A , there is no room between the output signal and the FCC mask indicated by the black bars at two sides of the signal. The diagram 200 shows that, as an example, the wireless terminal can transmit a +24 dBm signal with four carriers at an edge of a WCS band (2,305-2,360 MHz), thereby meeting the FCC out-of-band spurious emission requirements. FIG. 2B illustrates a diagram 202 showing up-link transmission power of a wireless terminal at a sub-carrier away from a band edge in a multi-carrier system in accordance with one embodiment. As shown in FIG. 2B , there is room between the output signal and the FCC mask indicated by the black bars at two sides of the signal. The diagram 202 shows that, as an example, the wireless terminal can transmit the signal with a 1 MHz or wider guard band from the band edge at +28 dBm and still meet the FCC out-of-band spurious emission requirements.
In another embodiment where a MMDS band (2,500-2,686 MHz) is used, the wireless terminal can transmit a +27 dBm signal with four sub-carriers at a band edge in a 5.5 MHz channel, and meet the FCC out-of-band spurious emission requirements. In this embodiment, the wireless terminal can again transmit the same four subscarrier signals with a 1 MHz or wider guard band from the band edge at +30 dBm, and still meet the FCC out-of-band spurious emission requirements.
FIG. 3 illustrates a flowchart 300 showing a method for optimizing up-link transmission power from a wireless terminal to a BTS in a multi-carrier system in accordance with one embodiment. In the flowchart 300 , a pathloss between the wireless terminal and the BTS is determined in step 302 . The BTS is designed with forward and reverse power control schemes, such that the pathloss between the wireless terminal and the BTS can be detected. In step 304 , the BTS determines if the pathloss is less than a predetermined value. For example, the predetermined value can be set from 60 to 80 percent of the maximum pathloss allowed for the BTS, or it can be a fixed pathloss from −60 dBm to −80 dBm. If the pathloss is less than the predetermined value, the process flow proceeds to step 306 , whereas if the pathloss is larger than the predetermined value, the process flow proceeds to step 308 .
In step 306 , the BTS assigns at least one sub-carrier at an edge of a frequency band to the wireless terminal. In this embodiment, the “edge of frequency band” or “band edge” refers to an edge of an operator-owned frequency band. Referring to FIG. 4 , an operator of a multi-carrier system has the rights to transmit and receive signals over a band of frequency from 2.305 GHz to 2.315 GHz, which contains two WCS bands A and B. The frequency spectrum of WCS band A ranges from 2.305 GHz to 2.310 GHz, and the frequency spectrum of WCS band B ranges from 2.310 GHZ to 2.315 GHz. With the rights to use the consecutive WCS bands A and B, the operator can design a BTS that transmits signals with full power at the border of bands A and B. The band B neighbors a band C, over which the operator has no rights to transmit or receive signals. Thus, the operator needs to design the BTS to transmit signals with lower power at the border of bands B and C.
In step 310 , the BTS sends out a power cap command to the wireless terminal for limiting its maximum allowable transmission power to a lower level. The wireless terminals that are closer to the BTS do not need to transmit signals with full power to communicate with the BTS. Thus, the BTS assigns the sub-carriers that are near the owned band edge, and caps the wireless terminal up-link transmission power at a lower maximum allowable power level such as from +24 to +27 dBm.
In step 312 , a modulation scheme with a low signal peak-to-mean ratio is assigned for the sub-carriers at the band edge. A signal with a low peak-to-mean ratio drives a power amplifier less intensively, thereby generating less amount of out-of-band emission. In step 314 , the transmission power is limited and the modulation schemes of the wireless terminal are updated, such that the allocation of sub-carriers for the wireless terminals can be optimized based on their pathloss with respect to the BTS.
In step 308 , the BTS assigns at least one sub-carrier away from an edge of a frequency band to the wireless terminal, when the pathloss between the wireless terminal and the BTS is larger than the predetermined value. For example, the sub-carrier assigned is away from the edge by at least 20 percent of the width of the operator owned frequency band.
In step 316 , the BTS sends a power cap command to the wireless terminal for limiting its maximum allowable transmission power to a higher level. The wireless terminals that are further away from the BTS need to transmit signals with more power than those close to the BTS do. Thus, the BTS assigns the sub-carriers that are away from the band edge, and caps the wireless terminal up-link transmission power at a higher maximum allowable power level such as from +28 to +30 dBm.
In step 318 , a modulation scheme with a high signal peak-to-mean ratio is assigned for the sub-carriers away from the band edge. Although a signal with a high peak-to-mean ratio drives a power amplifier, it will not generate a significant amount of out-of-band emission, as the sub-carrier is away from the band edge. The process flow then proceeds to step 314 where the transmission power limits and the modulation scheme of the wireless terminal are updated, such that allocation of sub-carriers for the wireless terminals can be optimized based on their pathloss with respect to the BTS.
In this embodiment, the power cap command can indicate a fixed cap or a power spectral density profile. FIG. 5 illustrates a spectral density profile 500 over a frequency band utilized by a multi-carrier system. The operator has the rights to transmit signals over sub-carriers on the right side of the frequency band, but do not have such rights to sub-carriers on the left side of the band. The height of the profile 500 at a specific frequency represents the maximum allowable transmission power at that frequency. As shown in the figure, the sub-carriers in section 502 have a lower maximum allowable transmission power, starting from the lowest at the left edge, with its value gradually stepping up until the border between sections 502 and 504 . The sub-carriers in the section 504 have a relatively stable allowable power distribution, as they are away from the band edge. The wireless terminal will adjust its signal transmission power based on its assigned sub-carrier and the spectral density profile.
The proposed method is able to optimize the up-link transmission power based on a pathloss between a wireless terminal and a BTS in a multi-carrier system. No high power amplifier, channel filter or extra guard band is needed in order for the multi-carrier system to meet the out-of-band emission requirements. As such, the proposed method allows the BTS of the multi-carrier system to be designed in a simple and cost-effective way.
The above illustration provides many different embodiments or embodiments for implementing different features for the techniques described herein. Specific embodiments of components and processes are described for clarity. These are, of course, merely embodiments and are not intended to limit the techniques described herein from the broader scope of the claims.
Although the invention is illustrated and described herein as embodied in one or more specific examples, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention, as set forth in the following claims. | Techniques are provided herein to optimize up-link transmission power from a wireless terminal to a base transceiver station in a multicarrier system. A pathloss between the wireless terminal and the base transceiver station is determined. A determination is made if the pathloss is less than or larger than a predetermined value. One or more sub-carriers are assigned to the wireless terminal based on whether the pathloss between the wireless terminal and the base transceiver station is less than or larger than the predetermined value. A power cap command signal is sent from the base transceiver station to the wireless terminal for limiting a maximum allowable power transmitted by the wireless terminal to a predetermined level based on proximity of the one or more sub-carriers to an edge of a frequency band used for up-link transmissions made by the wireless terminal. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to a squeeze film shaft damper oil system and more particularly to a circular array of radial oil inlets at unequally spaced and non-symmetrical positions circumferentially about the squeeze film space in a damper with a frequency independent, flexibility responsive, check valve in each inlet.
In a typical squeeze film shaft damper, a bearing support member such as the outer race of a rolling element bearing supported shaft is fitted in an annular chamber in its bearing housing to have limited radial motion therein. The outer planar surface of the outer race fits closely adjacent the opposed annular chamber wall to define a thin annular squeeze film space into which damper oil is introduced. Vibratory or radial motion of the shaft and its bearing generate hydrodynamic forces in the damper oil in the squeeze film space for damping purposes.
One problem associated with dampers as described involves orbital motion of a shaft. For example, in a damper bearing application for hot gas turbine engines, such as aircraft gas turbine engines, a turbine rotor/shaft imbalance may cause the shaft to undergo some limited orbital motion. This orbital motion causes alternate squeezing of the squeeze film space for very high oil pressure at one peripheral region and a lower pressure at an opposite region. The alternating action causes oil in the squeeze film space to flow circumferentially with an unequal pressure distribution such that, at the lower pressure region there may be a lack of a sufficient quantity of oil for damping effectiveness, referred to as cavitation or oil starvation. For this reason it has been a practice to utilize oil systems which supply oil to the low pressure region of the operating damper to prevent cavitation and modulate peripheral pressures in the squeeze film space. Such systems usually require complex and rigorous oil flow check valves to prevent backflow of high pressure oil from the rotating hydrodynamic peak pressure regions of the squeeze film space into the oil supply system. In addition, peripheral location of oil inlets are not always in an arrangement which accommodates both variable and static conditions of the damper.
OBJECTS OF THE INVENTION
It is an object of this invention to provide an improved oil supply system for squeeze film dampers.
It is another object of this invention to provide an improved peripheral arrangement of oil inlets into a squeeze film damper.
It is a further object of this invention to provide an improved oil flow check valve for squeeze film damper oil supply systems.
It is a still further object of this invention to provide a frequency independent, flexibility responsive, check valve controlled peripheral and radial oil supply system for squeeze film shaft dampers.
SUMMARY OF THE INVENTION
In a squeeze film shaft damper defining an annular squeeze film space, a dual section, dual pressure, circumferential oil manifold concentrically surrounds the squeeze film space. A non-symmetrical row of radially inwardly directed oil inlets open into the squeeze film space at predeterminedly advantageous locations with some of said inlets providing higher pressure oil than others. Each inlet is provided with a non-frequency dependent synthetic resin check valve to prevent backflow of oil through the inlet.
This invention will be better understood when taken in connection with the following drawings and description.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial and schematic view of a squeeze film damper to which this invention is applicable.
FIG. 2 is a cross-sectional and plan view of an oil supply system for the damper of FIG. 1.
FIG. 3 is a cross-sectional and plan view of the improved oil supply system of this invention as applied to the FIG. 1 damper.
FIG. 4 is a schematic and cross-sectional view of the improved automatic check valve of this invention in a radial oil inlet.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to FIG. 1, damper assembly 10 comprises a rolling element bearing housing 11 in which an outer annular race 12 of a rolling element bearing is fitted for limited radial motion. Outer race 12 fits closely adjacent an opposed housing wall to define a thin annular oil filled squeeze film space 13 which is closed or sealed by means of spaced piston rings 14 positioned in annular grooves in race 12 and bearing against the opposite wall of housing 11. An oil supply system for damper 10 may comprise a circumferential oil channel or manifold 15 concentrically surrounding squeeze film space 13, and damper oil is supplied to space 13 from a plurality of circumferentially spaced and radially inwardly oriented oil inlets 16 leading from manifold 15 into squeeze film space 13or interconnecting manifold 15 and squeeze film space 13 in fluid flow relationship as illustrated in FIG. 2.
Referring now to FIG. 2, oil supply system 17 comprises circumferential channel or manifold 15 concentrically surrounding damper assembly 10 and squeeze film space 13. Manifold 15 is usually located at the axial midpoint of a damper such as damper 10 of FIG. 1. Radial oil inlets 16 areusually positioned peripherally equidistantly in manifold 15 such as, in FIG. 2 at about 60° circumferentially spaced locations.
The oil supply system as illustrated in FIG. 2 has not been found to be optimally effective over a full range of damper operation. For example, a critical period for damper operation with respect to hot gas turbine engines is initial start up rotation of the turbine wheel and its shaft. After a long rest or non-operating period of time, the shaft supporting the relatively massive turbine wheel becomes very slightly bowed or set. Rapid start up under these conditions includes an initial high degree of orbiting motion of the shaft which imposes severe requirements on the damper and its oil supply system which may not provide an immediate lift off of the shaft and full support of the shaft by oil in squeeze film space 13. Under normal operating or running conditions, an oil supply system should immediately supply oil to the low pressure or cavitation side of the damper while preventing exit of high pressure oil from the squeeze film space when at its minimum thickness. An improved oil system which accommodates the noted problems is shown in FIG. 3.
Referring now to FIG. 3, an improved oil system 18 comprises a modified circumferential manifold or channel 19 with modified oil inlets 20. Modified radial oil inlets 20 are not arranged in equidistant circumferential relationship. Oil inlets 20 are arranged non-symmetricallycircumferentially, in that, of the 6 inlets illustrated, four are arranged at 90° intervals, but at the 180° position, the remaining two inlets are positioned closely adjacent the oil inlet at the 180° region which is described as the rest position of the gas turbine engine. This cluster or concentration of three or more inlets at the 180° region will supply the necessary oil at the shaft rest position on start up of the engine to lift race 12 from contact with housing 11 for better start up operation and cavitation control. Higher pressure oil to the cluster of inlets is advantageous for lift off and start up operation. In order to provide higher pressure oil to the clusterof oil inlets 20 a dual pressure manifold 19 is utilized. Dual pressure manifold 19 comprises a pair of separate and independent manifold segments21 and 22 defined by inner partitions 23 and 24 which effectively separate manifold 19 into the pair of arc segments 21 and 22. One segment 21 is connected to its separate oil supply by conduit 25 and serves the cluster of inlets 20 in the 180° region. The other segment 22 serves the remaining oil inlets and is connected, by means of conduit 26, to a supplyof oil at a pressure different from, and lower than, the supply of oil for segment 21. Oil system 18 is a dual pressure system with a non-symmetricalcircumferential array of oil inlets 20 operative to supply higher pressure oil to select or cluster inlets.
The higher pressure oil flowing to the cluster of inlets is prevented from backflowing through the inlets in the cluster or through other inlets by means of an improved combined oil inlet and check valve structure 27. Thischeck valve structure 27 is used in each oil inlet to prevent any backflow of oil due to high oil pressures generated in the damper during its operation. A cross-sectional illustration of such a combination oil inlet and check valve structure 27 is illustrated in FIG. 4.
Referring now to FIG. 4, the dual manifold assembly 28 similar to manifold 19 of FIG. 3, includes therein a combined oil inlet and check valve structure 27 for each oil inlet 20 of FIG. 3. Structure unit 27 comprises a hollow step bushing member 29 having a threaded shaft or shank part 30 with an expanded head part 31. Bushing 29 also includes a stepped coaxial passage 32 therethrough with a narrow part of a passage 32 in the shank part of the bushing and an enlarged part or counterbore in the head part 31. A shoulder 33 separates the passage sections. Bushing 29 is threaded into an appropriately threaded opening 34 in housing 11 opening into squeeze film space 13. The expanded head part 31 of bushing 29 is enclosedby manifold 19 (FIG. 3) which encircles squeeze film space 13 and defines ashoulder 35 for inlet openings 34. The expanded hollow head 31 of bushing 29 also defines a threaded counterbore opening into bushing 29 and rests on a gasket 36 on shoulder 35. As described, hollow bushing 29 defines a stepped cylindrical passage interconnecting manifold 19 and squeeze film space 13 in fluid flow relationship. Manifold 19 is larger than expanded head 31 so that, when manifold 19 is filled with oil, expanded head 31 is submerged and oil may flow through bushing 29 into squeeze film space 13. However, a synthetic rubber uniflow or single direction flow check valve 37 is inserted into bushing 29 to prevent backflow of oil from squeeze film space 13 into manifold 19.
Check valve 37 comprises a hollow conical section 38 with its cone base radially flared to form a gasket flange section 39 which rests on shoulder33 of bushing 29. A threaded cover plate 40 with a concentric aperture 41 therethrough is threaded into the expanded and internally threaded head ofbushing 29 to engage the flange extension 39 of cone 38 between the cover plate and shoulder 33. The described clamping arrangement prevents cone check valve 37 from being forced, by high pressure oil flow, into squeeze film space 13. Conical section 38 of valve 37 has a small opening at its apex to define an open oil flow channel from manifold 19 into squeeze filmspace 13 which remains open under the flow of oil in or through the cone section 38 into squeeze film space 13. In the event of a very high build up of oil pressure in space 13 tending to force oil into bushing 29 in a direction toward manifold 19, oil is forced into the intervening passage space between cone section 38 and bushing 29. Due to the readily flexible nature of the material of cone section 38, cone section 38 is caused to collapse inwardly along its axis to seal off the opening at its apex as well as a significant extent of its conical space and preventing backflow of oil from squeeze film space 13 into manifold 19. Check valve 37 is expeditiously produced from a strong durable but easily flexible material such as a synthetic rubber material. It is this flexibility which expands cone section 38 for full flow of oil into squeeze film space 13, and provides a rapid collapse, as described, for backflow conditions. Check valve 37 is described as a flexibility responsive check valve operationally independent of vibration frequency.
Concentric aperture 41 of cover plate 40 is a metering feed aperture of a predetermined size to control the flow rate of oil passing through check valve 37.
The number of oil inlets for the dual pressure system of this invention mayvary according to the needs of specific engine designs. One example of sucha system, as illustrated in FIG. 3, may comprise six inlets arranged at theclock hour positions of 12, 3, 5, 6, 7 and 9 o'clock, an arrangement which provides a cluster of three inlets adjacent the 180° or rest position.
The dual pressure oil system of this invention with non-symmetrical peripheral distribution of oil inlets, provides higher pressure oil to a group or cluster of oil inlets to the squeeze film space at the rest position of a shaft and its damper bearing race, and lower pressure oil tothe remaining inlets. Backflow of oil from all inlets is effectively controlled by means of self-acting flexibility responsive and vibration frequency independent check valves.
This invention particularly provides an improved oil system for an annular squeeze film damper which comprises a hollow manifold encircling the damper squeeze film space and a plurality of oil inlet means circumferentially distributed in a non-symmetrical manner along the manifold and opening from the manifold into the squeeze film space. The non-symmetrical arrangement provides a cluster of oil inlet means located near the rest position of the damper. The described system is broadly applicable to various damper applications involving other than rolling element bearings such as, for example, anti-friction and hydrodynamic journal bearings.
While this invention has been disclosed and described with respect to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention of the following claims. | A non-symmetrical circular row of oil inlets are located in a circular manifold surrounding a squeeze film space in a squeeze film damper. The oil inlets are directed radially inwardly from said manifold to open into the squeeze film space. Certain cluster of inlets provide higher oil pressure to the squeeze film space than other inlets. All inlets are equipped with automatically closing synthetic rubber check valves. | 5 |
BACKGROUND OF THE INVENTION
The invention relates to rotary drill bits, for drilling holes in subsurface formations, of the kind comprising a bit body, a plurality of cutting structures mounted on the bit body, and a fluid supply system for supplying drilling fluid to the surface of the bit body, to cool and clean the cutting structures, said fluid supply system comprising a number of nozzles mounted in the bit body, a main passage in the bit body and a number of auxiliary passages leading from the main passage to the nozzles respectively.
The invention is particularly, but not exclusively, applicable to drag-type drill bits of the kind where each cutting structure comprises a cutting element mounted on a carrier, such as a stud or post, which is received in a socket in the bit body. One common form of cutting element comprises a circular tablet having a hard facing layer of polycrystalline diamond or other superhard material bonded to a backing layer of less hard material such as cemented tungsten carbide.
Rotary drill bits of this kind are commonly formed by one of two basic methods. In one method, the bit body is machined from a solid blank of machinable metal, usually steel. Alternatively, the bit body may be formed by a powder metallurgy process. In this process a hollow mold is first formed, for example from graphite, in the configuration of the bit body or a part thereof. The mold is packed with a powdered matrix-forming material, such as tungsten carbide, which is then infiltrated with a metal alloy, such as a copper alloy, in a furnace so as to form a hard matrix.
Particularly in cases where the bit body is machined from steel, the surface of such a bit is susceptible to wear and erosion during use, particularly in the vicinity of the nozzles from which abrasive drilling fluid emerges at high velocity and with substantial turbulence. Accordingly, it is fairly common practice to apply a hard facing material to the outer surface of the bit body, at least around the cutting structures. The hard facing material is usually applied by a welding or plasma spraying process.
In addition to the erosion caused by drilling fluid and abrasion on the external surfaces of the bit body, the flow of fluid through the internal fluid supply system of the bit also tends to cause some erosion of the internal surfaces of the fluid flow passages. Hitherto, such erosion has not been considered as particularly significant since normally the drill bit will reach the end of its useful life, as a result of wear, damage and/or external erosion, before the internal erosion has any significant effect on the performance of the drill bit. However, with improvements in the design and construction of drill bits of this type, the life of such bits is being significantly increased, with the result that the problem of internal erosion requires to be addressed. The present invention therefore sets out to provide forms of drill bit construction, and methods of manufacture, where erosion of the internal surfaces of the drill bit is reduced.
SUMMARY OF THE INVENTION
According to the invention there is provided a rotary drill bit, for drilling holes in subsurface formations, comprising a bit body, a plurality of cutting structures mounted on the bit body, and a fluid supply system for supplying drilling fluid to the surface of the bit body, to cool and clean said cutting structures, said fluid supply system comprising a number of nozzles mounted in the bit body, a main passage in the bit body and a number of auxiliary passages leading from the main passage to said nozzles respectively, at least a part of at least one of said passages being lined with a lining material which is more erosion-resistant than the material of the bit body.
The lining material may comprise a layer of hardfacing material applied to the internal surface of part, or all, of a passage preformed in the bit body. The hardfacing material may for example be applied by a spraying, welding, electroplating or powder infiltration process. Alternatively, the hardfacing material may be applied to the surfaces of the passages as a layer of wear-resistant powder and binder, high pressure then being applied to the layer at elevated temperature to consolidate the layer, the pressure being applied via a grain bed of ceramic or refractory particles. Such methods, which are described for example in U.S. Pat. Nos. 4,630,692 and 4,640,711, are well known and will be referred to generally in this specification, for convenience, as grain bed consolidation methods.
Alternatively, the lining material may comprise a preformed rigid tube secured within a passage in the bit body, at least the interior surface of the tube comprising a material which is more erosion-resistant than the material of the bit body. Where at least one of said auxiliary passages is lined with a preformed rigid tube, one end of said tube may project into the interior of said main passage in the bit body.
Each rigid tube may itself be entirely from more erosion-resistant material, or it may comprise a tube of a first material, e.g. steel, to the interior surface of which is applied a hardfacing material. The hardfacing material may be applied to the interior surface of the tube by a method selected from: spraying, welding, electro-plating, a powder infiltration process, or a grain bed consolidation method.
The tube may be secured by mechanically fixing, brazing or shrink-fitting the tube within a correspondingly shaped passage in a preformed bit body, or by molding bit body material around the tube.
Thus, the invention includes within its scope methods of manufacturing a drill bit body of the kind first referred to. A first such method includes the steps of first manufacturing a bit body having an internal main passage and a number of auxiliary passages leading to respective sockets in the bit body to receive nozzles, and then lining at least a part of at least one of said passages with a lining material which is more erosion-resistant than the material of the bit body.
The lining material may be applied to the internal surface of part, or all, of said passage preformed in the bit body by a method selected from: spraying, welding, electro-plating, a powder infiltration process, or a grain bed consolidation method. Alternatively, the lining material may be applied to the bit body by brazing, shrink-fitting or otherwise securing a preformed rigid tube within part or all of a passage in the bit body. The method may comprise the further step of applying a hardfacing material to the internal surface of the tube by a method selected from: spraying, welding, electro-plating, a powder infiltration process, or a grain bed consolidation method. Such process may be effected before or after the tube is secured within the bit body.
The invention also provides a method of manufacturing a drill bit body of the kind first referred to comprising forming a hollow mold in the configuration of the bit body or a part thereof, locating within the mold a rigid structure provided said main passage and auxiliary passages, packing the mold around said structure with a powdered matrix-forming material, and then infiltrating said material with a metal alloy in a furnace so as to form a hard matrix, the material of said structure being more erosion-resistant than the solid infiltrated hard matrix, at least on the internal surfaces of said passages.
The structure may comprise a unitary structure or may comprise a plurality of elements secured together or otherwise located in the required position and orientation within the mold.
The invention further provides a modification of this method where the material of the structure itself is not necessarily of greater erosion-resistance than the solid infiltrated matrix material, and wherein the method includes the further step of applying to the internal surfaces of the passages in the said structure a hardfacing material by a spray, welding, electro-plating or powder infiltration process. Said hardfacing material may be applied to the internal surfaces of the structure before the solid matrix material is molded around it, or it may be applied after the bit body has been molded around the structure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of a typical drag-type drill bit incorporating the present invention.
FIG. 2 is an end elevation of the drill bit shown in FIG. 1.
FIG. 3 is a diagrammatic vertical section through the drill bit.
FIG. 4 is a diagrammatic vertical section through an alternative embodiment.
FIG. 5 shows a modified version of the embodiment of FIG. 4.
FIG. 6 is a diagrammatic vertical section through a mold showing one method of manufacture of a solid infiltrated matrix-bodied bit, in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, the bit body 10 is machined from steel, and has at one end a shank including a threaded pin 11 for connection to the drill string. The steel bit body is normally machined by computer-controlled turning and milling operations.
The operative end face 12 of the bit body is formed with a number of blades 13 radiating from the central area of the bit, and the blades each carry cutting structures 14 spaced apart along the length thereof.
The bit has a gauge section including kickers 16 which contact the walls of the borehole to stabilize the bit in the borehole. In known manner abrading elements are mounted in the kickers 16. Internally of the bit there is provided a fluid supply system, which will be described in greater detail in relation to FIG. 3, comprising a central passage in the bit body and shank which communicates through auxiliary passages with nozzles 17 received in the end face 12 of the bit body.
Each cutting structure 14 comprises a preform cutting element 18 mounted on a carrier 19 in the form of a stud which is secured within a socket machined into the bit body. Each preform cutting element 18 is usually in the form of a circular tablet comprising a thin facing table of polycrystalline diamond bonded to a substrate of cemented tungsten carbide, both layers being of uniform thickness. The rear surface of the substrate of each cutting element is brazed to a suitably orientated surface on the stud, which may also be formed from cemented tungsten carbide.
It will be appreciated that this is only one example of the many possible variations of the type of drill bit to which the present invention is applicable.
FIG. 3 shows diagrammatically the construction of the fluid supply system within the bit body. The system comprises a central main passage 20 which is cylindrical and of circular cross-section. Auxiliary passages 21, which are also generally cylindrical and of circular cross-section lead from the lower end of the main passage 20 to respective sockets 22 formed in the bit body and into which the nozzles 17 are secured.
In accordance with the present invention, the internal surfaces of the passages 20, 21 are lined with hardfacing material which is more erosion-resistant than the steel of the bit body 10. The sockets 22 may also be lined with hardfacing material, as shown, but this may not be necessary since the nozzle assemblies are usually themselves erosion resistant, in any case. In the embodiment of FIG. 3 the hardfacing material 23 is applied to the internal surfaces of the passages and sockets by any of the well known methods used for applying hardfacing material to the external surfaces of a bit body. For example the material may be applied by spraying on, tig, or stick, by manual metal arc welding, by fusing or brazing processes, by electro-plating or by a powder infiltration process where matrix-forming metal powder, usually tungsten carbide, is infiltrated with a binding alloy, usually copper-based, in a furnace. Alternatively, as previously mentioned, the hardfacing material may be applied to the surfaces of the passages by a grain bed consolidation method whereby a layer of wear-resistant powder and binder is applied to the surface, and a high pressure is then applied to the layer at elevated temperature, via a grain bed of ceramic or refractory particles, to consolidate the layer.
The nature of the hardfacing materials which may be applied by such processes is well known, and typically will contain coarse or fine particles of tungsten carbide, depending on the method of application. However, any other suitable hardfacing material may be employed, such as mixtures of materials selected from silicon carbide, tungsten carbide, diamond, steel, cobalt, and alloys thereof.
After the internal surfaces of the passages and sockets have been hardfaced, machining processes may be required in certain regions, and particularly the internal surfaces of the sockets 22. It may be necessary to machine such sockets, after hardfacing, for example to provide a seat for the nozzle 17 and an O-ring groove. Such machining may be effected by milling, boring or electron discharge machining, depending on the nature of the hardfacing material. Since the material is, of course, very hard, special machining tools will be required, for example tools of diamond or cubic boron nitride tips.
In the alternative arrangement shown in FIG. 4 the main passage 20 is lined with a preformed circular cross-section tube 24, which is fitted after the bit body 10 has been machined. The tube 24 may be fitted within the passage 12 by mechanical fixing, shrink-fitting or brazing, or by any other appropriate means.
Similarly lining tubes 25 are fitted within the auxiliary passages 21 and short tubes, or bushes, 26 within the sockets 22. The bushes 26 may be separately formed from the lining tubes 25 or may comprise enlarged outer diameter sections integrally formed on the ends of the tubes 25.
The tubes 24, 25 and 26 may be entirely formed of a metal which is of greater erosion-resistance than the steel of the bit body. Alternatively, the tubes may be formed of steel, or other metal, to the internal surface of which has been applied a layer of hardfacing material before or after the tubes are fitted within the bit body. The hardfacing material may be applied to the internal surfaces of the tubes by any of the methods described in relation to FIG. 3 and, again, the tubes and/or hardfacing may be subsequently machined as required and as described in relation to FIG. 3.
One suitable material for the tubes 24, 25, 26 may be solid infiltrated matrix material, of the kind from which molded bit bodies are formed, and comprising tungsten carbide particles infiltrated with a copper-based alloy. British Patent No. 2211874 describes a method for applying such infiltrated matrix hardfacing material to the external surfaces of a steel bit body, and methods similar to those described in that specification may be employed in the present invention to apply matrix hardfacing to the internal surfaces of the passages 20, 21 and 22 or to the internal surfaces of tubular linings 24, 25, 26 secured therein.
Although the invention is particularly applicable to steel-bodied bits, which have been described in FIGS. 1-4, the invention may also be applied to molded matrix-bodied bits. In that case, of course, the material of the internal hardfacing or lining requires to be of greater erosion-resistance than the solid infiltrated matrix from which the main part of the bit body itself is formed.
FIG. 5 shows a modified version of the arrangement of FIG. 4 where the upper ends of the wear-resistant lining tubes 25 project a short distance into the lower end of the main passage 20 in the bit body. Such arrangement may tend to reduce erosion of the bit body around the inlets of the tubes 25, which might otherwise occur due to the flow of abrasive drilling fluid into the tubes. Also, with the arrangement of FIG. 5, any debris entrained in the drilling fluid will tend to be precipitated at the bottom of the passage 20, below the inlets to the tubes 25, thus avoiding such debris passing along the tubes 25 perhaps to block the associated nozzles.
FIG. 6 shows diagrammatically a method of manufacturing a matrix-bodied bit incorporating the present invention.
Referring to FIG. 6, the basic process for molding a drill bit using a powder metallurgy process is well known. A machined steel former 27, providing the shank and pin of the drill bit, is located in a graphite mold 28 formed in the external configuration of the bit body. The mold is packed, around the lower part of the former 27, with powdered matrix-forming material 29 and a body of fusible alloy, usually a copper-based alloy, 30 is located above the matrix-forming particles.
The mold is then introduced into a furnace so that the alloy 30 fuses and infiltrates downwardly into the material 29 so as, upon subsequent cooling, to form a solid infiltrated matrix which is bonded on to the lower part of the former 27.
In order to provide sockets in the bit body to receive the cutting structures, graphite formers, such as is indicated diagrammatically at 31, are mounted in the walls of the mold so as to project into the matrix-forming material to form the socket.
Similarly, graphite formers are also normally inserted in the mold, before it is packed with matrix-forming material, to define the lower part of the central passage 20, auxiliary passages 21, and sockets 22. After the bit body has been formed the graphite formers are destructively removed to open the passages and nozzle sockets.
In accordance with the invention, however, the passages of the fluid supply system within the bit body are not defined by disposable graphite formers but by a structure 32 formed of material which is of greater erosion-resistance than the solid infiltrated matrix material. In the embodiment shown, the structure 32 comprises a main hollow cylindrical member 33 having an integral bottom closure 34. Auxiliary tubes 35 have their upper ends located within angled sockets within the closure portion 34 and have increased diameter lower portions 36 to define the sockets 22. The upper ends of the tubes 35 may be pre-secured within the angled sockets in the closure portion 34 by shrink-fitting, brazing or other means, although this may not be necessary since they will, in any case, automatically become "brazed" within the sockets by the infiltration alloy, as a result of the infiltration process.
In the course of infiltrating the matrix-forming material, and forming the bit body, the structure 32 becomes permanently embedded within the bit body so as to define fluid flow passages lined with a material which is of greater erosion-resistance than the material of the bit body itself.
As in the arrangement of FIG. 4, the structure 32 may be made entirely of material of greater erosion-resistance, but alternatively it might comprise some other material, only the internal surfaces of the structure being lined with a material of greater erosion-resistance, for example by any of the application methods referred to in relation to FIGS. 3 and 4.
The upper part of the main passage 20 in the steel former 27 is also preferably lined with erosion-resistant material 37, which may be in the form of a preformed inserted tube, or in the form of an applied layer of hardfacing material.
Whereas the present invention has been described in particular relation to the drawings attached hereto, it should be understood that other and further modifications, apart from those shown or suggested herein, may be made within the scope and spirit of the present invention. | A rotary drill bit, for drilling holes in subsurface formations, comprises a bit body, cutting structures mounted on the bit body, and a fluid supply system for supplying drilling fluid to the surface of the bit body, to cool and clean the cutting structures. The fluid supply system comprises a number of nozzles mounted in the bit body, a main passage in the bit body and a number of auxiliary passages leading from the main passage to the nozzles. Some or all of the passages are at least partly lined with an erosion-resistant lining material. The lining material may comprise a hard facing applied to the internal surface of a preformed passage or a rigid tube which itself defines the internal surface of the passage. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Patent Application entitled “TOILET FLUSH VALVE WITH BOWL OVERFLOW PREVENTION” having Ser. No. 61/504,176, filed on Jul. 2, 2011.
BACKGROUND
A typical toilet used in domestic applications includes a toilet bowl mounted on a floor surface and in communication with a drain to take away the contents of the toilet bowl, and a water supply tank at a higher elevation that provides the proper amount of water during a flush cycle of the toilet bowl. In order to re-fill the tank after a flush cycle, a float in the toilet tank moves down during a flush cycle and opens a fill valve to supply replacement water in the tank. The float responds to the rising level of the liquid in the tank to close the fill valve. If the drain opening of the toilet is clogged and the toilet is flushed, the fresh replacement water coming from the toilet tank to the bowl has no escape, the water level in the toilet bowl rises, and there is a hazard of overflow of the contents in the toilet bowl.
BRIEF DESCRIPTION OF THE DRAWINGS
Many aspects of the present disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
FIGS. 1A-1D are cross sections of a toilet tank flush valve assembly and illustrate the progressive steps of opening the flush valve and closing the flush valve in anticipation of an overflow condition of the toilet bowl.
FIGS. 2A-2D are similar cross sections of another toilet tank flush valve assembly illustrating similar progressive steps to avoid an overflow condition of a toilet bowl.
FIGS. 3A-3D are similar cross sections of a third toilet tank flush valve assembly illustrating similar progressive steps of an overflow condition of a toilet bowl.
FIGS. 4A-4C are similar cross sections of a fourth toilet tank flush valve assembly illustrating similar progressive steps of an overflow condition of a toilet bowl.
FIGS. 5A-5B are similar cross sections of a fifth toilet tank flush valve assembly illustrating similar progressive steps of an overflow condition of a toilet bowl.
FIGS. 6A-6C are cross sections of the toilet tank flush valve assemblies of FIGS. 1A-1D , but showing the stand pipe and connection of the toilet flush valve assembly to the toilet tank.
FIG. 7 shows a three-dimensional view of the portion of a toilet tank flush valve assembly.
DETAILED DESCRIPTION
The various structures described herein are applicable to single flush and/or dual flush systems for toilets. Referring now in more detail to the drawings, in which like numerals indicate like parts throughout the several views, FIG. 1A discloses a toilet flush valve assembly 10 that is to be mounted in a toilet tank (not shown) in registration with the inlet opening of a toilet bowl (not shown).
Toilet flush valve assembly 10 includes a housing 16 that includes at its bottom an outlet opening 18 that registers with an opening of the toilet bowl, and legs 38 define water ports that allow water to flow from the tank through the lower portion of the external housing 16 and through the outlet opening 18 of the toilet flush valve assembly 10 on down through the inlet opening of a toilet bowl.
Flush valve assembly 10 includes valve plate 24 that registers with and closes the outlet opening 18 of the toilet flush valve assembly 10 , and upright valve stem 26 is connected at its lower portion to the valve plate 24 . A sealing gasket 25 is disposed on the valve plate 24 and engages with a seal ring 27 that defines an opening of the flush valve assembly 10 . Valve stem 26 extends upwardly through the tubular passage 28 and a cable connector 30 comprising a tubular structure or other structure extends from the upper end of valve stem 26 .
Flush actuator cable 32 extends downwardly from the actuator handle (not shown) that is mounted on the toilet tank in which the toilet flush valve assembly 10 is mounted. The flush actuator cable 32 extends downwardly through the upper portion of the external housing 16 and its lower terminal end passes through slot 34 of the cable connector 30 , with an enlarged lower terminal end 36 that projects below the slots 34 . The flush actuator cable 32 is sized and shaped so that it may slip through the slots 34 when moved in an upward direction until the enlarged terminal end 36 engages the cable connector that forms the slots 34 , and further upward movement of the flush actuator cable 32 causes the enlarged terminal end 36 to lift the cable connector 30 and valve stem 26 which, in turn, lifts the valve plate 24 . This opens flush valve assembly 22 to the position as shown in FIG. 1B . The flush actuator cable 32 slides through a cable sleeve 37 that is rigidly connected to the housing 16 . Specifically, the cable sleeve 37 may be pressure fitted into recesses 39 formed in the housing 16 as shown. In another embodiment, a structural connector may be molded onto the end of the cable sleeve 37 that mates with an opposing structure embodied in the housing 16 .
When the valve plate 24 is lifted as described above, it passes the water ports defined by the legs 38 and allows water to flow from the toilet tank through the outlet opening 18 of the toilet flush valve assembly 10 and ultimately through a gasket 13 that mates with a flush orifice, according to one embodiment, that leads into the toilet bowl as will be described.
Tiltable float 40 is supported by pivot pin 47 at the mid-level of the external housing 16 , and the float 40 rests on the surface of the water and tilts in accordance with the vertical movement of the surface of the water. The valve stem 26 includes a lateral projection 42 that passes up through the tiltable float 40 when it is lifted by the flush actuator cable 32 . Float 40 includes a laterally extending hook 44 that faces the path of movement of the valve stem 26 . When the valve stem is raised high enough for its lateral projection 42 to pass the lateral extending hook 44 of the float 40 , the lateral extending hook 44 of the float prevents the valve stem 26 from moving in a downward direction. This holds the valve stem and valve plate 24 elevated so that the valve plate 24 does not descend to close the outlet opening 18 , thereby allowing water to drain from the toilet tank through the water port defined by legs 38 in the external housing 16 and into the toilet bowl. This is best illustrated in FIG. 1B .
Float 40 is supported on a pivot pin 47 so that when the water level descends, the float 40 progressively tilts and its laterally extending hook 44 slips out from beneath the lateral projection 42 of the valve stem 26 , allowing the valve stem and the valve plate 24 to move downwardly into closed relationship with respect to the outlet opening 18 of the external housing 16 , thus terminating the flow of liquid to the toilet bowl.
As shown in FIGS. 1A and 1B , a valve release actuator 46 is pivotally mounted on a support plate 48 by a pivot pin 50 extending through the support plate 48 and through the valve release actuator 46 . In this embodiment, the valve release actuator 46 is J-shaped with a downwardly extending foot 52 that is directed toward engagement with the upper surface of float 40 . The opposite end 50 of the valve release actuator 46 is connected to the terminal end 54 of the downwardly extending emergency stop cable 56 . When the actuator 46 is rotated, the foot 52 abuts float 40 , and the actuator 46 exerts a force on the float 40 in the downward direction.
When there is a hazard of an overflow condition in the toilet bowl below, the operator of the toilet can move the handle that is connected to the emergency stop cable 56 to lift the cable and thereby tilt the valve release actuator 46 from the position shown in FIGS. 1A and 1B to the position shown in FIGS. 1C and 1D . This causes the laterally extending hook 44 to engage the upper surface or any other appropriate portion of the float 40 , tilting the float 40 so that the float's outwardly extending hook 44 withdraws from beneath the lateral projection 42 of the valve stem 26 . This immediately removes the support from the valve stem and valve plate 24 so that, under the influence of gravity and the downward movement of the water through the valve outlet opening 18 , the valve stem and valve plate will move downwardly until the valve plate 24 is seated on the outlet opening 18 of the housing 16 . This maneuver tends to completely and abruptly terminate the flow of water from the toilet tank to the toilet bowl, thereby averting the overflow condition of the toilet bowl.
FIGS. 2A, 2B, 2C, and 2D illustrate a second embodiment. The valve plate and valve stem of this embodiment may be the same as previously described with respect to FIGS. 1A-1D . However, the valve release actuator is embodied in a projection 60 that is rigidly mounted to the float 62 . When the valve stem 64 moves upwardly in response to the pulling force applied by the flush actuator cable 66 , the lateral projection 68 of the valve stem passes the laterally extending hook 70 so that the valve stem comes to rest on the laterally extending hook, while the water in the toilet tank tends to flow out through the open valve of the toilet flush valve assembly and into the toilet bowl. This condition remains until the float 62 tilts enough to withdraw its laterally extending hook 70 out from beneath the lateral projection 68 of the valve stem, whereupon the valve stem and valve plate will move downwardly under the influence of gravity toward a closed relationship with respect to the outlet opening.
Should a toilet bowl be stopped up at the beginning of a flush cycle, the operator may pull the cable 72 upward so that its enlarged lower distal end 74 engages and lifts the projection 60 of the right side of the float 62 , tilting the float so that the laterally extending hook 70 slips out from beneath the lateral projection 68 of the stem 64 . The laterally extending hook 70 may tilt in a downward direction to release the valve stem from the buoyant float to prematurely terminate the flush cycle. This allows the stem and its valve plate to move in a downward direction to close the outlet opening of the toilet flush valve assembly.
FIGS. 3A, 3B, 3C, and 3D disclose another embodiment which includes a cable actuated lever 76 that is pivotal about pivot pin 78 in response to the tension applied by emergency stop cable 82 . When the water level is high in the bowl, the downward movement of the distal end 80 of the cable actuated lever 76 will engage the projection 84 of the cable connector 86 , applying downward force to the valve stem 88 , forcing the lateral projection 90 out from beneath the laterally extending hook 92 , allowing the valve stem 88 and its valve plate to move back into a closed relationship with respect to the bottom outlet opening 18 .
FIGS. 4A-4C illustrate a handle assembly that mounts to, for example, the front wall of a toilet tank of a toilet, which may be used for actuating the toilet flush valve assembly of the previously described products.
A flush lever assembly 101 includes a housing 102 that is mounted to the internal surface of the vertical sidewall of a toilet tank. A lever 104 has its stem 106 extending through an opening in the sidewall of the housing 102 , with the lever being positioned externally of the toilet tank and the housing internally of the toilet tank.
As shown in FIG. 4B , stem 106 is connected to cam 108 that rotates as indicated by the double-headed arrow in response to the rotation of the lever 104 . A slider 110 is located within the housing 102 and moves laterally with the housing as guided by rails 112 . Flush actuator cable 114 is connected at its internal end to slider 110 and extends laterally through the housing 102 .
When the lever 104 is pivoted downwardly as indicated by arrow 117 , the cam 108 pushes the slider 110 to the left as shown in FIG. 4B , causing the actuator cable 114 to retract into the housing 102 . This movement of the cable is used to begin a flush cycle in the previously described devices.
As shown in FIG. 4C , the same flush lever assembly 101 includes an emergency stop button 116 that is spring urged so as to protrude from the lever 104 . Alternatively, the emergency stop button 116 may be flush with the surface of the lever 104 or may be recessed with respect to the surface of the lever 104 . The stem 118 extends from the emergency stop button 116 into the housing 102 for engagement with an L-shaped lever 120 that is mounted on pivot pin 122 . Emergency stop cable 124 is connected to the downwardly extending arm 126 of the L-shaped lever 120 so that when the horizontally extending arm 128 of the lever is pivoted downwardly, the downwardly extending arm pulls the emergency stop cable 124 . The emergency stop cable 124 terminates into an enlarged end portion 127 that is retained by the downwardly extending arm 126 . It is understood that the cables 114 and 124 are enclosed in cable sleeves 129 .
It will be noted that the flush lever assembly of FIGS. 4A and 4B may be used with the previously described toilet flush valve assemblies.
FIGS. 5A and 5B show another flush lever assembly that may be used with the previously described toilet flush valve assemblies. Note that structural components that mate the lever 130 with the housing 134 are not shown.
The lever 130 is connected to a stem 132 that extends from outside to the inside of the toilet tank. A housing 134 is mounted to the inside vertical surface of the toilet tank housing. Laterally extending double ended actuator arm 136 is rigidly mounted to the stem 132 . Sliders 138 and 140 are movable along the length of the housing 134 . The ends of the actuator arm 136 engage the sliders so that when the flush lever 130 is rotated, the actuator arm 136 will move the sliders in opposite directions. This causes the flush actuator cable 142 to move along its length in directions opposite to the directions of movement of the emergency stop cable 144 .
When the user of the toilet rotates the flush lever in one direction, a flush cycle begins. However, should there be a hazard of toilet bowl overflow, the user can rotate the flush lever in the opposite direction to apply movement of the emergency stop cable and thereby terminate the flush cycle.
The foregoing disclosure is focused on the overflow prevention features of the toilet flush valve assembly. The mounting of the toilet flush valve assembly to the toilet tank, the arrangement of the stand pipe, the tank flush valve and float assembly and other items are not specifically disclosed herein but are shown in U.S. patent application Ser. No. 12/715,757. Further, applicant incorporates herein by reference U.S. patent application Ser. No. 12/715,757 in its entirety.
FIG. 6A shows the toilet flush valve assembly 10 that comprises an integrally molded portion of a flush valve 200 . Alternatively, the toilet flush valve assembly 10 may be rigidly connected to the remaining portion of the flush valve 200 via a screw fit connection, a pressure fitted connection, or some other connection that provides for proper sealing to prevent leakage of water. The flush valve 200 includes a standpipe 203 and is mounted to a floor 206 of a toilet tank. In one embodiment, the flush valve 200 includes a thread 209 that engages a nut (not shown) to fasten the flush valve 200 to the floor 206 of the toilet tank. A gasket 213 may be positioned to form a seal between the flush valve 200 and the floor 206 of the toilet tank to prevent leakage.
FIGS. 6B and 6C show the toilet flush valve assembly 10 mounted to a previously existing flush valve 230 via a gasket 233 that is attached to the toilet flush valve assembly 10 at slots 236 near the outlet opening 18 . In FIG. 6C , the toilet flush valve assembly may slide over or otherwise be connected to a standpipe 203 to align the toilet flush valve assembly 10 with the outlet opening 18 , as is shown in FIG. 6B .
FIG. 7 shows a bottom portion 253 of the toilet flush valve assembly 10 that illustrates the legs 38 and water ports 256 that allow water to flow through the opening 118 and into the toilet bowl.
Although preferred embodiments of the invention have been disclosed herein, it will be obvious to those skilled in the art that variations and modifications of the disclosed embodiments can be made without departing from the spirit and scope of the invention. | Disclosed are various embodiments for prematurely terminating a flush cycle. A valve stem may be coupled to a cable to move the valve stem in an upward direction to initiate a flush cycle. A buoyant float may be configured to engage the valve stem to prevent the valve stem from moving in a downward direction during the flush cycle, until a water level drops below a predefined level. Finally, a second cable coupled to a valve release assembly may be utilized to release the valve stem from the buoyant float to prematurely terminate the flush cycle. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to cardiac stimulation, and more particularly to implantable leads which simulate or sense electrical activity of the heart. The invention provides a replacement connector which can be connected to an implanted lead in place of a proximal end of the lead.
2. Prior Art
There are generally two types of body implantable leads used with cardiac pacemakers--one which requires surgery to expose the myocardia tissue to which an electrode is affixed and another which is inserted through a body vessel, such as a vein, into the heart where a electrode contacts the endocardial tissue. In the later type, the endocardial lead is often secured to the heart through an endothelial lining by a sharpened helix affixed to a distal end of the lead. When the end of the lead contacts the lining of the heart at a desired location, the lead may be secured in place by rotating the lead, thus screwing the helix into the heart tissue.
When an implantable lead is affixed to the heart tissue, it initially exhibits a certain impedance associated with the character and composition of the lead, the location and quality of fixation, and other factors. Over time, the heart tissue reacts to the presence of the foreign body, forming a fibrosis in the tissue near the electrode. Shortly after implantation, therefore, the impedance associated with an implanted electrode rises from an initial value to a peak value. Thereafter, the impedance associated with the electrode again falls to a lower value as the fibrosis stabilizes and eventually a relatively stable, long-term impedance value is attained.
This phenomenon is well known. One consequence of this condition is that initial settings for implanted pacers must be higher than the measured impedance at the time of implantation. An attending physician would expect the impedance to rise over time and would, therefore, adjust the pacer to produce pulses of higher energy in order to insure an appropriate response in the heart during the period of highest impedance. Frequently, the pacer is not adjusted after the impedance falls to its stable long-term value, resulting in an unnecessary use of pacer power. Higher power consumption results in more rapid battery depletion, which eventually requires that the pacer itself be replaced sooner than would be otherwise necessary. It is desireable, therefore, for a physician to be able to use a lead which has already stabilized to its long-term impedance, whenever the pacer is replaced. Use of a stabilized lead can permit the attending physician to more accurately adjust both sensing and stimulating parameters to conserve energy and to assure reliable long-term performance of the implanted pacer.
The replacement pacer, however, may not be the same type as the original pacer. Over the expected life of the pacer, on the order of ten years, it is to be expected that technology and manufacturing will have changed. New options in pacing technology have become and will become available. Moreover, the patient's condition may have changed, making it desireable to incorporate different features in the replacement pacer, which were not necessary in the original pacer.
Because it is quite likely that the electrical connections on the replacement pacer would not be identical to the original pacer, it is desireable to provide a means whereby a distal end of the implanted lead could be left in its stabilized condition near or on the heart tissue, while the proximal end of the lead is replaced with an end compatible with the replacement pacer.
SUMMARY OF THE INVENTION
The present invention provides a replacement connector for implanted leads. When a implanted lead is used with a replacement pacer, the proximal end of the implanted lead is cut away and discarded. A slip-on seal is placed on the remaining end of the lead. The replacement connector is connected to the implanted lead using an eccentric locking mechanism both to secure the implanted lead and the replacement connector together and to achieve a positive electrical connection. A boot mates with the slip-on seal to protect the connection from body fluids.
With the foregoing in mind, it is a principal object of the present invention to provide a replacement connector for implanted leads.
A further object of the invention is to provide a replacement connector which can be secured to an implanted lead by a reliable mechanical and electrical connection.
Another important object of the present invention is to provide a replacement connector which can be sealed against body fluids.
Another object of the invention is to provide a means for connecting an implanted lead and a replacement connector which can be engaged with a minimum of manipulation.
These and other objects and features of the present invention will be apparent from the detailed description taken with reference to the accompanying drawing.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a prospective view of an implantable endocardial lead with a replacement pacer connector according to the present invention;
FIG. 2 is prospective view of a proximal part of the implanted lead with the replacement connector attached thereto;
FIG. 3 is a sectional view of a slip-on seal and installation jig;
FIG. 4 is a sectional view of the slip-on seal and the installation jig showing the installation procedure;
FIG. 5 is a side view of the slip-on seal and jig;
FIG. 6 is a sectional view of a distal end of the replacement connector taken along line 6--6 of FIG. 1;
FIG. 7 is a cross-sectional view of the distal end of the replacement connector taken along line 7--7 of FIG. 6;
FIG. 8 is a cross-sectional view of the distal end of the replacement connector taken along line 8--8 of FIG. 2; and
FIG. 9 is a prospecive view of a wrench for use with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference is now made to the drawings, wherein like numerals designate like parts throughout. FIG. 1 shows an implanted endocardial lead generally designated 10 and a replacement connector generally designated 12. In accordance with the prior art, the implanted lead comprises a distal end 14 with a tip electrode 16 and a proximal end 18 with a connector 20. The replacement connector 12, according to the present invention, comprises a connector housing 22 at a connector distal end 24, a lead portion 26 and a connection 28 at a proximal end 30 of the replacement connector 12. An elastomeric boot 32 encloses most of the housing 22. The boot 32 mates with a slip-on seal 34 to inhibit body fluid from entering the housing 22. The slip-on seal 34 rides on a portion of the implanted lead 10, as will be more fully described below.
To install the replacement connector 12, an attending physician would cut the implanted lead 10 near the proximal end 18 with wire cutters or a similar tool and would discard the proximal end 18. The slip-on seal 34 must then be placed on the implanted lead 10. As seen FIG. 3, the slip-on seal 34 comprises an elastomeric, preferably silicone, tube 36 with a plurality of internal sealing fins 38. The sealing fins 38 are circumferential around the interior of the tube 36 and are inclined toward a proximal end 40 of the seal 34. Because of this configuration, it is relatively easier to slide the seal 34 along the implanted lead 10 toward the distal end 14 thereof. When the seal 34 is moved toward the proximal end of the lead 10, the fins 38 tend both to resist the motion and simultaneously to form a tighter seal on the lead 10.
The seal 34 further comprises a larger tube 42 at the distal end 40 of the seal 34 for engaging the housing 22 and boot 24 as more fully explained below. A lip 44 is provided at the distal end 40 of the seal 34 for locking with the housing 22 and the boot 24.
In order to provide reliable sealing, the slip-on seal 34 is provided with an installation jig 46. A handle 52 is attached to a proximal end 54 of a shaft 50 and a break-away pin 48 is attached to a distal end 56 of the shaft 50. In the preferred embodiment, the slip-on seal 34 rides on the break-away pin 48 until the replacement connector 12 is to be installed. The break-away pin 48 has a relative small diameter so that the tube 36 and fins 38 of the seal 34 are not distended prior to being placed on the implanted lead 10. Silicone and other elastomeric substances tend to deform permanently if placed under stress for an extended time. Just before installation, therefore, the slip-on seal 34 should be pushed off of the detachable pin 48 and onto a shaft 50 of the jig 46. The shaft 50 has an outside diameter roughly corresponding to the expected outside diameter of the implanted lead 10. With the slip-on seal 34 on the shank 50, the break-away pin 48 can be removed from the jig 46. The distal end 56 of the shank 50 is placed against a severed end 58 of the lead 10. The slip-on seal 34 can then be pushed onto the lead 10 using a push block 60, as shown in FIG. 4 and 5.
With the slip-on seal 34 on the implanted lead 10, the replacement connector 12 can be secured to the severed end 58 of the lead 10. The housing 22 which engages the severed end 58 will now be explained in connection with FIG. 6, 7, and 8. The lead portion 26 of the replacement connector 12 comprises a silicone sleeve 62 containing a trifilar coil conductor 64. A crimp slug 66 and a conductive body 68 make an electrical connection with the trifilar coil conductor 64 by mechanical pressure of a crimp 70. The conductive body 68 is in electrical communication with a conducting guide wire 72 which is spaced away from the longitudinal axis of the replacement connector 12, but parallel thereto. Affixed to the conducting portion 68 is a stationary housing 74 which is preferably formed of a relatively ridged plastic, such as high density polyacetate. The stationary housing 74 comprises a cylindrical chamber 76 which is coaxial with the conducting guide wire 72. The cylindrical chamber 76 has a diameter approximately equal to the outside diameter of the implanted lead 10 and is located adjacent the conducting part 68 and near the proximal end of the stationary housing 74. The distal end of the stationary housing 74 comprises a tube 78 which is concentric with the longitudinal axis of the replacement connector 12. A guide slot 80 in the tube 78 permits the housing 22 to be manipulated accurately, as will be more fully described below. A rotatable housing 82 rotatably engages the inner surface of the tube 78. The rotatable housing 82 has a coaxial bore 84 at a distal end of the rotatable housing 82. The coaxial bore 84 has an inside diameter similar to the outside diameter of the implanted lead 10. An inclined bore 86 joins with the proximal end of the coaxial bore 84 and can coincide with the cylindrical chamber 76. Wrench flats 88 at the distal end of the rotatable housing 82 permit the rotatable housing 82 to the rotated with the respect to the stationary housing 74. The elastomeric, preferably silicone, boot 24 surrounds the stationary housings 74 and the proximal end of the rotatable housing 82. A lip 90 at the distal end of the boot 24 engages a ring 92 on the rotatable housing 82 to hold the two housing 74, 82 together. A guide pin 94, attached to the rotatable housing 82 slides in the guide slot 80 and limits the rotation of the rotatable housing 82 with respect to the stationary housing 74.
When the replacement connector 12 is attached to a implanted lead 10, the conducting guide wire 72 is threaded into a trifilar coil 96 in the lead 10. The severed end 58 of the lead 10 is then pushed along the conducting guide wire 72, through the coaxial bore 84 and the inclined bore 86 into the cylindrical chamber 76. The rotatable housing 82 can then be rotated with a wrench 98 so that the lead 10 is pinched between the stationary housing 74 and rotating housing 82, as shown in FIG. 8. An electrical connection is formed by mechanical contact between the trifilar connector 96 and the conducting guide wire 72, particularly at the interface between the stationary housing 74 and the rotating housing 82. To indicate that rotation has been completed, a portion of the rotating housing 82 can be replaced by a colored plug 97. When rotation is complete the colored plug can be seen through a hole 99 in the stationary housing 74. The color of the plug 97 can be seen through the translucent silicone forming the boot 24. The wrench 98 can be removed from the wrench flats 88 on the rotatable housing 82 and slip on seal 34 can be pushed over the distal end of the rotating housing 82 and against the boot 24 to form a seal which resists the intrusion of body fluids into either the implanted lead 10 or the replacement connector 12.
In the preferred embodiment, a specialized wrench is provided having flats 100 for engaging the wrench flats 88 and ridged extensions 102 which can be manipulated by an attending physician wearing surgical gloves.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiment is therefore considered in all aspects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range equivalency of the claims are therefore intended to be embraced therein. | A replacement connector for implanted leads. The proximal end of the implanted lead is cut away and discarded. A slip-on seal is placed on the remaining end of the lead. The replacement connector is connected to the implanted lead using an eccentric locking mechanism both to secure the implanted lead and the replacement connector together and to achieve a positive electrical connection. A boot mates with the slip-on seal to protect the connection from body fluids. | 8 |
CROSS REFERENCES TO RELATED APPLICATIONS
This application claims priority from U.S. Provisional patent application Ser. No. 60/073,512 filed on Feb. 3, 1998.
FIELD OF THE INVENTION
The invention relates to transmission of information to and from downhole drilling equipment by a mud pulse telemetry system, and particularly to a mud pulse telemetry system for use in underbalanced drilling systems.
BACKGROUND OF THE INVENTION
In the process of drilling of wells into subsurface formations, it is common now to use "smart" motors at the end of the drillstring to adjust the rate and direction of drilling. Control of the motors is accomplished by means of signals from the surface. A number of known methods could be used for sending signals from the surface to a receiver at depth and vice-versa. This could be done by an acoustic signal carried by the mud or by the drillstring or it could be accomplished by an electromagnetic signal carried by the drillstring. These methods would be familiar to those versed in the art. However, these methods are difficult to use in continuing drilling operations because of the necessity of maintaining an adequate mud flow for drilling operations and of the noise associated with this and with the rotating drillstring. A common method of communicating the signals is by means of pressure pulses that alter the pressure of the drilling mud used in drilling operations. Prior art mud pulsing devices are generally classified in one of two categories. Either, the device generates positive pressure pulses or increases of pressure within the drill string over a defined basal level, or generates negative pressure pulses or decreases of the pressure for the drill string. U.S. Pat. No. 3,737,843, issued to Le Peuvedic, et al. is an example of a positive pulsing mud valve. A needle valve is mechanically coupled to a piston motor. The needle valve acts against a fixed seat. The piston motor in turn receives the continuous flow of control fluid. Information is transmitted to the surface in the form of rapid pressure variations ranging from 5 to 30 bars and succeeding one another at intervals of 1-30 seconds. Each pressure pulse is generated by reversing an electric current passing through a solenoid coil which is coupled to the needle valve.
Westlake, et al., (U.S. Pat. No. 4,780,620) shows a negative mud pulse system. A motor-driven valve is open in response to binary signals generated by a downhole sensor package. Upon opening the valve, portion of the mud flow is allowed to escape from the drill string to the annulus between the drill string and borehole.
Kotlyar (U.S. Pat. No. 4,703,461) discloses a device in which multistage mud pulsing is achieved by generating both positive and negative pulses within a drill string by means of a plurality of selectively operable bypass passages around a restriction to primary mud flow within a drill string or by venting to the outside of the drill string.
A major accompanying problem is that the signals get attenuated and dispersed as they propagate through the drilling mud. The attenuation and dispersion are unavoidable and are caused by various mechanisms, including viscous dissipation in the drilling mud as well as frictional energy loss at the borehole walls. The attenuation and dispersion of the signal becomes a particularly serious problem when underbalanced drilling mud is used to minimize reservoir damage. In normal drilling operations, or in drilling operations in geopressured formations where the risk of blowouts is high, the weight of the drilling mud is kept high enough so that the pressure of the mud exceeds hydrostatic pressure. In under-pressured reservoirs, use of heavy drilling mud could result in serious formation damage. Accordingly, drilling in such under-pressured reservoirs is carried out with underbalanced drilling muds that may contain nitrogen in the mud to reduce its density. The effect of the addition of nitrogen is to greatly increase the compressibility of the drilling mud: this reduces the bulk modulus and the velocity of propagation of the pulses in the drilling fluid. One result of an increased compressibility of the fluid is that a given pressure pulse at the source produces an increased flow pulse. In such a two-phase system consisting of a relatively incompressible liquid and a highly compressible gas, viscous dissipation greatly increases the attenuation and dispersion of mud pulse signals. For purposes of this application, any reference to a "compressible fluid" is intended to include a dissipative and attenuative fluid.
Another consequence of having a two-phase mixture of mud and a gas follows from the fact that the density and speed of propagation of sound in a gas (and a gas/liquid mixture) increases as the pressure is increased. When, as is typical in mud telemetry systems, the pressure pulses are comparable in magnitude to a "background"pressure, the trailing edge of a positive pulse may move faster than the leading edge. This greatly affects the shape of the pulse and complicates the process of pulse decoding.
SUMMARY OF THE INVENTION
The present invention is a method of and apparatus for improving the detectability of mud pulse telemetry signals in dissipative fluids (sometimes referred to as compressible fluids) used in underbalanced drilling by a modification to a conventional mud pulse telemetry method. The modification consists of measuring changes in the flow rate at the top of the wellbore instead of or in addition to changes in the pressure.
Another aspect of the invention relates to the location where the measurements are made. The surface equipment for a mud pulse telemetry system typically includes a pump and a pulsation dampener. Making measurements at the swivel or at the top of the Kelly, rather than immediately below the dampener, can give better results.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 illustrates a drilling arrangement using the present invention.
FIG. 2 shows the arrangement of the surface fluid system used in telemetry according to the present invention.
FIG. 2A shows a pulser according to the present invention
FIG. 3 shows a comparison between the received signal according to the present invention and a prior art pressure sensing arrangement.
FIG. 4 shows the effect of increasing the amount of nitrogen in the fluid on the received signals.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a schematic diagram of a drilling system 10 having a drilling assembly 90 shown conveyed in a borehole 26 for drilling the wellbore. The drilling system 10 includes a conventional derrick 11 erected on a floor 12 which supports a rotary table 14 that is rotated by a prime mover such as an electric motor (not shown) at a desired rotational speed. The drill string 20 includes a drill pipe 22 extending downward from the rotary table into the borehole 26. The drill bit 50 attached to the end of the drill string breaks up the geological formations when it is rotated to drill the borehole 26. The drill string 20 is coupled to a drawworks 30 via a Kelly joint 21, swivel, 28 and line 29 through a pulley 23. During drilling operations, the drawworks 30 is operated to control the weight on bit, which is an important parameter that affects the rate of penetration. The operation of the drawworks is well known in the art and is thus not described in detail herein.
During drilling operations, a suitable drilling fluid 31 from a mud pit (source) 32 is circulated under pressure through the drill string by a "compressible-fluid surface system" 34. The details of the compressible fluid surface system 34 are discussed below with reference to FIG. 2. The drilling fluid passes from the fluid surface system 34 into the drill string 20 via a fluid line 38 and Kelly joint 21. The drilling fluid 31 is discharged at the borehole bottom 51 through an opening in the drill bit 50. The drilling fluid 31 circulates uphole through the annular space 27 between the drill string 20 and the borehole 26 and returns to the mud pit 32 via a return line 35. A surface torque sensor S 2 and a sensor S 3 associated with the drill string 20 respectively provide information about the torque and rotational speed of the drill string. Additionally, a sensor (not shown) associated with line 29 is used to provide the hook load of the drill string 20.
In one embodiment of the invention, the drill bit 50 is rotated by only rotating the drill pipe 52. In another embodiment of the invention, a downhole motor 55 (mud motor) is disposed in the drilling assembly 90 to rotate the drill bit 50 and the drill pipe 22 is rotated usually to supplement the rotational power, if required, and to effect changes in the drilling direction.
In one embodiment of the invention shown in FIG. 1, the mud motor 55 is coupled to the drill bit 50 via a drive shaft (not shown) disposed in a bearing assembly 57. The mud motor rotates the drill bit 50 when the drilling fluid 31 passes through the mud motor 55 under pressure. The bearing assembly 57 supports the radial and axial forces of the drill bit. A stabilizer 58 coupled to the bearing assembly 57 acts as a centralizer for the lowermost portion of the mud motor assembly.
In one embodiment of the invention, a drilling sensor module 59 is placed near the drill bit 50. The drilling sensor module contains sensors, circuitry and processing software and algorithms relating to the dynamic drilling parameters. Such parameters preferably include bit bounce, stick-slip of the drilling assembly, rotation, torque, shocks, borehole and annulus pressure, acceleration measurements and other measurements of the drill bit condition. The drilling sensor module processes the sensor information and encodes it into a pattern of pulses. These pulses could be positive pressure pulses, negative pressure pulses, or a combination of positive and negative pressure pulses. This pattern of pulses is transmitted to the surface control unit 40 using a telemetry pulser 72.
Those versed in the art would recognize that instead of a drillstring, as discussed above, drilling operations could also be carried out by a mud motor conveyed at the end of a coiled tubing, the mud motor driving a drill bit at the end of its drive shaft, with the operation of the mud motor being carried out by means of drilling fluid carried by the coiled tubing. The present invention includes such a system.
FIG. 2 shows the compressible fluid surface system used in telemetry. The compressible fluid surface system 34 includes a mud pump 92, a nitrogen generator 96 that acts as a source of gas, and an injection control device 98 that combines the nitrogen and the mud from the mud pit coming via the line 38'. Nitrogen is preferably used as a gas for reducing the density of the fluid in the borehole because it is relatively inert and readily available. The dual phase fluid coming out of the injection control device 98 is pumped via line 38" to the kelly joint 21. The fluid surface system 34 also includes a pulsation dampener 94, a venturi flow meter 100, a differential pressure transducer 102, a signal conditioner 104 and a conventional control and recording system 106.
The orifice flow meter 100 measures changes in the rate of flow of the mud through the line 38. Those versed in the art would recognize that pulses produced downhole by the pulser 72 would produce pressure changes in the line. Associated with these pressure changes are changes in the rate of flow of the two phase fluid in the line 38. In a conventional fluid surface system (not shown) used with incompressible, nondissipative fluids, a pressure transducer would be used at this point to detect the pressure pulses. These pressure pulses would then be sent to the surface system 106. In contrast, in the present invention, as noted above, a fluid flow meter is used. In order to be able to use this with the conventional surface system 106, the signal from the flow meter 100 is converted into a pressure signal by the differential pressure sensor 102 and suitably scaled by the signal conditioner 104 so that the resulting signal to the surface system 106 is comparable to the signal from a pressure sensing device in the line.
The embodiment of the invention described above uses an orifice flow meter. Other types of flow meters would be known to those versed in the art and could be used instead of an orifice flow meter. These types of flow meters include sonic, electromagnetic, turbine, venturi, temperature and coriolis flow meters. While these different types of flow meters are not specifically described here, any of these different types of flow meters could be used in the present invention without detracting from its effectiveness, and are intended to be within the scope of the present invention.
The coding of the pressure pulses corresponding to conditions of the measurement-while-drilling system and the decoding of the received signal would be familiar to those versed in the art and are not discussed here.
The pulsation dampener 94 is a gas-charged accumulator. The effect of the dampener on the detected signals is complicated due to the manner of operation of the dampeners. Its function is to absorb pressure surges generated by the mud pump 92. However, it is incapable of distinguishing between pressure surges from the mud pump and pressure pulses generated by the downhole pulser 72. When a positive pressure pulse arrives, the gas volume in the dampener 94 is reduced. This has the effect of taking up some of the fluid from the pump and reducing the flow rate proceeding downhole. The reduction in flow rate proceeding downhole is equivalent to a positive pressure pulse, so that the pulsation dampener tends to enhance the pulse as seen in the flow domain. On the other hand, a constant-flow pump acts as a "reflector" that enhances pressure pulses while diminishing velocity pulses. The surface geometry can therefore have a strong influence on the pulse shape. In the preferred embodiment of the invention, the monitoring of the pressure and flow is done near the kelly joint.
U.S. Pat. No. 4,742,498, issued to Barron, discloses a pilot operated mud pulse valve in which operation of a pilot valve causes a piston to move, causing a main valve to close and thereby create a pressure pulse. This patent, now expired, is incorporated in full by reference. The device in the patent forms the basis of the pulser used in one embodiment of the present invention.
FIG. 2A illustrates the operation of a pilot operated mud pulse valve. The upper figure shows the configuration in the standby mode, the middle figure shows the pilot valve in the closed position and the bottom figure shows the main valve in the closed position. The actuator body 101 is connected to the fluid line (not shown). The main valve stem 109 is attached to the main valve base 107 and operates to close an opening in the main valve housing 110. A screen 115 is provided in the main valve. Also shown in the figure are the main valve fishing head 113 and the pilot valve housing 105. In typical arrangements, the pilot valve opening is 0.01 in 2 .
Still referring to FIG. 2A, in the standby mode (upper figure), the pilot valve 103 and the main valve 109 are open. There are three components to the fluid flow: the bypass flow path, indicated by 111, the main valve flow path 112 and the pilot valve flow path 114 The main valve flow path allows fluid to enter the main valve on inlet ports (not shown) on the main valve fishing head 113, pass between the main valve stem 109 and the main valve bypass housing 110, and exit the bypass housing just above the main valve base 107. The inlet ports on the main valve fishing head 113 are at the same high pressure as the uphole side of the restrictor. The exit ports on the bypass housing 110 are at the same low pressure as the downhole side of the restrictor block. The pilot valve flow path 114 allow drilling fluid to pass through the main inlet valve screen 115, through the inside of the main valve stem 109 and the main valve base 107 and then exit into the area between the outside of the probe and the inside collar wall through exit ports (not shown) on the poppet valve housing 105. The pressure at the main inlet valve screen is the same as the high pressure in the fluid above the restrictor block. The pressure at the exit ports of the poppet valve housing 105 are at low pressure and the pressure drop is graduated from the inlet screen to the exit ports.
Movement of the pilot valve to the closed position, 103' results in the configuration shown in the middle figure, where the pilot valve fluid path 114 is absent. When the pilot valve 103 closes completely, fluid is no longer allowed to leave the exit ports of the poppet valve housing 105. The fluid directly behind the main valve base 107 increase to the inlet screen pressure which is a higher pressure than the fluid directly above the main valve base 107. This moves the main valve base forward until the main valve base comes in contact with the main valve seat.
Movement of the main valve to the closed position 109' results in the configuration shown in the bottom figure, with the main valve flow path 112 also absent. Once the main valve base stops the fluid flow, a positive pressure is created that travels inside the drillpipe.
When used with highly compressible and dissipative fluids, the hydraulically assisted main valve becomes inoperable. In the present invention, the pulser is modified so that the main valve remains closed at all times and the area of the pilot valve is increased from 0.01 in 2 to 0.1 in 2 . The result is that the pilot valve becomes a direct drive pulser with adequate signal strength for compressible fluid operations.
Other types of pulsers can also be used in the invention. The device described above with reference to FIG. 2A produces positive pressure pulses by blocking a passage for the flow of fluid. Those versed in the art would recognize that other types of pulsers could also be used. For example, there are pulsers that produce negative pulses by opening up a passage for the flow of fluid. This type of pulser would produce a negative pressure pulse. Other pulsers open up a valve allowing downgoing fluid under pressure to drain directly into the returning fluid: this also creates a negative pulse. A pulser that produces both positive and negative pulses would rely on both types of operations, i.e., constricting a passage for the flow of fluid as well as opening up a passage for the flow of fluid. Pulsers of these different types and the pressure pulses produced by these different types of pulsers are intended to be within the scope of the present invention.
Those versed in the art would recognize that underbalanced drilling could also be carried out with dual-phase systems that have different components than mud and gas. For example, light-weight beads could be incorporated into the drilling mud. Yet another situation of underbalanced drilling would be drilling with just a gas, as is done in air drilling. Propagation of pressure pulses through such dual-phase systems or through a gas has characteristics similar to those discussed above with respect to the dual-phase system consisting of mud and gas, and the present invention is intended to include such systems.
FIG. 3 shows data gathered using the present invention in a well. The signal from the flow transducer 201 may be compared with the signal 203 from the pressure transducer. Indicated on the figure are timing marks that are one second apart. These data were recorded with the borehole fluid being water, essentially incompressible. For such an essentially incompressible fluid, there is no visual difference between the detectability of the signal from either sensor, i.e., a pulse telemetry system would not have problems decoding either set of signals. Visually, the signal from the flow sensor appears to be of higher frequency than the signal from the pressure sensor. In addition, comparison of the pair of pulses 205, 206 on the flow sensor with the corresponding pulses 205' and 206' shows that the signals from the flow sensor arrive ahead of the signals from the pressure sensor. However, this same relationship is not observed at later places in the wavetrains, so that the flow sensor signal is not simply the time derivative of the pressure signal. The actual wavetrains are complicated by reflections from the pump and the pulsation dampener.
FIG. 4 shows similar comparisons of signals from the flow sensor and the pressure sensor as the fluid composition is changed and nitrogen is added to the fluid using the injection control device 98. Curves 211 and 211' are measurements from the flow sensing transducer and the pressure transducer respectively when the borehole fluid has no nitrogen in it. The signals 213 and 213' are measurements from the flow sensing transducer and the pressure transducer respectively when the borehole fluid has 4% nitrogen added to it. Addition of nitrogen has the effect of increasing the compressibility of the borehole fluid and of increasing dissipation losses in the fluid. As can be seen, there is some deterioration in the quality of the signals from the two sensors with more degradation of the pressure transducer signal. In particular, in the zone indicated by 214, it is hard to identify the times of the individual pulses and the signal to noise ratio is much poorer.
The curves 215 and 215' are for 7% nitrogen in the fluid. The individual pulses in the fluid flow sensor are readily identifiable while their inception times are essentially undetectable with the pressure sensor. Finally, when the amount of nitrogen is increased to 18%, the fluid flow sensor signal 217 has an adequate signal to noise ratio while the signal 217' from pressure sensor shows no detectable signal.
The foregoing description has been limited to specific embodiments of this invention. It will be apparent, however, that variations and modifications may be made to the disclosed embodiments, with the attainment of some or all of the advantages of the invention. Therefore, it is the object of the appended claims to cover all such variations and modifications as come within the true spirit and scope of the invention | A mud pulse telemetry system uses a downhole pulser to produce sequences of positive and/or negative pulses according to a selected pattern. Positive pulses, negative pulses, and combinations thereof may be produced. A flow rate sensor at the surface measures changes in the flow rate at the top of the wellbore instead of or in addition to changes in the pressure. The flow rate changes are detectable even though the pressure pulses themselves may have a poor signal to noise ratio. This enables the invention to function effectively in underbalanced drilling wherein the use of light muds with a high gas content is required. One embodiment of the invention uses a conventional downhole pulser with the main valve closed and the pilot valve operating in a direct pulse mode. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to circuits that electrically compensate for temperature changes, and, more specifically, to circuits that compensate for signal errors induced by temperature changes when a circuit including GaAs elements is interfaced with a circuit containing Silicon-based elements.
2. Description of the Related Art
The majority of electronic systems in production and use today are made using Silicon technology. A systems designer who wants to produce the fastest circuit possible using Silicon-based components would likely use emitter-coupled logic circuitry (ECL), which also provides the advantage of low power consumption.
Faster technologies exist, however, including the popular III-V technology using the likes of Gallium Arsenide (GaAs). GaAs circuits and components, however, suffer from fragility during manufacture, and, thus, are relatively expensive Until GaAs chips are available at lower cost, they will be short in both supply and variety. A designer, therefore, must integrate GaAs technology into ECL circuitry to achieve the highest-speed circuits until GaAs chips are more plentiful.
A problem exists, however, when interfacing the two technologies. Silicon chips behave differently than do GaAs chips when both are operated in the same temperature-varying environment. Since electronic circuits inherently produce heat, the difference in electrical behavior between Silicon chips and GaAs chips in the same circuit due to temperature effects must be compensated. The present invention is designed to obviate the problem.
SUMMARY OF THE INVENTION
The present invention incorporates a temperature-compensating network into a GaAs output buffer interfaced to Silicon-based circuitry to regulate the output voltage and current of the buffer under changing temperature conditions. The buffer includes a differential amplifier stage, an output stage, and the temperature-compensating network that responds with temperature to vary the current and voltage on the output of the differential amplifier stage so that the differing temperature characteristics of GaAs with respect to silicon is properly compensated.
The entire buffer, including the differential amplifier stage, the output stage, and the temperature-compensating network, is designed using metal-semiconductor field-effect transistors (MESFETs) as the control and switching elements. The temperature-compensating network includes a differential amplifier and two voltage dividers whose node voltages vary differently with temperature. The output of the temperature-compensating network differential amplifier controls the gate of a "bleeder" MESFET, which channel is connected to the line connecting the buffer differential amplifier to the output stage. As temperature rises, the bleeder FET shunts less current away from the buffer differential amplifier output line so that a higher output buffer voltage results, in accordance with interface requirements of Silicon ECL technology.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows an electrical circuit designed in accordance with the teachings of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows in detail a preferred embodiment of the present temperature-compensated GaAs output buffer. Output buffer 4 includes differential amplifier stage 6 and output stage 8, the transistors of which are all preferably GaAs MESFETs. The high speed of GaAs components makes them desirable for use in a variety of systems. GaAs circuits, however, respond to variations in temperature differently than do circuits fabricated using Silicon technology. Since GaAs is very expensive at present, and very fragile during chip or wafer manufacture, circuits using GaAs chips are used sparingly. Where used, they must be interfaced with surrounding circuitry so that the effects of temperature variations are reflected uniformly throughout the circuit.
For this reason, the present invention includes temperature-compensating network 10, which operates in conjunction with MESFET T 6 to regulate the voltage appearing on buffer differential amplifier output line 14 in response to variations in temperature.
In preferred form, output buffer 4 interfaces with a following Silicon-based circuit stage 2. Differential amplifier 6 comprises MESFETs T 1 and T 2 , whose drains are connected to power supply V H via resistors R 1 and R 2 , respectively. The sources of T 1 and T 2 are connected in common to power supply V L via MESFET T 3 , which has its gate tied to its source in a known constant-current configuration. The output of stage 2 controls the gate of T 1 , while the gate of T 2 is tied to a reference voltage on the order of -2.6 V.
The output of differential amplifier 6 appears at node 14, and is a function of the difference in gate voltages between T 1 and T 2 . Node 14 controls the gate of MESFET T 4 , of output stage 8. The drain of T 4 is connected to V H MESFET T 5 has its gate tied to its source between the source of T 4 and V L .
Temperature-compensating network 10 comprises differential amplifier 16, voltage dividers 18 and 20, and "bleeder" MESFET T 6 . Differential amplifier 16 includes MESFETs T 7 and T 8 , whose drains are tied to V H via resistors R 3 and R 4 . The sources of T 7 and T 8 are tied in common to V L via MESFET T 9 , which has a constant-current configuration similar to T 3 .
Voltage divider 18 comprises resistor R 5 in series with three series Schottky diodes D 1 , D 2 and D 3 . Three diodes are preferable by design, although the circuit will operate substantially as designed using fewer or more diodes. Moreover, diodes other than Schottky diodes may perform similarly, but Schottky diodes are preferred for their speed and for their simplicity of manufacture. Node 22 controls the gate of T 7 . Similarly, reference voltage divider network 20 comprises resistors R 6 and R 7 , with node 24 tied to the gate of T 8 . The terminals of resistors R 5 and R 6 that do not comprise nodes 22 and 24, respectively, are tied to V H .
The output of network 10 is taken from node 26, and controls the gate of bleeder FET T 6 . As temperature increases, the voltages at nodes 22 and 24 differ due to the differing temperature coefficients of the diode network and the resistors. Increased temperature causes decreased voltage at node 22 with respect to node 24, since the series resistance of diodes D 1 , D 2 and D 3 decreases with increasing temperature. The ratio of resistances R 5 /R D , where R D is the series resistance of the Schottky diodes, increases in comparison to the ratio R 6 /R 7 . Consequently, the voltage differential between the gates of T 7 and T 8 changes in favor of T 8 , resulting in a decrease in voltage at node 26 (more negative).
The decreasing voltage on node 26 increases the resistivity in the channel of bleeder FET T 6 , which results in decreased conductivity of the channel. As the channel conductivity decreases, the portion of the current drawn from line 14 also decreases. The current drawn through R 2 likewise decreases, resulting in a smaller voltage drop across R 2 , and thus a higher voltage on line 14. Network 10 thus operates to vary the voltage and current on line 14 to make the GaAs buffer compatible with the ECL Silicon circuit.
In the circuit just described, V H and V L are set at levels consistent with conventional ECL technology. For example, V H may be set to OV, and V L to -5.2V. Resistors may comprise resistive regions in the monolithic circuit or may be constructed using FETS having gates tied to sources. The various MESFET pairs are preferably matched for balanced differential pair operation.
The output swings for V OH and V OL vary with temperature, of course, and for ECL 10,000 family, V OH preferably ranges from -930 mv to -1080 mV at -55.C ° C.; from -810 m V to -960 mV at 25° C.; and from -660 mV to -810 mV at 125° C. V OL preferably ranges from -1770 mV to -1970 mV at -55° C.; from -1650 mV to -1850 mV at 25° C.; and from -1575 mV to -1775 mV at 125° C. The temperature coefficient of V OH is thus about 1.5 mV/° C.; for V OL is about 0.75 mV/° C.
The use of MESFETs instead of conventional JFETs, depletion-mode MOSFETs or other suitable devices is a design choice made in light of the speed advantages achieved by MESFETs. The higher carrier mobilities and carrier saturation velocities of III-V semiconductors such as GaAs or InP in MESFETs give these advantages, making MESFETs especially useful in high-speed digital or microwave applications. Furthermore, GaAs chips can be operated at higher temperatures, and thus higher power levels, than can Silicon chips, and, since no diffusions are necessary (although possible) in MESFETs, close geometrical tolerances may be achieved and the MESFETs made very small. This is especially important at high frequencies, where drift time and stray capacitances must be kept to a minimum.
Various modifications to the invention described above will become apparent to those skilled in the art. All such modifications that basically rely on the teachings through which the invention has advanced the art are properly considered within the spirit and scope of the invention. | A temperature-compensated output buffer is disclosed that incorporates a temperature-compensating network into a GaAs output buffer that has been interfaced to Silicon-based circuitry to regulate the output voltage of the buffer under changing temperature conditions. The temperature-compensating network includes a differential amplifier whose output varies with temperature due to a network of series-connected Schottky diodes. The output of the differential amplifier controls a bleeder MESFET that controls the output voltage of the buffer so that temperature variations do not adversely affect the buffer output. | 7 |
BACKGROUND OF THE INVENTION
[0001] A. Field of the Invention
[0002] This invention relates to a foil composite material, to a method for manufacturing the foil composite material, as well as to a card body, in particular a card body for a portable data carrier, which contains the foil composite material, and to a method for manufacturing the card body.
[0003] B. Related Art
[0004] In the production of card bodies, in particular for portable data carriers, such as e.g. chip cards, several plastic foils lying one over the other are laminated to each other. As plastic foils there are usually employed thermoplastic foils because of their good laminatability, e.g. foils made of polyvinyl chloride, polycarbonate, polypropylene, polyethylene terephthalate or thermoplastic polyurethanes. A disadvantage of card bodies made of such thermoplastic foils is their deficient mechanical properties with regard to bending stress and the action of impact force. There result stresses in the card body, and finally cracks. The installation of electronic modules also usually leads to stresses, a weakening of the card body, and ultimately to an elevated susceptibility to cracks and breaks.
[0005] To improve the mechanical properties of such card bodies it is advantageous to employ foils made of thermoplastic elastomer, for example based on urethane, within the framework of the laminating process. These foils are exceptionally elastic and can considerably improve the bending strength and breaking strength of the card construction. In the print EP 0 430 282 A2 there is described a card body in the form of a multilayer identification card wherein a layer of thermoplastic elastomer is respectively provided between the card core and corresponding cover foils.
[0006] However, it is very difficult to process foils made of thermoplastic elastomer, so-called TPE foils, within the framework of a laminating process upon the manufacture of a card body. On account of their high elasticity the foils are very “limp”. The lack of stiffness leads to problems upon processing in the production machines, and the low dimensional stability can also cause register problems upon printing of the foils. In addition, the material tends to flow out upon laminating. Further, such foils possess a low glass transition range, which lies under 0° C., whereby it remains flexible and does not become brittle in this temperature range. Furthermore, the foils tend to block upon stacking on account of their smooth surfaces, so that the foils in a stack are hard to single and transport. To obtain a sufficient connection stiffness upon lamination of such foils to other materials such as polycarbonate, polyethylene terephthalate, polyethylene terephthalate copolyesters or blends of polyesters and polycarbonate, it is moreover necessary to reach the glass point of the respective other material. Because this glass point regularly lies far above the glass transition range of thermoplastic elastomers, this frequently leads to the thermoplastic elastomer floating off, in connection with the dependence on the strength of the viscosity drop in the corresponding temperature range. This has the consequence that the employed laminating machines must often be cleaned. In some cases the foils adjacent to the thermoplastic elastomer can even likewise start to flow, and deform a printed image located thereon. Although it is possible to laminate at lower temperatures to thereby prevent the foils from floating off, an insufficiently good laminate bond is normally obtained upon laminating at low temperatures.
[0007] These problems already occur when employing the foil thicknesses of 100 μm to 300 μm that are usual in the manufacture of data carriers. To appreciably protect a data carrier against the risk of breakage, however, it is usually already sufficient to incorporate into the construction on both sides, as far outwardly as possible, layers made of thermoplastic elastomer that are only approximately 30 μm to 50 μm thick. However, these thicknesses are difficult to handle in conventional processing operations. Even very stiff foils such as polycarbonate foils can no longer be processed at layer thicknesses of 50 μm or therebelow.
[0008] Hence, it is desirable to combine the positive properties of relatively stiff thermoplastic foils and of foils made of thermoplastic elastomer in a single foil material. A solution approach in this direction is disclosed in the document EP 0 384 252 B 1. The therein described foil composite material has a multiplicity of layers, whereby a middle layer is made of thermoplastic elastomer. This layer is adjoined by layers made of thermoplastic plastics. Upon the manufacture of the composite there are applied to a foil forming the middle layer the further layers. One application method is simultaneous extrusion.
SUMMARY OF THE INVENTION
[0009] An object of the present invention is to provide a highly flexible foil material that is suitable for use as a layer in a card body. In particular, the foil material should be readily processable within the framework of producing a card body, and guarantee good mechanical properties of the card body. Desired properties of such a foil material are
high flexibility in order to guarantee the desired bending strength, in particular dynamic bending strength, of the card; the capability to avoid stresses, cracks and breaks in the card, in particular also upon installation of electronic modules into the card; good laminatability to common card materials, in particular thermoplastic foils, preferably without auxiliary layers; good printability, preferably without pretreatment for printing; good dimensional stability upon manufacture and processing; simple, and preferably inexpensive, manufacturability; good handling upon further processing, in particular avoidance of blocking, and unproblematic integratability into the conventional process of data-carrier manufacture.
[0018] Another object of the present invention is to provide a card body, in particular a card body for a portable data carrier, that avoids the disadvantages of the prior art. In particular, the card body should readily tolerate the installation of electronic modules and have good resistance to stress cracks and breaks, for example upon bending stress and the action of impact force.
[0019] According to the invention there is provided a foil composite material having at least three, preferably five, and optionally more than five, layers, i.e. at least one inner layer and one first and one second outer layer which cover the inner layer on both its surfaces. The layers respectively consist of a plastic material, i.e. of plastic that is optionally mixed with usual additives. The plastic of the first and the second outside layer is respectively a thermoplastic polymer or a mixture of thermoplastic polymers. The plastic of the at least one inner layer is a mixture of at least one thermoplastic elastomer and at least one thermoplastic polymer. Such a foil composite material combines the advantageous elasticity properties of the elastomer with the advantageous properties of the thermoplastic, for example with regard to laminatability and handling. The manufacture of such a composite material raises technical problems, because the usable materials must be carefully coordinated with each other to achieve the desired foil properties. An important role is also played by the choice of the respective layer thicknesses, of the suitable process parameters and extruder configurations, and the suitable composition of the formulations.
[0020] The inner plastic layer of the foil composite material preferably consists of more than one layer, particularly preferably of three partial layers, an interior inner plastic layer and two exterior inner plastic layers. The reason for this construction comprising several partial layers is primarily that the optimal extrusion temperatures and melt viscosities of thermoplastics and thermoplastic elastomers are relatively far apart. Hence, an extrusion of a foil composite material having an inner layer made of at least one thermoplastic elastomer and outer layers made of at least one thermoplastic is technically very difficult and typically fails to yield good and reproducible foil qualities. According to the invention, the melt viscosities and extrusion temperatures of the materials forming the individual layers are gradationally approximated to each other by compoundings. This makes it possible for extruders that extrude the respective neighboring layers of the foil composite material being manufactured to be operated with similar or gradationally approximated process parameters, which in turn results in a better, more homogeneous superimposition of the melt layers and an improved mutual adhesive strength of the layers.
[0021] The two outer plastic layers can be identical or different. Typically, the outer plastic layers of the foil composite material consist of the same materials and have the same thickness, i.e. the foil composite material is symmetrical with regard to its outer layers. This is not necessary, however, i.e. the outer layers can differ with regard to their plastics, as well as with regard to their thicknesses, as well as with regard to any additives.
[0022] The inner plastic layer consists of a mixture of at least one thermoplastic elastomer and at least one thermoplastic, whereby, in order to achieve a suitable gradation of the properties of neighboring layers, the thermoplastic is preferably the same thermoplastic that was used in the neighboring outer layer. At least in the case of only a single inner plastic layer it is hence very advantageous to respectively use the same thermoplastic material for both outer plastic layers.
[0023] When the inner plastic layer of the foil composite material is constructed from several partial layers, each of the partial layers respectively contains a mixture of at least one thermoplastic elastomer and at least one thermoplastic, whereby the proportion of the thermoplastic elastomer is higher, the further inward in the foil composite material the respective partial layer lies. For the purposes of achieving good foil qualities and a good mutual adhesive strength of the layers it is preferred to use the same thermoplastic elastomer or mixture of thermoplastic elastomers for all partial layers of the inner layer. It is equally preferred to use the same thermoplastic polymer or mixture of thermoplastic polymers for all partial layers of the inner layer. If the first outer plastic layer and the second outer plastic layer contain different thermoplastic polymers, it is preferred to perform a stepwise approximation of the composition inwardly. For a foil composite material having an inner layer made of three partial layers, this would mean that the first exterior inner plastic layer preferably contains the same thermoplastic as the first outer plastic layer, and the second exterior inner plastic layer preferably contains the same thermoplastic as the second outer plastic layer. The interior inner plastic layer would then preferably contain the thermoplastic of the first outer plastic layer as well as the thermoplastic of the second outer plastic layer.
[0024] Although the partial layers of an inner plastic layer preferably have the same types of thermoplastic elastomer and thermoplastic, they can readily differ with regard to their thicknesses and their accessory agents. In an inner layer comprising three partial layers, the innermost layer is preferably the thickest partial layer. Typically, the foil composite material is symmetrical with regard to its inner layers. Such materials can be manufactured most easily.
[0025] The thermoplastic elastomers and thermoplastics must be compatible with each other and readily intermiscible. Moreover, their extrusion temperatures and melt viscosities should be as similar as possible. As a plastic for the outer layers it is preferred to use polyester (preferably PETG), polycarbonate or blends of polyester and polycarbonate. As a thermoplastic elastomer for the inner layer or inner layers, thermoplastic urethane elastomers, in particular thermoplastic urethane elastomers based on aromatic esters or ethers, are preferred. Although aliphatic thermoplastic elastomers based on urethane have the advantage of being UV-stable, they can hardly be processed by coextrusion with the preferred thermoplastics. Reproducible foil qualities can only be obtained with difficulty. Although the aromatic types have the disadvantage of low UV stability, this disadvantage can easily be remedied by the addition of UV stabilizers, as are commercially available. For gradational approximation of the properties, each inner layer has an admixture of a thermoplastic, preferably of the thermoplastic of the bordering outer layer.
[0026] There are thermoplastic elastomers with different Shore D hardnesses, whereby the respective hardness should be coordinated with the thermoplastic of the bordering or nearest outer layer. When the thermoplastics are polyesters, there is preferably used as a thermoplastic elastomer a thermoplastic elastomer with a Shore D hardness of 35 to 50, and when the thermoplastic is a polycarbonate, there is preferably used as an elastomer an elastomer with a Shore D hardness in the range of 40 to 70, in particular between 50 and 65. Further, the thermoplastic elastomers should have as many as possible of the following properties: they should have an elongation at break between 300% and 700%, in particular between 350% and 500%; they should possess a melt viscosity in dependence on the melt temperature, and preferably have an MFI of 7 to 11 cm 3 /10 min; their processing temperatures should lie between 190° C. and 240° C., in particular between 210° C. and 240° C.; they should be resistant to hydrolysis; they should possess an affinity for the thermoplastics used for the outer layers, in particular for polyesters and/or polycarbonates.
[0027] The foil composite material according to the invention can be manufactured in transparent, colored or colorless, and opaque embodiments. Opaque embodiments contain besides the plastic components, and optionally other additives, fillers such as for example titanium dioxide (white) and carbon black (black). Colored pigments such as various metal oxides can also be contained. For example, opaque embodiments contain TiO2BaSO4 as a filler as a white pigment. In particular in stretched foils, the opacity can also be produced by voids.
[0028] When the foil composite material is used as an outer layer of a card body, it is preferably transparent. Preferred plastic compositions (without consideration of additives) for a five-layered transparent foil composite material are respectively 0% thermoplastic elastomer and 100% thermoplastic for the first and the second outer layer, respectively 20% to 50% thermoplastic elastomer and 80% to 50% thermoplastic for the first and the second exterior inner layer, and 30% to 70%, preferably 50% to 70%, thermoplastic elastomer and 70% to 30%, preferably 50% to 30%, thermoplastic for the interior inner layer.
[0029] When the foil composite material according to the invention is used in the interior of a card construction, it is preferably opaque. Preferred compositions (with consideration of plastics and fillers) for a five-layered opaque foil composite material are: respectively 0% elastomer, 85% to 95% thermoplastic and 5% to 15% filler for the first and the second outer layer; respectively 20% to 50% elastomer, 75% to 35% thermoplastic and 5% to 15% filler for the first and the second exterior inner layer, and 50% to 70% thermoplastic elastomer, 45% to 15% thermoplastic and 5% to 15% filler for the interior inner layer.
[0030] These figures are in percent by weight, no consideration being taken of any additives such as UV stabilizers, dyes, laser additives, etc.
[0031] The foil composite material according to the invention can also have more than three partial layers made of elastomer/thermoplastic mixtures. Independently of the exact composition and the kind of thermoplastics and elastomers used, it is always essential that the content of thermoplastic elastomer in an interior partial layer is at least as high as, and preferably higher than, the content of thermoplastic elastomer in the bordering exterior partial layer.
[0032] Besides the plastics themselves, the materials for the individual layers can contain common additives, for example the above-mentioned fillers and UV stabilizers, or also color pigments, flame retardants, optical brighteners, oxidation stabilizers and laser additives. The admixture of auxiliary agents is preferably kept low so as to interfere with the mutual coordination of the plastic materials as little as possible. The respective outer layers of the foil composite material can also contain an admixture of antiblocking agents.
[0033] The total thickness of the foil composite material according to the invention typically lies between 50 μm and 350 μm, whereby the thickness varies, depending on the place in the layer sequence of a card body where the foil composite material is to be provided. When the foil composite material is used as an interior layer, i.e. as a part of the core layer construction, total layer thicknesses in the range of about 150 μm to 350 μm, for example 240 μm, are preferred. When the foil composite material is used as a cover layer, total layer thicknesses in the range of about 80 μm to 130 μm, for example 105 μm, are preferred. Referring to the total layer thickness as 100%, about 10% to 30% respectively falls on the first and the second outer plastic layer here, and accordingly about 80% to 40% on the inner plastic layer. A particularly preferred layer thickness distribution is, with a deviation of respectively about ±3%, 10% respectively for the first and the second outer plastic layer, 20% respectively for the first and the second exterior inner plastic layer, and 40% for the interior inner plastic layer.
[0034] The manufacture of the foil composite material according to the invention is effected by coextrusion. In so doing, the plastic materials provided for the individual layers of the foil composite material according to the invention are respectively melted in suitable extruders, optionally with the admixture of the corresponding additives, and the melt is supplied to a feedblock or a wide slot nozzle. The foil materials are so merged in the feedblock or wide slot nozzle prior to discharge that the layer sequence of the hereinabove described foil composite material arises. Upon manufacture, attention should be paid in particular to the following:
[0035] The thermoplastic elastomers, in particular the preferred thermoplastic elastomers based on urethane, are hygroscopic. Hence, the elastomers must be predried well prior to processing, i.e. the residual moisture should be less than 0.05%, because otherwise a degradation through hydrolysis can occur during the processing operation in the extruder.
[0036] The thermoplastic elastomers are thermally degraded at elevated temperatures. Hence, their residence time in the extruders must be kept as short as possible, i.e. a continuous feed of the melt without interruption be ensured.
[0037] The foil composite materials must contain a minimum total amount of thermoplastic elastomer in order for the foil to possess a sufficient elasticity to be able to compensate the occurring stresses and mechanical loads in the structure of a card body later. Typically, about 40% thermoplastic elastomer is required, but the value can be lower or higher depending on the card construction and the thermoplastic elastomer. It is necessary to provide extruder configurations that are able to feed the corresponding layer thicknesses continuously. Normally, it is advantageous to make the layer thicknesses of the layers with thermoplastic elastomer as large as possible, and to make the proportion of thermoplastic elastomer in the respective layers likewise as large as possible.
[0038] Thermoplastics and thermoplastic elastomers (in particular the preferred thermoplastic polyesters and thermoplastic elastomers based on urethane) have optimal extrusion temperatures and melt viscosities that are relatively far apart. Hence, the formulations must be so adjusted that the extrusion temperatures and the melt viscosities of neighboring layers are approximated by the compoundings of thermoplastics and thermoplastic elastomers, so that a homogeneous superimposition of the melt layers is guaranteed. Exemplary formulations were already stated hereinabove. Exemplary processing parameters are stated for FIG. 1 .
[0039] For a five-layered foil composite material, the extrusion (temperature of the extrusion nozzle or the melt temperatures of the individual molten streams) of the first and the second outer plastic layer is preferably effected at 200 to 280° C., particularly preferably at 210 to 260° C., the extrusion of the first and the second exterior inner plastic layer preferably at a temperature of 200 to 270° C., particularly preferably at 210 to 260° C., and the extrusion of the interior inner plastic layer preferably at 190 to 270° C., particularly preferably at 220 to 250° C.
[0040] In the foil composite material according to the invention, excellent bond values of the layers with each other are obtained, i.e. the mutual adhesive strength of the layers typically amounts to at least 30 N/cm.
[0041] The foil composite material according to the invention is in particular suitable for being used as a layer in the layer construction of a card body in order to improve the mechanical properties of the card body.
[0042] Card bodies, in particular card bodies for chip cards and other data carriers, typically consist of a multiplicity of layers which are interconnected by laminating. The individual layers usually consist of thermoplastic polymeric materials, such as polyvinyl chloride, polycarbonate or polyethylene terephthalate. Between the layers or in recesses of the layers there can be located electronic components and imprinted antennas. As at least one of the layers of the card body here there is used a foil composite material according to the invention. In particular, the foil composite material according to the invention is used as one or as both cover layers (overlay foil) of the card body. Alternatively or additionally, the foil composite material according to the invention can be provided within the card construction (inlay foil), i.e. form a core layer.
[0043] For manufacturing the card body, the plastic foils that are to form the later card body are laminated to each other. Laminating can be effected in a single operation, i.e. all foil materials that are to form the card body are stacked and laminated in one operation. Alternatively, laminating can be carried out in two or more operations, that is, only a portion of the foils is respectively laminated jointly into a partial stack, and the partial stacks are then stacked and laminated into the card body in a further operation later. A good laminate bond is obtained here by laminating at a temperature between 120° C. and 200° C., in particular between 130° C. and 180° C., preferably between 140° C. and 160° C.
[0044] Preferably, laminating is carried out in a heating station and a cooling station, whereby the pressure in the heating station and the pressure in the cooling station are chosen suitably. The laminating time preferably lies respectively between 10 minutes and 25 minutes in the heating and/or cooling station.
[0045] The card bodies according to the invention typically have total thicknesses in the range of about 0.5 to 1.0 mm. The total thickness of the foil composite material according to the invention normally lies between 80 μm and 350 82 m, depending on the place in the layered composite of the card body where the foil composite material is to be used. Inlay foils are usually thicker than overlay foils, whereby the total thickness for inlay foils typically lies in the range of 150 μm to 350 μm, and the total thickness for overlay foils typically lies in the range of 80 μm to 130 μm. The foil composite materials according to the invention, due to their outer layers made of thermoplastic plastic, fuse very well with neighboring layers of the card-body layer construction, so that a stable card-body laminate bond is obtained. Simultaneously, the outer layers made of thermoplastic ensure, when the foil composite material according to the invention is used as an overlay foil or when for example a foil according to the invention is used as a core foil, that the card bodies can be printed and handled without any problems, and do not tend to block.
DESCRIPTION OF THE DRAWINGS
[0046] The invention will hereinafter be illustrated further on the basis of figures. It is pointed out that the figures are not true to proportion and not true to scale. Moreover, it is pointed out that the figures are only intended to explain the invention more closely and are by no means to be understood as restrictive. Identical reference numbers designate identical elements.
[0047] There are shown:
[0048] FIG. 1 a section through a foil composite material according to the invention having an inner plastic layer which consists of an interior inner layer and two exterior inner layers, a first outer plastic layer and a second outer plastic layer,
[0049] FIG. 2 a section through a foil composite material according to the invention having an inner plastic layer, a first outer plastic layer and a second outer plastic layer,
[0050] FIG. 3 a section through a foil composite material according to the invention having an inner plastic layer which consists of an interior inner layer and two exterior inner layers, as well as having two first outer plastic layers and two second outer plastic layers,
[0051] FIG. 4 a section through a card body according to the invention having two foil composite materials according to the invention as cover layers and having a chip module,
[0052] FIG. 5 a section through a card body according to the invention having two foil composite materials according to the invention as partial layers of the card core and having a chip module, and
[0053] FIG. 6 a section through a card body according to the invention having two foil composite materials according to the invention as cover layers, as well as two foil composite materials according to the invention as partial layers of the card core, and having a chip module.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0054] FIG. 1 shows a first embodiment of a foil composite material 4 according to the invention in cross section. In this embodiment, the inner plastic layer consists of an interior partial layer 31 , a first exterior partial layer 32 and a second exterior partial layer 33 . Located thereon are a first outer plastic layer 1 and a second outer plastic layer 2 . These outer plastic layers contain as the plastic component (besides any additives that might be present) a thermoplastic polymer or a mixture of thermoplastic polymers. The inner layers 31 , 32 , 33 contain as the plastic component (besides any additives that might be present) respectively a mixture of at least one thermoplastic elastomer and at least one thermoplastic polymer. The interior inner layer 31 has a higher content of thermoplastic elastomer than the exterior inner layers 32 , 33 . In the inner layer 3 or the partial layers 31 , 32 , 33 there is used the same thermoplastic polymer or mixture of thermoplastic polymers as in the outer layers 1 , 2 . Through the gradation in the compositions of the layers from pure thermoplastic on the outside to a mixture with a high elastomer content in the innermost layer, respective neighboring layers are relatively similar to each other or approximated to each other, and upon extrusion there can be obtained a homogeneous superimposition of the melt layers and a good mutual adhesion of the individual partial layers.
[0055] The manufacture of the foil composite material 4 can be effected for example by melting granules with three different compositions or compoundings (granules A for the first and the second outer plastic layer 1 , 2 ; granules B for the first and the second exterior inner plastic layer 32 , 33 ; granules C for the interior inner plastic layer 31 ) in three extruders A, B, C, and respectively extruding the corresponding molten streams (material A from extruder A, material B from extruder B, material C from extruder C) through a wide slot nozzle and merging them into the represented layer construction. Alternatively, it is possible to merge the layers in the feedblock prior to extruding through the wide slot nozzle. Further, there is the alternative possibility of merging the layers only in the wide slot nozzle, a so-called multi-channel nozzle, itself, prior to the melt discharge. In the represented embodiment, the foil composite material is symmetrical in construction, i.e. the outer layers 1 , 2 and the partial layers of the inner layer 32 , 33 respectively have the same composition and the same thickness. This is not necessary, however. In the case of asymmetrical foil composite materials, a corresponding greater number of extruders and a different corresponding feedblock constellation are required for manufacture.
[0056] Hereinafter there will be stated some concrete exemplary formulations for a transparent foil composite material and an opaque foil composite material.
Transparent foil, material thickness 105 to 110 μm, layer thickness ratio 1/32/31/33/2=10/20/40/20/10: Layers 1 , 2 : 4% S462+4% S465+92% PETG Layers 32 , 33 : 4% S465+32% 9665 DU+64% PETG Layer 31 : 4% S465+65% 9665 DU+31% PETG Opaque foil, material thickness 120 μm, layer thickness ratio 1/32/31/33/2=10/20/40/20/10: Layers 1 , 2 : 20% S469-YE+80% PETG Layers 32 , 33 : 55% PETG+25% DP 9665 DU+20% S469-YE Layer 31 : 30% PETG+50% DP 9665 DU+20% S469-YE
[0065] Desmopan 9665 DU, from the company Bayer Material Science, is a thermoplastic elastomer based on urethane (ether type) with a Shore D hardness of 75 (Shore A hardness 98) and an elongation at break of 350% (foil M5e). It is UV-stabilized, resistant to microbes and to hydrolysis.
[0066] S469-YE from the company Sukano is a white additive.
[0067] S462 from the company Sukano is an antiblocking agent.
[0068] S465 from the company Sukano is a laser additive.
[0069] Hereinafter there will be stated some exemplary extruder settings for manufacturing the foil composite material 4.
Processing Parameters:
[0070]
[0000]
Preferred processing temperatures Extruder C
Zones 3
Melt pipes,
Feedblock/
Zone 1
Zone 2
to n
pump, filter
Nozzle
30° C.-
180° C.-
190° C.-
190° C.-
190° C.-
80° C.
270° C.
270° C.
270° C.
270° C.
[0000]
Particularly preferred processing temperatures Extruder C
Zones 3
Melt pipes,
Feedblock/
Zone 1
Zone 2
to n
pump, filter
Nozzle
40° C.-
200° C.-
210° C.-
210° C.-
220° C.-
70° C.
250° C.
250° C.
250° C.
250° C.
[0000]
Preferred processing temperatures Extruder B
Zones 3
Melt pipes,
Feedblock/
Zone 1
Zone 2
to n
pump, filter
Nozzle
30° C.-
190° C.-
200° C.-
200° C.-
200° C.-
70° C.
270° C.
270° C.
270° C.
270° C.
[0000]
Particularly preferred processing temperatures Extruder B
Zones 3
Melt pipes,
Feedblock/
Zone 1
Zone 2
to n
pump, filter
Nozzle
40° C.-
200° C.-
210° C.-
210° C.-
210° C.-
60° C.
260° C.
260° C.
260° C.
260° C.
[0000]
Preferred processing temperatures Extruder A
Zones 3
Melt pipes,
Feedblock/
Zone 1
Zone 2
to n
pump, filter
Nozzle
30° C.-
200° C.-
200° C.-
200° C.-
200° C.
70° C.
280° C.
280° C.
280° C.
280° C.
[0000]
Particularly preferred processing temperatures Extruder A
Zones 3
Melt pipes,
Feedblock/
Zone 1
Zone 2
to n
pump, filter
Nozzle
40° C.-
210° C.-
210° C.-
210° C.-
210° C.-
60° C.
260° C.
260° C.
260° C.
260° C.
[0071] The respective favorable extruder settings can vary in dependence on the extruders used (throughput, screw geometries). They provide information for orientation, which a person skilled in the art can optionally adapt to the given extruder configurations by a few routine tests.
[0072] FIG. 2 shows another embodiment of the foil composite material 4 according to the invention. This embodiment has the simplest layer construction with a single inner layer 3 and two outer layers 1 , 2 . The outer layers 1 , 2 consist in turn of a thermoplastic polymer or a mixture of thermoplastic polymers. As in all embodiments, polyester, polyester mixtures, in particular PETG, polycarbonate, polycarbonate mixtures and blends of polyester and polycarbonate are preferred thermoplastic polymers. The inner layer 3 consists of a mixture of at least one thermoplastic elastomer, preferably an elastomer based on urethane, with a proportion of thermoplastic polymer. The thermoplastic polymer used for the inner layer 3 is identical with the thermoplastic polymer or polymer mixture that is used for the outer layers 1 , 2 . For all embodiments of the foil composite material according to the invention, urethane elastomers based on aromatic esters or aromatic ethers are particularly preferred because of their special suitability for coextrusion with thermoplastics. They are very particularly preferred for an only three-layered foil composite material as represented in FIG. 2 , because there are fewer possibilities for gradation with only a single inner layer than for example with a three-layered inner layer as represented in FIG. 1 . Hence, it is more difficult to create compatible transitions between the individual layers.
[0073] FIG. 3 shows a further embodiment of the foil composite material 4 according to the invention wherein the inner layer 3 is constructed as in the foil composite material represented in FIG. 1 , but the first outer layer 1 and the second outer layer 2 are respectively constructed from an exterior outer layer 12 , 22 and an interior outer layer 11 , 21 . The foil composite material thus has altogether seven layers. As a general rule, the manufacture of the foil composite material is the more difficult the more layers the foil composite material has. Hence, variants with outer layers 1 , 2 that are constructed from several partial layers are less preferred. They are expedient primarily when there is to be incorporated into an exterior partial layer 12 , 22 a constituent that is incompatible with a constituent of the inner layer 3 , or when for example a separate partial layer is to be equipped with an antiblocking agent. The corresponding admixtures are then present only in the exterior first outer layer 12 and/or the exterior second outer layer 22 .
[0074] FIGS. 4 , 5 and 6 respectively show exemplary layer constructions for card bodies 5 according to the invention. In general, card bodies according to the invention consist of a card core 6 which is typically constructed from one to seven layers. In the figures there are respectively represented three core layers, an inner core layer 9 , a first outer core layer 7 and a second outer core layer 7 ′. In card bodies of the prior art, the card cores consist of thermoplastic foils, typically made of PVC, PET, ABS, polyester, PC, PEC and the like. Such foils can also be used for card cores according to the invention. Between the foil layers and/or in recesses of the foil layers there can be located electronic components such as electronic modules and antennas. Other features, such as for example security elements or imprints, can also be provided. The layer construction of the card bodies 5 is respectively completed on the outer side by a cover layer 8 , 8 ′. The foils forming the layer construction are preferably interconnected by laminating, which is why all materials used should be readily laminatable to each other.
[0075] FIG. 4 shows an embodiment of a card body 5 according to the invention having a card core 6 , consisting of a PVC or PET foil 9 onto which a coil (not shown) is imprinted, and two PVC films 7 , 7 ′. The layer construction is completed by the two cover foils 8 , 8 ′ which consist of the foil composite material 4 according to the invention, as was described hereinabove.
[0076] In recesses of the foils 7 , 8 there is located a chip module 15 which is glued to the card body by means of a module pad 16 made of module adhesive. Contacts 17 establish the electrical contact to the coil (not shown) imprinted onto the foil 9 .
[0077] When the foil composite material 4 according to the invention is used as a cover layer (overlay foil), as represented in FIG. 4 , it is preferably transparent. The use of the foil composite material according to the invention exclusively as a cover layer has the advantage that the gluing of the chip module 15 is effected exclusively to standard card foils, so that the usual standard module adhesive can still be used for the module pad 16 .
[0078] FIG. 5 shows another embodiment of a card body 5 according to the invention. Here the card core 6 consists of a PVC or PET foil 9 with an imprinted antenna coil (not shown) which is adjoined on both sides by the layers 7 , 7 ′ made of the foil composite material 4 according to the invention. The layer construction is completed by the two cover layers 8 , 8 ′ made of PVC foil. As in the embodiment represented in FIG. 4 , a chip module 15 is glued into the card body 5 by means of a module pad 16 and has contacts 17 for contacting the antenna coil.
[0079] When the foil composite material 4 according to the invention forms a partial layer or partial layers of the core 6 , as in the embodiment represented in FIG. 5 , it is preferably of opaque design. This embodiment has the advantage that the foil composite material according to the invention, because it is located in the gluing region of the chip module, can especially well compensate stresses that are built up in the material through the action of temperature (hot-melt gluing) upon implanting of the module.
[0080] A further alternative embodiment of a card body 5 according to the invention is represented in FIG. 6 . Here, the card core 6 consists of the inner core layer 9 made of PVC or PET foil, the first outer core layer 7 and the second outer core layer 7 ′, both made of foil composite material 4 according to the invention in opaque design. The two cover layers 8 , 8 ′ likewise consist of foil composite material 4 according to the invention, this time in transparent design. A chip module 15 is implanted into the card body and glued as in the embodiments of FIG. 4 and FIG. 5 . This embodiment with foil composite material 4 according to the invention both as a partial core layer and as a cover layer gives the card body 5 especially advantageous mechanical properties. On the one hand, stresses built up through the action of temperature upon implanting of the module are compensated well by the partial core layers according to the invention, and, on the other hand, the far outwardly located cover foils 8 , 8 ′ made of foil composite material 4 according to the invention ensure a high breaking strength, lack of tendency to block, good printability and stiffness.
[0081] In FIGS. 4 , 5 and 6 , the card constructions are respectively represented symmetrically, but this is not necessary. Embodiments are for example also possible wherein the foil composite material 4 according to the invention is used only as one of the cover layers and/or as a partial core layer. Upon use as a cover layer, the layer thickness of the foil composite material 4 is typically no more than half as great as upon the use as a partial core layer.
[0082] Through the employment of the foil composite material according to the invention as a cover layer (or cover layers) and/or as a core layer (or core layers) in a card body, the mechanical properties of card bodies can be decisively improved over card bodies of the prior art. The card bodies can be subjected to stronger and more frequent bending loads without there occurring stresses, cracks or breaks of the card body. Stresses arising from the installation of electronic modules, which always cause a weakening of the card body, can also be compensated and thus the mechanical properties of the card body improved. The foil composite material according to the invention can be employed in the card bodies instead of any standard foil.
[0083] In particular card constructions wherein the foil composite material according to the invention is employed in the interior of the card construction, as represented by way of example in FIG. 5 , have excellent mechanical properties, such as excellent strength and stiffness. This becomes evident particularly in the case of actions of impact force, which otherwise as a rule lead to card breakage. This is due to the greater thickness of the foil composite material core layers, and thus the higher proportion of the foil composite material according to the invention in the card body altogether.
[0084] The foil composite material according to the invention is also very stable in itself, i.e. there is a firm bond between its individual partial layers without any danger of the partial layers separating from each other upon load. This stability is achieved by suitable gradations of the compositions of the partial layers which result in similar processing properties of neighboring partial layers.
[0085] The foil composite material according to the invention can be manufactured inexpensively, and there is a wide spectrum of suitable thermoplastic elastomers with different properties available on the market. The foil composite material is easy to process by the coextrusion method and is also characterized by especially simple handling in further processing, i.e. it can for example be printed without any problems and laminated to all common card materials. It also does not tend to block. The foil material can be manufactured with a high proportion of thermoplastic elastomer, which makes it very elastic and, upon use as a layer in a card body, considerably improves the mechanical properties of the card body over card bodies without the foil composite material according to the invention. | A foil composite material usable as a layer in a card body of a portable data carrier, that includes one outer plastic layer, one inner plastic layer and one second outer plastic layer. All the layers jointly form a coextruded composite, and the plastic of one outer layer is a thermoplastic polymer or a mixture thereof. The plastic of the one inner layer is a mixture of at least one thermoplastic elastomer and at least one thermoplastic polymer. The plastic of the second outer layer is a thermoplastic polymer or a mixture thereof. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims domestic priority to commonly owned copending U.S. Provisional Application Ser. No. 62/160,026, filed May 12, 2015, the disclosure of which is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] U.S. Pat. No. 9,045,386 describes a process to produce trans-1-chloro-3,3,3-trifluoropropene (HCFO-1233zd(E)) at high purity on a commercial scale. This patent is hereby incorporated herein by reference.
[0003] It has been discovered that certain by-products can be generated in the HCFO-1233zd(E) manufacturing process, including HCFC-241 isomers, HCFC-242 isomers, HCFC-243 isomers, HCFC-244 isomers, and the cis-isomer of HCFO-1233zd. These by-products are produced at a ratio of 0.25-35 kg per kg of the trans-isomer of HCFO-1233zd. Since these by-products are not simple precursors to HCFO-1233zd, they cannot be readily recycled in the process. The volume of these by-products and their cost of disposal could significantly impact the economic viability of this commercial process.
SUMMARY OF THE INVENTION
[0004] This invention is based on the discovery that the HCFO-1233zd by-products can instead be used in a manufacturing process for the production of 1,1,1,3,3-pentafluoro-propane (HFC-245fa), another commercially useful product. Other sources of the isomers of HCFC-241, HCFC-242, HCFC-243, and the cis isomer of HCFO-1233zd, may likewise be used in this process—since these materials may be available from processes that are not based on them only being HCFO-1233zd by-products.
[0005] In one embodiment, combining these two manufacturing processes into an integrated manufacturing scheme is accomplished by feeding the isolated by-products from the 1233zd process to a reactor used to produce HFC-245fa, either alone, or in tandem with the normal HCC-240fa raw materials and HF. The HCFO-1233zd by-products are then converted into HFC-245fa, and are recovered therefrom as a commercially viable product.
[0006] The ability to integrate the HCFO-1233zd process with a HFC-245fa process removes the financial penalty of producing un-recyclable by-products and greatly improves the commercial viability of the HCFO-1233zd production process.
[0007] It should be appreciated by those persons having ordinary skill in the art(s) to which the present invention relates that any of the features described herein in respect of any particular embodiment and/or embodiment of the present invention can be combined with one or more of any of the other features of any other embodiments and/or embodiments of the present invention described herein, with modifications as appropriate to ensure compatibility of the combinations. Such combinations are considered to be part of the present invention contemplated by this disclosure.
[0008] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
[0009] The present invention was based on the realization that the process for producing HCFO-1233zd and the process for producing HFC-245fa both utilize similar raw materials. The present inventors thus theorized that the HCFO-1233zd process by-products could be used as precursors in the production of HFC-245fa.
[0010] U.S. Pat. Nos. 5,574,192 and 5,616,819 describe processes for the production of HFC-245fa from HCC-240fa. However these patents do not teach or suggest the use of the 1233 by-products as raw materials for HFC-245fa production. These patents are hereby incorporated herein by reference.
[0011] Fluorination catalysts useful in the process of the invention include: (I) pentavalent antimony, niobium, arsenic and tantalum halides; (II) pentavalent antimony, niobium, arsenic and tantalum mixed halides; and (III) mixtures of pentavalent antimony, niobium, arsenic and tantalum halide catalysts. Examples of catalysts of group (I) include antimony pentachloride and antimony pentafluoride. Examples of catalysts of group (II) include SbCl 2 F 3 and SbBr 2 F 3 . Examples of catalysts of group (III) include a mixture of antimony pentachloride and antimony pentafluoride.
[0012] Pentavalent antimony, niobium, arsenic and tantalum halides are commercially available, and mixed halides thereof are created in situ upon reaction with HF. Antimony pentachloride is preferred because of its low cost and availability. Pentavalent antimony mixed halides of the formula SbCl n F 5-n where n is 0 to 5 are more preferred. The fluorination catalysts used in this invention preferably have a purity of at least about 97%. Although the amount of fluorination catalyst used may vary widely, we recommend using from about 5 to about 50%, or preferably from about 10 to about 25% by weight catalyst relative to the organics.
[0013] The temperature at which the fluorination reaction is conducted and the period of reaction will depend on the starting material and catalyst used. One of ordinary skill in the art can readily optimize the conditions of the reaction without undue experimentation to get the claimed results, but the temperature will generally be in the range of from about 50° to about 175° C., and preferably from about 115° C. to about 155° C., for a period of, for example, from about 1 to about 25 hours, and preferably from about 2 to about 8 hours.
[0014] Pressure is not critical. Convenient operating pressures range from about 1500 to about 5000 KPa, and preferably from about 1500 to about 2500 KPa.
[0015] The equipment in which the fluorination reaction is conducted is preferably made of corrosion resistant material such as Inconel or Monel.
[0016] HFC-245fa may be recovered from the mixture of unreacted starting materials, by-products, and catalyst by any means known in the art, such as distillation and extraction. At the end of the heating period, i.e., the amount of time for complete reaction in batch mode operations, the fluorination reaction product and remaining HF may be vented through a valve on the autoclave head, which in turn is connected to an acid scrubber and cold traps to collect the product. Alternatively, unreacted HF and organics may be vented and condensed, and the HF layer recycled to the reactor. The organic layer can then be treated, i.e., washed with an aqueous base, to remove dissolved HF and distilled. This isolation procedure is particularly useful for a continuous fluorination process.
EXAMPLES
[0017] The following examples illustrate the advantages of this invention but are not to be construed as limiting the invention.
Example 1
[0018] 30,000 lbs of mixture of isomers of HCFC-241, HCFC-242, HCFC-243, and the cis isomer of HCFO-1233zd was fed to a commercial reactor producing HFC-245fa from HCC-240fa. The reaction was conducted at a temperature of 215° F. and a pressure of 150 psig. Reaction products were removed continuously. HFC-245fa meeting all product specifications was produced from the mixture.
[0019] Example 2
[0020] In a laboratory setting, a small quantity of a mixture of isomers of HCFC-241, HCFC-242, HCFC-243, and the cis isomer of HCFO-1233zd was mixed with HF and fluorinated antimony pentachloride catalyst. The reactions were run by first charging SbCl 5 and HF at room temperature with agitation of about 180 RPM. The HCl generated by the fluorination of the catalyst was vented to a scrubber carboy containing KOH solution. The reactor was then heated to 95° C. while the organic feed cylinder was also heated to about 95° C. When at temperature the organic was quickly charged.
[0021] It was observed for each experiment that the temperature first decreased by about 10° C. to 12° C. and then heated up to between 112° C. and 118° C. Thereafter, within a few minutes, the reaction cooled back down to about 95° C. The pressure of each reaction increased to between 700 to 800 psig. The pressure rise stopped after about 1-2 minutes for all of the runs. The reactions were held at the final temperature for between 5 to 8 additional minutes. Then the reaction was stopped abruptly by opening a vent valve to an evacuated liquid N 2 cooled 500 cc product collection cylinder (PCC).
[0022] The remaining reactor contents were quenched with about 100 grams of water and 20 grams of MeCl 2 . HFC-245fa and normally-observed pre-cursors to HFC-245fa were the observed reaction products.
[0023] As used herein, the singular forms “a”, “an” and “the” include plural unless the context clearly dictates otherwise. Moreover, when an amount, concentration, or other value or parameter is given as either a range, preferred range, or a list of upper preferable values and lower preferable values, this is to be understood as specifically disclosing all ranges formed from any pair of any upper range limit or preferred value and any lower range limit or preferred value, regardless of whether ranges are separately disclosed. Where a range of numerical values is recited herein, unless otherwise stated, the range is intended to include the endpoints thereof, and all integers and fractions within the range. It is not intended that the scope of the invention be limited to the specific values recited when defining a range.
[0024] From the foregoing, it will be appreciated that although specific examples have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit or scope of this disclosure. It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims, including all equivalents, that are intended to particularly point out and distinctly claim the claimed subject matter. | A process is described wherein otherwise unusable by-products from a process for the manufacture of trans HCFO-1233zd(E) are converted to a valuable product by introducing them into a process for the production of HFC-245fa. The process includes the catalytic hydrofluorination of a reaction mixture comprising the HCFO-1233zd production by-products. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to processes for producing olefin polymers. More specifically, this invention relates to a process for producing olefin polymers characterized by the use of a ctalyst which can provide highly stereoregular polymers in a high yield in the polymerization of α-olefins having not less than 3 carbon atoms.
2. Description of the Prior Art
Hitherto, it has been said that a catalyst system consisting of (i) a solid catalyst component having a titanium compound carried on a magnesium halide and (ii) an organoaluminum compound has a higher polymerization activity than conventional catalyst systems having no titanium compound carried thereon and may not need removal of catalyst residue from the resulting polymer. However, because the use of this carried catalyst causes low stereoregularity, it has been considered that the resulting polymer must be subjected to extraction procedure of so-called atactic polymers Recently, the stereoregularity owing to this carried catalyst has been considerably improved by the use of new co-catalyst systems. More specifically, it is known that a certain degree of highly active and highly stereoregular polymerization can be obtained by using, as polymerization additives, esters (U.S. Pat. No.4,226,741, Japanese Patent Laid-Open Publication No.157808/83, etc.) or phenyl- or alkyl-containing silicon compounds (European Patent Gazette E.P. No. 45975, E.P. No. 45976, E.P. No. 45977, etc.). Even by the use of these polymerization additives, however, it has been difficult to eliminate removal of catalyst residue and extraction process. Thus, further improvement has been desired in this respect.
SUMMARY OF THE INVENTION
We have conducted intensive research on such highly active additives for highly stereoregular polymerization as can make possible a polymerization process without the need for removal of catalyst residue and extraction of undesired polymers. As a result, highly active and highly stereoregular polymerization has been unexpectedly realized by using an ether compound having a specified structure. The present invention is based on this result.
Thus, the process for producing olefin polymers according to the present invention comprises contacting an olefin with a catalyst thereby to polymerize the olefin, the catalyst comprising the following components (A), (B) and (C):
(A) a solid catalyst component comprising as essential components a magnesium halide and a titanium halide,
(B) an organic aluminum compound, and
(C) an ether compound represented by the formula R 1 R 2 R 3 C(OR 4 ), R 1 R 2 C(OR 4 ) 2 or R 1 C(OR 4 ) 3 , wherein: R 1 stands for an aromatic or alicyclic hydrocarbon group, and R 2 , R 3 and R 4 stand for hydrocarbon groups which may be the same or may be different.
According to the present invention, there is provided a catalyst which provides high stereoregularity in addition to high activity inherent in a carried catalyst, whereby the polymerization process can be carried out without the need for removal of catalyst residue and extraction to achieve the above set forth objects.
These effects are brought about by using a specific ether compound as an additive. It can be said such effects exhibited by the specific ether compound have been beyond expecation and anticipation by those skilled in the art.
DETAILED DESCRIPTION OF THE INVENTION
Catalyst
The catalyst to be used in the present invention comprises the following components (A), (B) and (C).
Component (A)
The solid catalyst component (A) to be used in the invention contains as essential components a magnesium halide and a titanium halide.
As the magnesium halide, magnesium chloride, magnesium bromide and magnesium iodide, preferably magnesium chloride, and more preferably substantially anhydrous magnesium chloride can be used.
As the titanium halide, chlorides, bromides and iodides of titanium, preferably chlorides thereof such as titanium tetrachloride, titanium trichloride, etc., and more preferably titanium tetrachloride can be used. It is possible to provide a titanium halide by subjecting an alkoxyl-containing titanium compound of the general formula: Ti(OR) n Cl 4-n (wherein R denotes an alkyl and n is an integer of 1 to 4) to halogenation treatment in a later step.
In the preparation of the solid catalyst component of the present invention, various electron donors can be used, and the use thereof is preferred.
The electron donors include oxygen-containing compounds and nitrogen-containing compounds.
Oxygen-containing compounds suitable for use are ethers, ketones, acid halides and esters, preferably esters and acid halides.
As the esters, mainly carboxylic acid esters can be used. Aliphatic carboxylic acid esters are exemplified by relatively lower alkyl or alkoxyalkyl esters of relatively lower mono- or di-carboxylic acids such as ethyl acetate, methyl cellosolve acetate, ethyl cellosolve acetate, methyl methacrylate, diethyl oxalate, and dibutyl maleate. Aromatic carboxylic acid esters are exemplified by ethyl benzoate, methyl p-toluylate, diethyl phthalate, and diheptyl phthalate. Of these esters, particularly preferred are phthalates such as diethyl phthalate, and diheptyl phthalate.
As the acid halide, phthaloyl chloride is preferred.
Examples of nitrogen-containing compounds which can be used are amines, nitriles and nitro compounds, of which nitro compounds are preferable.
Suitable nitro compounds are, for example, aromatic or aliphatic mono- and di-nitro compounds.
Examples of suitable nitro compounds are aromatic compounds such as nitrobenzene, o-nitrotoluene, o-dinitrobenzene, m-dinitrobenzene, 2,3-dinitrotoluene, o-nitrobenzonitrile, o-nitroacetophenone, and 1,8-dinitronaphthalene, and aliphatic compounds such as 2-nitro-n-butane, 1,2-dinitrocyclohexane, and 1-nitro2-cyanocyclohexane.
Among the above nitro compounds, the aromatic compounds are preferred. Dinitro compounds or nitro compounds having both a nitro group and another functional group are preferable to the mononitro compounds.
In the preparation of the solid catalyst component, it is desirable to subject magnesium chloride to pretreatment. Such treatment can be carried out by either pulverization or dissolution and precipitation. Pulverization of magnesium chloride can be conducted by using a ball mill or a vibration mill. Dissolution of the magnesium chloride can be conducted by using as a solvent a hydrocarbon or a halogenated hydrocarbon and as a dissolution accelerator an alcohol, a phosphate ester or a titanium alkoxide. Precipitation of the once-dissolved magnesium chloride can be conducted by adding thereto a poor solvent, an inorganic halide, methylhydrogenpolysiloxane, or an electron donor such as an ester. Details of such pre-treatment of magnesium chloride can be found in Japanese Patent Laid-Open Specifications Nos.45688/78, 31092/79, 180612/82, 5309/83 and 5310/83.
Sequence of the contact of the pre-treated magnesium chloride, a titanium halide and an electron donor is arbitrarily chosen. For example, it is possible to (i) form a complex from a titanium halide and an electron donor and then to contact the resulting complex with magnesium chloride, (ii) contact magnesium chloride with a titanium halide and then contact the resulting mixture with an electron donor, or (iii) contact magnesium chloride with an electron donor and then contact the resulting mixture with a titanium halide.
Alternatively, magnesium chloride is contacted with an alkoxy titanium, and then the resulting mixture can be contacted with a halogenating agent such as silicon tetrachloride, titanium tetrachloride or the like.
Such contact can be carried out by a pulverizing contact method in a ball mill, vibration mill or the like, or by adding magnesium chloride or magnesium chloride treated with an electron donor to a liquid phase containing titanium halide.
Washing with an inert solvent may be conducted after contacting the three components or in an intermediate step of the contact of each component.
The solid catalyst component thus obtained contains approximately 1 to 20% by weight of a titanium halide. The molar ratio of the electron donor to the titanium halide both contained in the solid catalyst component is approximately 0.05 to 2.0.
Component (B)
The (B) organic aluminum compound used in the present invention is preferably trialkyl aluminum. The alkyl group suitably contains approximately 1 to 8 carbon atoms. Such trialkyl aluminum compounds include, for example, trimethyl aluminum, triethyl aluminum, tri-i-butyl aluminum, and tri-n-hexylaluminum. Particularly preferred is triethyl aluminum. It is possible to use an organic aluminum compound such as an alkyl aluminum halide or an alkyl aluminum alkoxide in combination with a trialkyl aluminum.
The molar ratio of the organic aluminum compound to the titanium halide in the solid catalyst both used for polymerization is ordinarily in the range of 10 to 1,000.
Component (C)
The component (C) used in the present invention is an ether compound represented by the general formula: R 1 R 2 R 3 C(OR 4 ), R 1 R 2 C(OC 4 ) 2 , or R 1 C(OR 4 ) 3 . In the above formulae, R 1 stands for an aromatic or alicyclic hydrocarbon group having approximately 5 to 15 carbon atoms, preferably 6 to 12 carbon atoms. R 1 is preferably an aromatic hydrocarbon having benzene ring(s) or an alicyclic hydrocarbon having a polycyclic structure. Each of R 2 , R 3 and R 4 stands for a hydrocarbon group having approximately 1 to 10 carbon atoms, preferably approximately 1 to 7 carbon atoms. More preferably, R 2 and R 3 are an aromatic or alicyclic hydrocarbon having 1 to 10 carbon atoms or an alkyl having approximately 1 to 3 carbon atoms, and R 4 is an alkyl having 1 to 3 carbon atoms. Examples of such compounds are represented by the following structural formulae. ##STR1##
The molar ratio of the ether compound (C) to the organic aluminum compound (B) is ordinarily in the range of 0.01 to 1.0, preferably 0.02 to 0.5.
As to the ether compounds represented by the formula R 1 C(OR 4 ) 3 , the molar ratio is preferably in the range of 0.01 to 0.5, more preferably 0.02 to 0.2.
Polymerization of Olefins
Polymerization using a catalyst system according to the present invention is applicable to homopolymerization of each of ethylene, propylene and butene and copolymerization of two or more of these monomers.
Particularly, the catalyst is preferably used for polymerization of α-olefins having not less than 3 carbon atoms as well as for copolymerization of an α-olefin having not less than 3 carbon atoms with ethylene or with an α-olefin having not less than 4 carbon atoms.
The polymerization can be carried out either in the presence of an inert solvent or in the absence of such solvent, that is, in a gas phase or a liquid phase bulk polymerization. The polymerization can be carried out in either a continuous or batch-wise fashion. The molecular weight of the resulting polymer can be regulated by controlling the concentration of hydrogen in a polymerization vessel. The polymerization temperature is in a range of the order of 0° to 200° C., preferably of the order of 50° to 100° C. The polymerization pressure is ordinarily in the range of 1 to 100 atm.
Experimental Example
EXAMPLE 1
Preparation of solid catalyst component
A 500-ml three-necked glass flask (equipped with a thermometer and a stirrer) was purged with nitrogen gas and was charged with 75 ml of purified heptane, 75 ml of titanium tetrabutoxide, and 10 g of anhydrous magnesium chloride. Then the flask was heated to 90° C. to completely dissolve the magnesium chloride over 2 hours. The flask was then cooled to 40° C., and 15 ml of methylhydrogenpolysiloxane was added to separate out a magnesium chloride-titanium tetrabutoxide complex. After washing with purified heptane, 8.7 ml of silicon tetrachloride and 1.8 ml of diheptyl phthalate were added to the complex, which was maintained at 50° C. for 2 hours. Thereafter, the complex was washed with purified heptane, supplied with 25 ml of titanium tetrachloride, and maintained at 90° C. for 2 hours. The resulting product was washed with purified heptane to produce a solid catalyst component.
The resulting solid catalyst contained 3.0% by weight of titanium and 25.0% by weight of diheptyl phthalate.
Polymerization
A 3-liter stainless steel autoclave was purged with nitrogen and then charged with 1.5 liters of purified heptane, 0.75 g of triethyl aluminum (B), 0.15 g of diphenyl dimethoxymethane (C), and 50 mg of the solid catalyst component (A) obtained above. Hydrogen was introduced thereto in an amount corresponding to a partial pressure of 0.15 kg/cm 2 . Then, the autoclave was heated to 70° C., and propylene was introduced thereinto and pressurized to 7 kg/cm 2 G to initiate polymerization. Polymerization was continued for 3 hours by supplying propylene so as to maintain this pressure.
After 3 hours, introduction of the monomer was stopped and unreacted monomer was purged therefrom to terminate the polymerization.
The resulting polymer was filtered off from the heptane and dried to produce 783.1 g of a polypropylene powder. The heptane was removed from the resulting filtrate by heating to obtain 2.3 g of amorphous polymers. The percentage of the amorphous polymer based on the total amount of the polymer (hereinafter referred to as yield of APP by-product) was 0.29%.
The content of substances insoluble in boiling n-heptane (hereinafter referred to as P-II) in the polypropylene powder was 98.7%. The polymer yield per the solid catalyst (hereinafter referred to as CY) was 15708. The MFR (melt flow index measured according to ASTM-D1238) of the polymer was 2.13 and the bulk specific gravity thereof was 0.46.
EXAMPLE 2
The solid catalyst component (A) was prepared similarly as in Example 1, and polymerization was carried out similarly as in Example 1 except that 0.12 g of 1-(2-norbornyl)-1,1-dimethoxyethane (C) was used as a polymerization additive.
As a result, 811.2 g of polypropylene powder was obtained. The yield of APP by-product was 0.35%. P-II: 97.9%, CY: 16284, MFR: 2.37, and bulk specific gravity: 0.46.
EXAMPLE 3
The solid catalyst component (A) was prepared similarly as in Example 1, and polymerization was carried out as in Example 1 except that 0.07 g of phenyltriethoxymethane (C) was used as a polymerization additive.
As a result, 583.3 g of polypropylene powder was obtained, and the yield of APP by-product was 0.31%. P-II: 97.4%, CY: 11702, MFR: 2.63, bulk specific gravity: 0.46.
EXAMPLE 4
The solid catalyst component (A) was prepared similarly as in Example 1, and polymerization was carried out as in Example 1 except that 0.19 g of 5- ethylidene-2-norbornyltriethoxymethane (C) was used as a polymerization additive.
As a result, 632.4 g of polypropylene powder was obtained, and the yield of APP by-product was 0.28%. P-II: 98.7%, CY: 12688, MFR: 2.51, bulk specific gravity: 0.47.
EXAMPLES 5 through 10
The solid catalyst component (A) was prepared similarly as in Example 1, and polymerization was carried out as in Example 1 except that the compounds in the following table were respectively used as polymerization additives. The results are shown below.
__________________________________________________________________________Example Quantity Bulk specificNo. Additive added (g) CY P-II (%) APP (%) MFR gravity__________________________________________________________________________ ##STR2## 0.16 15312 98.2 0.31 2.96 0.466 ##STR3## 0.12 16114 97.9 0.35 3.12 0.467 ##STR4## 0.19 13212 97.1 0.91 3.51 0.458 ##STR5## 0.11 16919 96.3 1.26 4.63 0.449 ##STR6## 0.07 10691 97.1 0.35 2.34 0.4610 ##STR7## 0.07 9830 98.0 0.31 2.03 0.47__________________________________________________________________________
EXAMPLE 11
Preparation of solid catalyst component
A 500-ml three-necked glass flask (equipped with a thermometer and a stirrer) was purged with nitrogen gas and charged with 75 ml of purified heptane, 75 ml of titanium tetrabutoxide, and 10 g of anhydrous magnesium chloride. Then the flask was heated to 90° C. to completely dissolve the magnesium chloride over 2 hours. The flask was then cooled to 40° C., and 15 ml of methylhydrogenpolysiloxane was added to separate out magnesium chloride-titanium tetrabutoxide complex. After washing with purified heptane, 8.7 ml of silicon tetrachloride and 1.5 ml of phthaloyl chloride were added to the complex, which was maintained at 50° C. for 2 hours. Thereafter, the complex was washed with purified heptane, supplied with 25 ml of titanium tetrachloride, and maintained at 30° C. for 2 hours. The resulting product was washed with purified heptane to produce a solid catalyst component.
The resulting solid catalyst contained 3.3% by weight of titanium. The specific surface area of the solid catalyst component was 1.2 m 2 /g.
Polymerization
Polymerization was carried out as in Example 1. As a result, 811.2 g of polypropylene powder was obtained, and the yield of APP by-product was 0.31%, P-II: 98.5%, CY: 16273, MFR:1.93, bulk specific gravity: 0.46.
EXAMPLE 12
Preparation of solid catalyst component
A 500-ml three-necked glass flask (equipped with a thermometer and a stirrer) was purged with nitrogen gas and charged with 75 ml of purified heptane, 75 ml of titanium tetrabutoxide and 10 g of anhydrous magnesium chloride. Then the flask was heated to 90° C. to completely dissolve the magnesium chloride over 2 hours. The flask was then cooled to 40° C., and 15 ml of methylhydrogen polysiloxane was added thereto to separate out the magnesium chloride-titanium tetrabutoxide complex. After washing with purified heptane, the complex was supplied with 8.7 ml of silicon tetrachloride and 1.8 ml of diheptyl phthalate, and maintained at 50° C. for 2 hours. Thereafter, the complex was washed with purified heptane, supplied with 25 ml of titanium tetrachloride and maintained at 90° C. for 2 hours. The resulting product was washed with purified heptane to obtain a solid catalyst component.
The resulting solid catalyst contained 3.0% by weight of titanium and 25.0% by weight of diheptyl phtha- late.
Polymerization
A 3-liter stainless steel autoclave was purged with nitrogen and then charged with 1.5 liters of purified heptane, 0.75 g of triethyl aluminum (B), 0.10 g of α-cumyl methyl ether (C), and 50 mg of the solid catalyst component (A) obtained as described above. Hydrogen was introduced thereinto in an amount corresponding to a partial pressure of 0.15 kg/cm 2 . Then the autoclave was heated to 70° C., and propylene was introduced thereinto and pressurized to 7 kg/cm 2 G to initiate polymerization. Polymerization was continued for 3 hours with supplying of propylene so as to maintain this pressure.
After 3 hours, introduction of the monomer was stopped, and unreacted monomer was purged therefrom to terminate polymerization.
The resulting polymer was filtered off from the heptane and dried to obtain 764.5 g of polypropylene powder. The heptane was removed from the resulting filtrate by heating to obtain 4.1 g of amorphous polymer. The yield of APP by-product in the whole polymer was 0.53%.
The P-II of this polypropylene powder was 97.1%. The yield of the polymer per the solid catalyst was 15372. MFR was 1.94 and bulk specific gravity was 0.46.
EXAMPLE 13
Solid catalyst ccmponent (A) was prepared similarly as in Example 12, and polymerization was carried out as in Example 12 except that 0.11 g of α-cumyl ethyl ether (C) was used as a polymerization additive.
As a result, 748.1 g of polypropylene powder was obtained, and the yield of APP by-product was 0.69%. P-II: 96.4%, CY: 15067, MFR: 2.11, bulk specific gravity: 0.46.
EXAMPLE 14
Solid catalyst component (A) was prepared similarly as in Example 12, and polymerization was carried out as in Example 12 except that 0.16 g of 1,1-diphenylethyl methyl ether (C) was used as a polymerization additive.
As a result, 788.3 g of polypropylene powder was obtained, and the yield of APP by-product was 0.32%. P-II: 98.6%, CY: 15817, MFR: 1.87, bulk specific gravity: 0.47.
EXAMPLE 15
Preparation of solid catalyst component
A 500-ml three-necked glass flask (equipped with a thermometer and a stirrer) was purged with nitrogen gas and charged with 75 ml of purified heptane, 75 ml of titanium tetrabutoxide and 10 g of anhydrous magnesium chloride. Then the flask was heated to 90° C. to completely dissolve the magnesium chloride over 2 hours. The flask was then cooled to 40° C., and 15 ml of methylhydrogenpolysiloxane was added thereto to separate out a magnesium chloride-titanium tetrabutoxide complex. After washing with purified heptane, the complex was supplied with 8.7 ml of silicon tetrachloride and 1.5 ml of phthaloyl chloride and maintained at 50° C. for 2 hours. Thereafter, the complex was washed with purified heptane, supplied with 25 ml of titanium tetrachloride, and maintained at 30° C. for 2 hours. The resulting product was washed with purified heptane to produce a solid catalyst component.
The resulting solid catalyst contained 3.3% by weight of titanium. The specific surface area of the solid catalyst component was 1.2 m 2 /g.
Polymerization
Polymerization was carried out as in Example 12. As a result, 793.1 g of polypropylene powder was obtained. The yield of APP by-product was 0.59%. P-II: 96.7%, CY: 15956, MFR: 2.02, bulk specific gravity: 0.46. | An olefin is polymerized by using a catalyst consisting essentially of (A) a solid catalyst component containing a magnesium halide and a titanium chloride, (B) an organic aluminum compound, and (C) an ether compound represented by the formula: R 1 R 2 R 3 C(OR 4 ), R 1 R 2 C(OR 4 ) 2 or R 1 C(OR 4 ) 3 . The catalyst has high catalytic activity and high stereoregularity as well as good activity endurance and is especially suitable for production of block copolymers. | 2 |
RELATED APPLICATION
The present application claims the benefit of U.S. Provisional Patent Application 60/451,151, filed on Feb. 28, 2003, which is incorporated herein in its entirety by reference.
TECHNICAL FIELD
The invention relates generally to network communications and, more particularly, to allocating resources among clients and servers on a network.
BACKGROUND OF THE INVENTION
The rapid growth of computer networks, both public and private, in recent years has been spurred, in large part, by “client/server computing.” In this model, one computing device, the client, requests that another computing device, the server, provide services or features to it. Note that “client” and “server” are used solely to denote the parties in a request transaction. While some computing devices are implemented as dedicated servers that can serve multiple clients, a client and a server can switch roles from one transaction to another. In a “peer-to-peer” network (common, for example, among devices communicating via short range radio), every computing device has the potential to be both a client and a server, serially or simultaneously.
Servers often have to allocate precious resources to fulfill a request for a feature or for a service. Upon receiving a request from a client, a server checks the availability of its resources. Traditionally, if the server does not have the resources to fulfill the request, then the server rejects the request. If the client can proceed without the requested feature or service, then it does so and resubmits the request later, at which time the server may have the necessary resources available to fulfill the request.
In order to ensure that precious server resources are dedicated only to those clients authorized to use them, servers often check the identity of a client making a request. If the client cannot authenticate itself to the satisfaction of the server, then the server rejects the request.
This protection against unauthorized clients is not perfect, however. Some types of requests are made before the authorization process is complete. Processing these requests, even if they are ultimately rejected, consumes some level of server resources. For example, a nefarious client could bring a “denial of service” (DOS) attack against a server by repeatedly making requests of the server. Although this client will fail to authenticate itself and its requests will ultimately be rejected, the server may in the mean time utilize so many resources attempting to authenticate the client during each request that the server exhausts its resource pool until the server is rendered incapable of fulfilling any requests, even those made by authorized clients.
SUMMARY OF THE INVENTION
In view of the foregoing, the present invention allows a server to delay allocating resources to a client's request. When the client requests a service or a feature that requires server resources (such as, for example, encryption or compression of the messages between the client and the server), the server accepts and acknowledges the client's request, but the client is prohibited from using the requested feature until further notice from the server. For example, during an authorization process, the server allocates only the minimum resources required to maintain the session and to authorize the client. Thereafter, the server allocates the resources necessary to support the client's request only when the resources become available. Until then, the server maintains the communications session without supporting the request. Thus, the server shepherds its resources rather than committing them at the whim of a potentially malicious, malfunctioning, or misconfigured client. Also, a legitimate client need not repeat its request if the server cannot immediately satisfy it; instead, the server accepts the request and then later begins to support it when adequate resources become available.
According to one embodiment, after receiving a request for data compression from a client, the server accepts and acknowledges the request but delays allocating the resources necessary to compress communications data. Indeed, the server might not even check to see whether resources are available until the client has successfully authenticated itself to the server. Even though the compression request has been accepted, the client and server communicate without compressing their data. This continues until, and if, the resources necessary for compression become available on the server. At that time, the server allocates the necessary resources and indicates to the client that compression is now supported. The server can signal this by, for example, sending compressed data to the client. Upon receiving the signal (e.g., the compressed data), the client realizes that it is now permitted to communicate with compression. The client responds by beginning to transmit compressed data to the server.
Compression is just one example of a communications feature that can be requested by a client. Other examples include the wide range of features commonly called Quality of Service (QOS). QOS features include, generally, bandwidth, response time guarantees, immunity to error, integrity of message sequence and lack of duplication, maximum permissible loss rates, and the like. QOS features provide examples where, in keeping with one embodiment of the present invention, the server can allocate resources level by level rather than all at once. For example, the client requests a great amount of guaranteed bandwidth. The server initially accepts the request but allocates resources sufficient to support only a low amount of guaranteed bandwidth. The client recognizes this and uses only the low amount of bandwidth. Later, the server allocates more bandwidth to this client (in response, for example, to another client releasing bandwidth), and the client begins to use the greater bandwidth amount.
Also in keeping with the invention, a server or a client (or both) maintains information about the requested feature and about the actual level of service being supported. The server monitors this information for each client and allocates additional resources to the clients as resources become available in order to more fully support the clients' requests.
A client can display to its user the status of requests as accepted and supported, accepted but not yet supported, and rejected. The server can provide similar information to an administrator or to a log file.
BRIEF DESCRIPTION OF THE DRAWINGS
While the appended claims set forth the features of the present invention with particularity, the invention, together with its objects and advantages, may be best understood from the following detailed description taken in conjunction with the accompanying drawings of which:
FIG. 1 is a block diagram of an exemplary computer networking environment within which the present invention can be practiced;
FIG. 2 is a schematic diagram generally illustrating an exemplary computer system that supports the present invention;
FIGS. 3 a and 3 b together form a data-flow diagram illustrating an exemplary message exchange between a client and a server during negotiation of the client's communications feature request;
FIG. 4 is a data-structure diagram of an exemplary message exchanged between the client and the server during the scenario of FIGS. 3 a and 3 b;
FIGS. 5 a and 5 b together form a flowchart illustrating an exemplary resource allocation method performed by a server;
FIG. 6 is a data-structure diagram of a request status list usable by a server; and
FIGS. 7 a and 7 b together form a flowchart illustrating an exemplary feature request method performed by a client; and
DETAILED DESCRIPTION OF THE INVENTION
Turning to the drawings, wherein like reference numerals refer to like elements, the present invention is illustrated as being implemented in a suitable computing environment. The following description is based on embodiments of the invention and should not be taken as limiting the invention with regard to alternative embodiments that are not explicitly described herein.
In the description that follows, the present invention is described with reference to acts and symbolic representations of operations that are performed by one or more computing devices, unless indicated otherwise. As such, it will be understood that such acts and operations, which are at times referred to as being computer-executed, include the manipulation by the processing unit of the computing device of electrical signals representing data in a structured form. This manipulation transforms the data or maintains them at locations in the memory system of the computing device, which reconfigures or otherwise alters the operation of the device in a manner well understood by those skilled in the art. The data structures, where data are maintained, are physical locations of the memory that have particular properties defined by the format of the data. However, while the invention is being described in the foregoing context, it is not meant to be limiting as those of skill in the art will appreciate that various of the acts and operations described hereinafter may also be implemented in hardware.
The present invention allows a server to accept a client request but to delay allocating the resources necessary to support that request. FIG. 1 gives an example of a computer networking environment 100 in which the invention can be used. The example network 100 includes a server computing device 102 and three client computing devices 104 , 106 , and 108 . The network 100 can be a corporate local area network (LAN), a wireless network, the Internet, or anything in between and can include many well known components, such as routers, gateways, hubs, etc. In an example transaction, the client 104 requests a service or a communications feature from the server 102 . The server 102 provisionally accepts the request but does not allocate resources to support the requested feature until, for example, the client 104 authenticates itself to the server 102 or until the resources become available. Until the resources are allocated and the server 102 informs the client 104 of that fact, the client 104 and the server 102 communicate without using the requested feature. Thus, the server 102 shepherds its resources rather than committing them at the whim of a potentially malicious, malfunctioning, or misconfigured client.
In another transaction, the client 104 and the server 102 can switch roles with the “server” 102 requesting a service from the “client” 104 . In a peer-to-peer network, every computing device can be both a client and a server, serially or simultaneously. Accordingly, embodiments of the invention can be practiced on clients, servers, peers, or any combinations thereof.
The computing device 110 is another server but one that only directly communicates with the server 102 to provide resources to it. Its presence illustrates that by following the methods of the present invention, the server 102 shepherds not just its own resources but the resources of the networking environment 100 generally.
The computing devices 102 and 104 of FIG. 1 may be of any architecture. FIG. 2 is a block diagram generally illustrating an exemplary computer system that supports the present invention. The computer system of FIG. 2 is only one example of a suitable environment and is not intended to suggest any limitation as to the scope of use or functionality of the invention. Nor should the computing device 102 be interpreted as having any dependency or requirement relating to any one or combination of components illustrated in FIG. 2 . The invention is operational with numerous other general-purpose or special-purpose computing environments or configurations. Examples of well known computing systems, environments, and configurations suitable for use with the invention include, but are not limited to, personal computers, servers, hand-held or laptop devices, tablet devices, multiprocessor systems, microprocessor-based systems, set-top boxes, programmable consumer electronics, network PCs, minicomputers, mainframe computers, and distributed computing environments that include any of the above systems or devices. In its most basic configuration, the computing device 102 typically includes at least one processing unit 200 and memory 202 . The memory 202 may be volatile (such as RAM), non-volatile (such as ROM or flash memory), or some combination of the two. This most basic configuration is illustrated in FIG. 2 by the dashed line 204 . The computing device 102 may have additional features and functionality. For example, the device 102 may contain additional storage (removable and non-removable) including, but not limited to, magnetic and optical disks and tape. Such additional storage is illustrated in FIG. 2 by removable storage 206 and by non-removable storage 208 . Computer-storage media include volatile and non-volatile, removable and non-removable, media implemented in any method or technology for storage of information such as computer-readable instructions, data structures, program modules, or other data. Memory 202 , removable storage 206 , and non-removable storage 208 are all examples of computer-storage media. Computer-storage media include, but are not limited to, RAM, ROM, EEPROM, flash memory, other memory technology, CD-ROM, digital versatile disks, other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage, other magnetic storage devices, and any other media that can be used to store the desired information and can be accessed by the computing device 102 . The device 102 may also contain communications channels 210 that allow the computer to communicate with other devices. Communications channels 210 are examples of communications media. Communications media typically embody computer-readable instructions, data structures, program modules, or other data in a modulated data signal such as a carrier wave or other transport mechanism and include any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communications media include wired media, such as wired networks and direct-wired connections, and wireless media such as acoustic, RF, infrared, and other wireless media. The term “computer-readable media” as used herein includes both storage media and communications media. The computing device 102 may also have input devices 212 such as a keyboard, mouse, pen, voice-input device, tablet, touch-input device, etc. Output devices 214 such as a display (which may be integrated with a touch-input device), speakers, and printer may also be included. All these devices are well known in the art and need not be discussed at length here.
FIGS. 3 a and 3 b together show an exemplary exchange of messages when the client 104 requests a feature from the server 102 . FIGS. 5 a , 5 b , 7 a , and 7 b , below, present further details of possible message exchanges. The client 104 requests the feature in step 300 of FIG. 3 a . The feature can be of any type including data compression, data encryption, and the numerous QOS features. The message protocol can also be of any type, such as, e.g., SIP (the Session Initiation Protocol). Note that the feature request in step 300 need not be explicit: It may instead be implied by the message protocol used between the client 104 and the server 102 .
In step 302 , the server 102 receives the feature request and decides whether it will support that feature. If not, then the server 102 uses the methods defined in the protocol to reject the request (not shown). If the server 102 will support the requested feature and is ready to do so immediately, then the server 102 allocates the resources needed to support the feature and accepts the request (also not shown). The scenario depicted in FIGS. 3 a and 3 b concerns a third possibility for the server 102 : It may be willing to support the requested feature in the future but is not yet ready to do so. One example that leads to this scenario is the case where the server 102 currently does not have the resources available to support the feature but expects to acquire those resources soon. In another example, the server 102 does not yet trust the client 104 enough to allocate precious resources to its request. The server 102 does not yet allocate the resources but waits until the client 104 has successfully authenticated itself. (See the discussion of steps 310 and 312 of FIG. 3 b below.) In the scenario of FIG. 3 a , the server 102 in step 302 sends a message to the client 104 indicating that the request has been accepted but also indicating that the requested feature is not yet supported.
There are numerous ways in which the server 102 can indicate that the requested feature is not yet supported. In SIP, for example, when data compression is allowed on a communications link, “tags” are added to the data fields. (See FIG. 4 and the accompanying discussion.) Not all data messages are compressed even when compression is enabled (for example, a given message may be too short to benefit from compression), so a flag in a tag indicates whether the accompanying data are compressed. Embodiments of the present invention can use this tag and flag in step 302 : The acceptance message is tagged indicating that the request for data compression has been allowed, but the data in that message are not compressed, as indicated by the flag. In step 304 , the client 104 receives the acceptance message and notes that the requested feature is not yet supported. In the data compression example, the tag indicates the acceptance of the request, but the lack of compression indicates that the server is not ready for compressed data.
In steps 306 and 308 , the client 104 and the server 102 communicate without using the requested feature. Depending upon circumstances, these steps can continue for a long time (until, e.g., the server 102 acquires the necessary resources) or can be very short (e.g., only until the client 104 successfully authenticates itself to the server 102 ).
Steps 310 and 312 of FIG. 3 b are, in one sense, optional but are included because they illustrate a scenario in which the methods of the present invention are very useful. During these steps, the client 104 authenticates itself to the server 102 using the methods established by the protocol they are using. (Many such methods are known in the art.) The server 102 is understandably reluctant to allocate precious resources until these steps are complete. Although this scenario is not the only one in which delayed allocation of resources proves valuable, it is one scenario closely tied to preventing DOS attacks.
Finally, in step 314 the server 102 decides to allocate the resources to support the client 104 's request. In step 316 , the server 102 indicates to the client 104 that the feature is now supported. Just as with the numerous possible indications discussed above with respect to step 302 , there are numerous ways in which the server 102 can indicate that the feature is now supported. Using the data compression example, the server 102 can simply send compressed data to the client 104 . Upon receiving the indication, whatever it is, the client 104 notes that the feature is now supported in step 318 . From that point on, the client 104 and the server 102 can communicate either using or not using the requested feature, as appropriate to the situation.
FIG. 4 shows a message data structure 400 used for sending compressed or uncompressed data. The data structure 400 includes three tag fields. The first tag field 402 is designated for flags (herein “flags tag”). The flags tag field 402 is used for indicating the format of the data in field 408 , specifically whether the data are compressed. Under this implementation, the flag field includes mutually exclusive bits. As an example, a 0x80 bit is used to indicate that the data are uncompressed, and a 0x20 bit indicates that the data are compressed.
In some embodiments, there are at least three types of data packets: (1) untagged data indicating that data compression is not available for the current connection; (2) data tagged indicating that compression is possible, but the data in field 408 are flagged as not compressed; and (3) data tagged indicating that compression is possible, and the data in field 408 are compressed. In steps 304 and 318 of FIGS. 3 a and 3 b , respectively, the client 104 determines the type of data packet it receives from the server 102 to know whether or not data compression is supported.
A flowchart illustrating exemplary steps performed by the server 102 is shown in FIGS. 5 a and 5 b . In step 500 , the server 102 receives a request from the client 104 for a service or for a communications feature. As mentioned above, this request may be in the form of an explicit message sent by the client 104 , or it may be implicit in the communications protocol used between the client 104 and the server 102 . The server 102 checks, in step 502 , its own configuration to see whether it can support the requested feature. It could happen that the client 104 is requesting a feature that the server 102 is not configured to support. In that case, the method proceeds to step 510 where the server 102 rejects the request.
If the server 102 could, at least theoretically, support the requested feature, then in step 504 it accepts the request but tells the client 104 that the client 104 may not yet use the feature.
There are some features that the server 102 will only provide to authenticated clients. If the client 104 has requested such a feature, then in step 506 an authentication process is carried out. If the client 104 fails the authentication in step 508 , then the server 102 can reject the request in step 510 , even though it provisionally accepted the request earlier in step 504 . Note that an authentication failure does not necessarily imply that the client 104 must terminate its communications session with the server 102 . While that is a possible outcome, for the present discussion, the consequence of an authentication failure is the client 104 's inability to use the requested feature.
If the client 104 successfully authenticates itself to the server 102 (or if such authentication is not necessary), then the client 104 and the server 102 begin to communicate with each other but without using the requested feature. If necessary, the server 102 checks for the availability of sufficient resources in step 512 and when, in step 514 of FIG. 5 b , such resources become available, the server 102 allocates them to support the feature requested by the client 104 . As mentioned above in relation to FIG. 1 , these resources need not reside on the server 102 itself. They may be provided by another server 110 . In some scenarios, the resources may become available in step 514 when another client gives them up. In other scenarios, the resources are always available, but the server 102 is reluctant to commit them to the client 104 until the client 104 successfully authenticates itself in step 508 of FIG. 5 a.
In step 516 of FIG. 5 b , the server 102 indicates that it is now ready to support the requested feature. Some features can be supported at different levels. For example, the client 104 requests a minimum bandwidth guarantee of 512 kbps. If the server 102 does not have the resources to fully support that request, it could simply reject it. Alternatively, the server 102 can accept the request but tell the client 104 that the server 102 can only support a 128 kbps bandwidth guarantee. The client 104 decides whether the lower guarantee is acceptable or not and reacts accordingly.
Throughout this procedure, the server 102 tracks its resource levels and allocations, as indicated in step 518 . The server 102 uses this information when deciding whether it has sufficient resources to support a requested feature. System administrators use this information when deciding whether the server 102 is optimally configured.
FIG. 6 gives an example of the server 102 's resource log. The resource allocation log 600 contains four entry rows, each one pertaining to a single feature request. In the log 600 , the client 104 (field 602 ) has requested data compression (field 604 ), and that request has been accepted (field 606 ). The client 106 's request for data compression was rejected, possibly because the client 106 failed to authenticate itself to the server 102 . The client 108 's request for data compression has been provisionally accepted, but that feature is not yet supported. The client 108 has made another request, this time for a guaranteed bandwidth of 512 kbps. The request has been accepted, but the feature is currently supported only at the lower level of 128 kbps.
In step 520 of FIG. 5 b , the client 104 and the server 102 can use the requested feature in their communications. However, they are not required to use the feature. For example, even when compression is supported, some messages are too short to benefit from being compressed.
Another use of the server 102 's resource allocation log 600 is illustrated in step 522 . Here, some resources are freed up (probably from another client), and the server 102 checks its resource allocation log 600 . It notes, for example, that the client 108 requested 512 kbps of guaranteed bandwidth but was only granted 128 kbps. If the server 102 can and wishes to support the client 108 's request at a higher level, it can now do so. For some features, the server 102 can even use this method to reduce its level of support. Other features do not allow for this, and the level of support must be renegotiated.
The client 104 's side of a feature request transaction is illustrated in the flowchart of FIGS. 7 a and 7 b . As the bulk of the client 104 's procedure is evident in light of the above discussion of the server 102 's procedure, only a few aspects need be discussed here. The client 104 can maintain a log of its own requests similar to the server 102 's resource allocation log 600 of FIG. 6 . The status of feature requests, including their level of support if appropriate, can be displayed to a user of the client 104 as indicated in steps 716 and 720 of FIG. 7 b.
The above discussion focuses on the expected course of an exchange between the server 102 and the client 104 . The following table illustrates some of the unexpected things that can occur and how the client 104 should react.
Potential Responses That the Client Should Be Prepared
to Handle When Requesting a Feature
Response
Meaning
Appropriate Handling
Transaction timeout.
Negotiation has failed.
Fall back to not using the
Invalid response.
requested feature on this
Response with no
link.
indication of the
requested feature.
Response with an
invalid indication of the
requested feature.
400
The server does not support
Fall back to not using the
the NEGOTIATE method at
requested feature on this
this point in time or fails to
link.
recognize the method as
valid.
405, 501
The server does not support
Fall back to not using the
the NEGOTIATE method.
requested feature on this
link.
488, 606
The server does not support
Fall back to not using the
the requested feature.
requested feature on this
link.
403
The server is denying the
Close the connection. Open
request.
a new connection and do
not request the feature. Do
not use the requested
feature on this link.
408, 480, 504
Timeout.
Retry after a suitable delay.
Multiple timeouts should
result in closing the
connection and raising an
appropriate alarm. This
indicates loss of
connectivity to the server.
1xx
Provisional response.
Ignore.
2xx
Success.
Enable the requested feature
for this link.
3xx
The server is redirecting the
Ignore. Fall back to not
request.
using the requested feature
on this link.
4xx, 5xx, 6xx
Other errors.
Ignore. Fall back to not
using the requested feature
on this link.
In view of the many possible embodiments to which the principles of the present invention may be applied, it should be recognized that the embodiments described herein with respect to the drawing figures are meant to be illustrative only and should not be taken as limiting the scope of the invention. For example, those of skill in the art will recognize that the illustrated embodiments can be modified in arrangement and detail without departing from the spirit of the invention. Although the invention is described in terms of software modules or components, those skilled in the art will recognize that such may be equivalently replaced by hardware components. Therefore, the invention as described herein contemplates all such embodiments as may come within the scope of the following claims and equivalents thereof. | The present invention allows a server to delay allocating resources to a client's request. When the client requests a feature that requires server resources, the server accepts and acknowledges the client's request, but the client is prohibited from using the requested feature until further notice from the server. For example, during an authorization process, the server allocates only the minimum resources required to maintain the session and to authorize the client. Thereafter, the server allocates the resources necessary to support the client's request only when the resources become available. Until then, the server maintains the communications session without supporting the request. Thus, the server shepherds its resources rather than committing them at the whim of a client. Also, a client need not repeat its request if the server cannot immediately satisfy it; instead, the server accepts the request and then later begins to support it when adequate resources become available. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to tools used in installing carpets. More particularly, the invention relates to tools used in carpet seaming operations in which adjacent pieces of carpet are cemented to a common backing surface with a hot-melt adhesive in a manner intended to minimize the visibility of the resulting seam.
2. Description of Background Art
In the course of installing or laying carpets on the floors of residences, commercial or industrial buildings, it is frequently necessary to use more than one piece of carpeting to cover the desired floor space. Therefore, it is often necessary to join adjacent pieces of carpeting. This usually results in seams of substantial length.
From an aesthetic standpoint, it is almost always desired to minimize the visibility of carpet seams. The ideal appearance sought is that of continuous expanse of carpeting covering the entire floor area, with any seams being invisible. To produce invisible seams in carpeting, there are a number of procedures well known in the art.
In one commonly used method of laying two adjacent pieces of carpet together to form an invisible seam between the abutting straight edges of the two pieces of carpet, the following steps are performed. First, the two pieces of carpet are cut to size, with the edges to be joined cut in a straight line. The two pieces of carpet are then positioned in place with their straight edges abutting. Next, a length of carpet seaming tape is laid underneath the cut edges. Half of the width of the tape extends under one piece of carpet, while the other half of the tape extends under the adjacent piece of carpet. The carpet seaming tape has a tear resistant, fabric-like back and is coated on its upper surface with a hot-melt adhesive.
With a length of carpet seaming tape in place under the entire length of the edges of the carpet segments to be joined, the edges of the carpet at one end of the joint are folded upwards and away from the joint, exposing the carpet seaming tape below. A heat iron with an elongated flat rectangular bottom approximately as wide as the carpet seaming tape is then placed on the upper surface of the tape and pushed along the tape in the direction of the seam, forward from the rear edges of the carpet segments. The heat flowing from the heat iron to the carpet seaming tape raises the temperature of the hot-melt adhesive sufficiently to make it semi-liquid. With the adhesive in that state, it readily adheres to materials such as carpeting. Thus, at this time, the edges of adjacent carpet segments which were initially folded up and away from the carpet seaming tape may be folded back down into place onto the tacky upper surface of the carpet seaming tape. A downward pressure is then placed on the upper surfaces of the edges of the carpet segments, forcing the lower surfaces of the segments into intimate contact with the semi-liquid adhesive on the upper surface of the carpet seaming tape. When the adhesive cools, a tight bond forms between the lower surfaces of the carpet segments and the carpet seaming tape, and therefore between the carpet segment edges.
As has been mentioned, a downward pressure must be exerted on the upper surfaces of carpeting to make it adhere tightly to the tacky hot-melt adhesive on the upper surface of carpet seaming tape, which underlies the edges of the carpet to be joined. A heavy implement with a flat, smooth bottom surface is useful for this purpose.
In some carpet seaming operations, it is desired to intermingle fibers from adjacent edges of carpet segments to conceal the seam line. For this purpose, a roller having a number of parallel discs each having a plurality of evenly spaced spikes projecting radially outward from the disc is often used. The spiked roller is rolled back and forth along a previously cemented seam, teasing or pulling up the ends of fibers from adjacent carpet edges and intermingling them across the seam. This helps to create the appearance of a continuous, seamless carpet.
In performing the steps of melting adhesive on the carpet seaming tape, applying a downward pressure to the carpet edges, and teasing the seam with a spiked roller, carpet installers using presently available equipment encounter a number of problems. In working his way along the length of the joint line to form a seam, the installer usually has to travel a distance of many feet. Therefore, each of the tools and implements required for the carpet seaming operation must be dragged along with him, since they cannot be placed in a position accessible from all points along the seam.
Also, the installer must be careful to place the heat iron which he has used to melt adhesive on the carpet seaming tape in a location where liquid adhesive will not flow onto the carpet, and where the iron will not cause burns.
The present invention was conceived of in an effort to alleviate some of the aforementioned problems experienced in the installation and seaming of carpets.
OBJECTS OF THE INVENTION
An object of the present invention is to provide a carpet seaming tool useful in forcing carpeting onto an adhesive coated backing surface.
Another object of the invention is to provide a tool which can provide a substantial downward pressure on carpeting to be cemented to a backing surface, while not requiring the installer to exert an excessive amount of force on the tool.
Another object of the invention is to provide a carpet installation tool which may be used to tease and intermingle fibers of adjacent carpet segments joined side by side.
Another object of the invention is to provide a carpet installation tool which may be used to provide a storage compartment for the safe storage and transportation of a hot heat iron.
Another object of the invention is to provide a carpet seaming tool in which the various implements used in the seaming operation are all readily accessible in a single portable unit.
Various other objects and advantages of the present invention, and its most novel features, will become apparent to those skilled in the art by reading the accompanying specifications and claims.
It is to be understood that although the invention disclosed herein is fully capable of achieving the objects and providing the advantages described, the description of the invention contained herein is merely illustrative of the preferred embodiments. Accordingly, I do not intend that the scope of my exclusive rights and privileges in the invention be limited to the details of the embodiments described. I do intend that reasonable equivalents, adaptations and modifications of the various embodiments and alternate forms of the present invention which are described herein be included within the scope of this invention as particularly pointed out by the appended claims.
SUMMARY OF THE INVENTION
Briefly stated, the present invention comprehends a tool for use in laying adjacent pieces of carpeting to form an elongated linear seam between abutting edges of the pieces of carpet. The carpet seaming tool according to the present invention includes an elongated box-like member with an open top and ends. An open, inverted U cross-section channel of substantially the same length as the box-like member is fastened to its under side. The front and rear side walls of the channel are approximately co-planar with the front and rear side walls of the box-like member. A plurality of parallel, horizontal axles disposed perpendicular to the channel front and rear side walls are secured thereto. A plurality of evenly spaced parallel discs each having evenly spaced spikes projecting radially outward from the hub of the disc are rotatably mounted on each axle. The spiked discs and supporting axle together form a spiked roller. The weight of the carpet seaming tool according to the present invention is sufficiently large to exert a substantial downward force on spikes contacting carpeting on which the tool is placed.
Preferably, an elongated, flat metal heat shield and support plate for a heat iron is mounted on and parallel to the upper surface of the bottom of the box-like member. The support plate is adapted to receive a heat iron having a flat, rectangular sole plate, and to hold the heat iron in place by means of spring clips which can engage the front and rear edges of the sole plate.
In a modified embodiment of the invention, the structure previously described includes an elongated cover shell having a plurality of fasteners which may be readily engaged or disengaged with complementary fasteners mounted on the front and rear sides of the box-like member. A carrying handle is centrally fastened to the upper surface of the cover shell. Thus, with the cover shell fastened to the box-like member, the interior of the box-like member, which may contain a heat iron, is covered and protected. Also, the handle provides a convenient means for carrying the tool.
In addition to the cover shell, the tool according to the present invention may include an elongated bottom shell which can be fastened over the spiked rollers on the bottom of the tool. The bottom shell includes fasteners which permit the shell to be easily installed on or removed from the tool.
The front and rear surfaces of the bottom shell of the tool curve gently upward from the bottom surface. Thus, with the bottom shell in place, the tool is suited to applying a reciprocating ironing motion on a carpet surface.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an upper perspective view of the carpet seaming tool according to the present invention.
FIG. 2 is an end elevation view of the device of FIG. 1.
FIG. 3 is a front elevation view of the device of FIG. 1.
FIG. 4 is a bottom plan view of the device of FIG. 1.
FIG. 5 is a front elevation view of an alternate embodiment of the device of FIG. 1.
FIG. 6 is an end elevation view of the device of FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1 through 4, a carpet seaming tool 10 according to the present invention is shown. As may be seen best by referring to FIG. 1, the tool 10 includes an elongated upper box-like member 11. Box-like member 11 has a U-shaped transverse cross-sectional shape, with flat, rectangular, parallel front and rear walls 12 and 13, respectively, and an elongated, rectangular bottom wall 14 joined perpendicularly to the bottom edges of front and rear walls 12 and 13. Upper box-like member 11 is preferably fabricated by bending a flat blank of sheet metal.
As may be seen best by referring to FIGS. 1, 2, and 3, a lower, inverted U cross-section channel section 15 similar in size and shape to upper box-like member 11 is fastened to the underside of upper member 11. Lower channel section 15 has flat rectangular front and rear walls 16 and 17 respectively, joined at right angles at their upper edges to front and rear edges of elongated rectangular bottom wall 18. Lower channel section 15 is preferably fabricated from a single piece of sheet metal. The upper surface of bottom wall 18 of lower channel section 15 is joined conformally to the lower surface of bottom wall 14 of upper box-like member 11 by rivets 19. As shown in FIG. 3, bottom wall 18 and bottom wall 14 are fastened with their respective long and short sides in congruent alignment. As may be seen best by referring to FIGS. 3 and 4, a plurality of circular cross-section, cylindrical axles 20 parallel to each other and parallel to bottom wall 18 of lower channel section 15 are disposed perpendicularly between front wall 16 and rear wall 17 of the lower channel section. Axles 20 are preferably fabricated from a durable metal such as steel, and are held to front wall 16 and rear wall 17 by nuts 21.
As shown in FIGS. 2, 3, and 4, a plurality of circular discs 22 having radially outward projecting spikes 23 are rotatably mounted on each axle 20. The spikes 23 have a generally triangular cross sectional shape transverse to the rotational axis of disc 22, and project outward from a central hub section 24 at evenly spaced polar angles. Spiked discs 22 are preferably fabricated as stampings from heavy gauge steel plate.
As may be seen best by referring to FIG. 2, spiked discs 22 are mounted at even longitudinal distances along the length of axle 20 spanning the distance between front wall 16 and rear wall 17 of lower channel section 15. The axial spacing between discs 22 on axle 20 is maintained by spacing washers 25 mounted over axle 20 on either side of each disc 22.
As may be seen best by referring to FIGS. 1 and 3, an elongated, flat rectangular heat shield 26 having upwardly curved edges 27 is mounted on the upper surface of bottom wall 14 of upper box-like member 11. Heat shield 26 is symmetrically disposed between the inner facing surfaces of front wall 12 and rear wall 13 of box-like member 11, with its long axis parallel to the front and rear walls. Also, heat shield 26 is symmetrically disposed between front opening 28 and rear opening 29 of upper box-like member 11.
Approximately halfway between the transverse center line of heat shield 26 and either longitudinal end of the shield, vertical rectangular support plates 30 are mounted to the upper surface of the heat shield. Support plates 30, positioned at the front and rear of heat shield 26, are perpendicularly disposed between the long edges of the heat shield, and fastened to its upper surface. Support plates 30 are preferably fabricated from medium gauge, heat resistant metal.
Near the front and rear edges of heat shield 26, L-shaped retainer clips 31 are fastened to the upper surface of the heat shield with their bases 32 perpendicularly disposed towards the transverse center plane of the heat shield, and their legs 33 extending perpendicularly upwards from the plane of heat shield 26. The upper end of each leg 33 of spring clip 31 has a serpentine series of bends, bending inward to form ridge 34 and then outward and downward to form curved finger grip 35. Spring clips 31 are fabricated of spring steel, and the spacing between ridges 34 of the spring clip adapts the spring clip to snap over the front and rear edges of the sole plate B of heat iron A.
As shown in FIG. 3, heat iron A may thus be locked in position between ridges 34 of spring clips 31, with the bottom surface of sole plate B of the heat iron resting on the upper edges of support plates 30. With iron A locked in place, U-shaped handle bail 36, which is pivotably mounted between the upper, inner facing walls 12 and 13 of apparatus 10, may be pivoted upward to a vertical position where the handle 36 may be easily grasped for carrying the apparatus, along with the contained heat iron A.
With heat iron A secured in carpet seaming tool 10, both implements may be easily carried to and from job sites, using handle 36. At a carpet installation site, heat iron A can be plugged in to an electrical outlet, causing iron A to heat up. During the warm-up period, iron A may remain locked in position in apparatus 10. When it is desired to use heat iron A, handle 36 may be pivoted forward as shown in FIG. 1, allowing the iron to be lifted backwards and upwards away from the apparatus.
After heat iron A has been used to melt adhesive on carpet seaming tape placed underneath adjacent carpet segments, tool 10 may be rolled back and forth along the seam. Spiked discs 22, forced down on the carpet surface by hand pressure and by the force of gravity acting upon the substantial weight of the apparatus, efficiently tease carpet fibers and tend to intertwine fibers of adjacent carpet segments in a criss-cross fashion across the seam. Thus, the apparatus 10 provides an effective means of minimizing the visibility of the seam.
To provide additional force useful in pressing spiked discs 22 down upon the carpet segments, weights may be incorporated into apparatus 10. Additionally or alternatively, heat iron A may be placed in position on support plates 30 of apparatus 10. In this position installed carpeting and floor surfaces are protected from the possibility of being damaged by contacting semi-liquid adhesive adhering to sole plate B of heat iron A. Moreover, the weight and low center of gravity of the apparatus 10 helps to insure that it will not tip over, spilling liquid adhesive which may have dropped from sole plate B of heat iron A onto the surface of heat shield 26. Any liquid adhesive which does fall on the heat shield is prevented from spilling off the heat shield by the upward curved edges 27 of the heat shield.
FIGS. 5 and 6 illustrate an alternate embodiment 40 of the apparatus shown in FIGS. 1 through 4. Alternate embodiment 40 includes an elongated, hollow cover shell 41 having elongated, parallel rectangular front and side walls 42 and 43 respectively. The upper edges of front wall 42 and rear wall 43 are joined perpendicularly to the long front and rear edges, respectively, of top panel 44 of cover shell 41.
Extending downward from the left and right edges, respectively of top panel 44 of cover shell 41 are left and right side panels 45 and 46, respectively. Side panels 45 and 46 are rectangular and extend some distance below the lower edges of front wall 42 and rear wall 43 of cover shell 41. As shown in FIG. 6, side panels 45 and 46 are adapted to closing the openings in either end of upper box-like member 11 of apparatus 40 when cover shell 41 is down in place on top of box-like member 11. Cover shell 41 is preferably fabricated from a single piece of medium gauge steel plate.
As may be seen best by referring to FIG. 5, luggage-type fastener posts 47 are mounted near the lower edges of the front and rear walls 42 and 43 of cover shell 41. One fastener 47 is mounted near the left side of front wall 42, and a second fastener 47 is mounted in a parallel position on the outer surface of back wall 43. A third fastener 47 is mounted near the right side of front wall 42, and a fourth fastener is mounted in a parallel position on the outer surface of back wall 43.
As shown in FIG. 5, four fastener mechanisms 48, engageable with fastener posts 47, are mounted on front wall 12 of box-like member 11, near its upper edge, and on rear wall 13 of box-like member 11, near its upper edge. Fastener mechanisms 48 are mounted in positions which will place each of them adjacent to a fastener post 47, with cover shell 41 in place on box-like member 11. Thus, with cover shell 41 in place on box-like member 11, fastener mechanisms 48 may be snapped into engagement with fastener posts 47, thereby securing cover shell 41 to box-like member 11. Carrying handle 49 is fastened to top panel 44 of cover shell 41, permitting cover shell and attached apparatus to be carried as a unit.
Preferably, alternate embodiment 40 also includes a detachable bottom cap 50. As may be seen best by referring to FIG. 5, bottom cap 50 is a generally trough-shaped, elongated rectangular cross-section structure having left and right edge walls 51 and 52 that curve smoothly upward from bottom wall 53 of cap 50. Bottom cap 50 is preferably fabricated by die casting from aluminum or other light metal. Bottom cap 50 includes fastener posts 54 analogous in form, location and function to fastener posts 47 on cover shell 41, previously described. Fastener mechanisms 55 engageable with fastener posts 54 are mounted on front wall 16 and rear wall 17 of lower channel section 15 and function analogously to fastener mechanisms 48, previously described. Thus, with bottom cap 50 in place beneath lower channel section 15, fastener mechanism 55 may be snapped into engagement with fastener posts 54, thereby securing bottom cap 50 to lower channel section 15. In this position, apparatus 40 may be transported without the possibility of damage occurring to spiked discs 22, or of injury or damage being caused by spiked discs 22.
In addition to covering spiked discs 22, bottom cap 50 provides additional capability to alternate embodiment 40 of the carpet seaming tool according to the present invention. Specifically, bottom cap 50 provides a flat, smooth rigid elongated structure with gently curved edges needed for certain cold "ironing" operations associated with the installation of carpets. | A tool useful in carpet laying operations for producing seams in adjacent pieces of carpeting has an elongated upper box-like member with an open top and ends. A generally flat support plate within the box-like member is adapted to hold a heat iron used to melt adhesive on carpet seaming tape. An inverted, elongated channel member supports the upper box-like member, and also supports a number of transversely disposed horizontal axles. Each axle contains a plurality of concentrically mounted, parallel, freely rotatable discs spaced regularly along the length of the axle. Each disc has evenly spaced spikes projecting radially outward from the hub of the disc. Rolling the tool along a joint between adjacent pieces of carpeting intermingles the fibers of the two pieces of carpeting to minimize the visibility of the seam. Alternate embodiments of the tool include a cover and carrying handle fastenable over the box-like member, and a smooth base plate fastenable to the elongated channel member to cover the discs. | 8 |
This application claims the benefit, under 35 U.S.C. §119 of EP Patent Application 11305635.2, filed 24 May 2011.
TECHNICAL FIELD
The present invention relates generally to 3-D models and in particular to the protection of graphical objects of such models.
BACKGROUND
This section is intended to introduce the reader to various aspects of art, which may be related to various aspects of the present invention that are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present invention. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.
The use of three-dimensional (3D) objects has been increasing in the last years, particularly with the emergence of metaverses. There are multiple usages for 3D objects: socializing worlds, games, mirroring worlds, simulation tools, but also 3D User interfaces, animation movies and visual effects for television. Generally, 3D virtual objects represent real money value. In socializing worlds and games, players are selling virtual objects or avatars to other players for real money. Building an experienced character within an online game is a very lengthy process that can require hundreds of hours behind the keyboard. The 3D model of a real-world object from a simulation tool allows manufacturing the real (counterfeit) object and selling it. Leaking the 3D model for a scene of the next blockbuster from Hollywood studios may result in bad press for the studios. As can be seen, in many cases, 3D objects are assets of great value for their owner.
Strategies for content protection comprise confidentiality protection—intended to make it impossible for unauthorized users to access the content, e.g. by encryption—and watermarking—intended to make it possible to track a user who has disseminated the content without authorization to do so.
Basic methods of 3D content protection focus on the entire data, i.e. all the data is either encrypted or watermarked (or both), although these methods are somewhat crude.
More subtle ways of protecting 3D content is to protect one or more of its 3D objects. This is possible as 3D content often is made up of a number of distinct objects positioned in a setting. When each 3D object is coded as a separate entity, it becomes possible to protect each of these separately and it is not necessary to protect all of them.
For example, US 2008/0022408 describes a method of 3D object protection by storing the “bounding box” of the object as non-encrypted data in one file and the protected 3D object as encrypted data in a separate file. Any user may access the non-encrypted data, but only authorized users can access the encrypted data; non-authorized users see a basic representation thereof (i.e. the bounding box), such as a parallelepiped instead of a car. However, this method was developed to be used with 3D rendering software and is less suited for multimedia content, such as video and film. In addition, the file format (one file with non-encrypted data and one file with encrypted data) is non-standard and is thus usable only by adapted rendering devices, not standard ones. Indeed, the encrypted data does not respect the syntax of most 3D techniques and can thus normally not be used.
U.S. Pat. No. 6,678,378 describes a solution for protecting a 3D Computer Aided Design (CAD) object by encryption. The solution may encrypt one of the coordinate values of the nodes and the equations for the edges or the contours, by nonlinear or affine transformation, thereby distorting the 3D object or by ‘normal’ encryption such as RSA.
Problems with this solution is that the calculations may be costly (in particular when using RSA) and that the distortions may not be sufficient to deter a malicious user from using the content nevertheless. In addition, in the case of ‘normal’ encryption, the 3D object may not be readable at all by a content consuming device—such as a computer or a television—which may be a drawback in some cases.
A digital rights enabled graphics processing system was proposed in 2006 by Shi, W., Lee, H., Yoo, R., and Boldyreva, A: A Digital Rights Enabled Graphics Processing System. In GH '06: Proceedings of the 21 st ACM SIGGRAPH/EUROGRAPHICS symposium on Graphics hardware, ACM, 17-26.]. With this system, the data composing the 3D object (collection of vertices, textures) is encrypted. Their decryption is handled within the Graphic Processing Unit, under control of licenses. It is proposed also to use multi resolution meshes to deliver simultaneously a protected and unprotected version of a 3D element. Although the system itself is a real progress towards secure 3D environments, the use of protected scenes with other Virtual Reality Modelling Language (VRML) renderers will lead to interoperability issues.
David Koller and Marc Levoy describe a system for protection of 3D data in which high-definition 3D data is stored in a server. The users have access to a low-definition 3D object that they can manipulate and when a user has chosen a view, a request is sent to the server that returns a two-dimensional JPEG that corresponds to the view. Hence the high-definition 3D data is protected as it is never provided to the users. (See “Protecting 3D Graphics Content” by David Koller and Marc Levoy. Communications of the ACM, June 2005, vol. 48, no. 6.) While this system works well for its intended use, it is not applicable when the full 3D data is to be transferred to a user.
A common problem with the prior art solutions is that they are not format preserving, but that they are based on the encryption of 3D data and that they provide a second set of 3D data that is usable by non-authorized devices so that the user can see something, e.g. a bounding box.
European patent application 10305692.5 describes a format preserving solution in which a 3D object comprising a list of points (i.e. vertices) is protected by permuting the coordinates of at least some of its points. European patent application 10306250.1 describes a similar solution in which the coordinates of at least one dimension of the vertices of a 3D object are permuted independently of the other dimensions. The lists detailing how the points are connected remain unchanged, but the 3D object no longer “makes sense” as these points no longer have the initial values. Advantages of these solutions is that the protected 3D object is readable also by devices that are not able to ‘decrypt’ the protected 3D object—although it does look very strange—and that the protected 3D object is inscribed in a bounding box of the same size as the original 3D object.
While the latter solutions work well, it will be appreciated that there may be a need for an alternative solution that can enable protection of 3D objects with quick calculations that still enables an unauthorized content consuming device to read and display the 3D object, albeit in a manner that renders the viewing thereof unsatisfactory. The present invention provides such a solution.
SUMMARY OF INVENTION
In a first aspect, the invention is directed to a method of protecting a graphical object. A device receives the graphical object comprising a plurality of points; obtains a protected graphical object by, for each of at least some of the plurality of points: generating a translation vector and transforming the point by adding the point to the translation vector, and outputs the protected graphical object that is visually different from the graphical object.
In a first preferred embodiment, the graphical object is a three-dimensional object.
In a second preferred embodiment, the translation vector is generated using a key-based generator function using a secret value.
It is advantageous that the graphical object is associated with a bounding box and that it is verified if the translation vector would result in a transformed point outside the bounding box and, if this is the case, the translation vector is adjusted modulo a size of the bounding box for at least one dimension so that the transformed point will be located within the bounding box.
It is further advantageous to use at least one of a lower bound and an upper bound to control at least one value of the translation vector.
In a second aspect, the invention is directed to a method of unprotecting a protected graphical object. A device receives the protected graphical object comprising a plurality of points, obtains an unprotected graphical object by, for each of at least some of the plurality of points: generating a translation vector and transforming the point by subtracting the point from the translation vector; and outputs the unprotected graphical object.
In a first preferred embodiment, outputting comprises rendering.
In a third aspect, the invention is directed to a device for protecting a graphical object. The device comprises a processor configured to receive the graphical object comprising a plurality of points; obtain a protected graphical object by, for each of at least some of the plurality of points: generating a translation vector; and transforming the point by adding the point to the translation vector; and output the protected graphical object that is visually different from the graphical object.
In a fourth aspect, the invention is directed to a device for unprotecting a protected graphical object. The device comprises a processor configured to receive the protected graphical object comprising a plurality of points; obtain an unprotected graphical object by, for each of at least some of the plurality of points: generating a translation vector and transforming the point by subtracting the point from the translation vector; and output the unprotected graphical object.
In a first preferred embodiment, processor is further configured to use a key-based generator function using a secret value to generate the translation vector.
It is advantageous that the graphical object is associated with a bounding box and that the processor is further configured to verify if the translation vector would result in a transformed point outside the bounding box and, if this is the case, to adjust the translation vector modulo a size of the bounding box for at least one dimension so that the transformed point will be located within the bounding box
It is further advantageous that the processor is further configured to generated the translation vector using at least one of a lower bound and an upper bound to control at least one value of the translation vector.
In a second preferred embodiment, the graphical object is a three-dimensional object.
In a fifth aspect, the invention is directed to a computable readable storage medium comprising stored instructions that when executed by a processor performs the method the first aspect of the invention.
In a sixth aspect, the invention is directed to a computable readable storage medium comprising stored instructions that when executed by a processor performs the method the first aspect of the invention.
BRIEF DESCRIPTION OF DRAWINGS
Preferred features of the present invention will now be described, by way of non-limiting example, with reference to the accompanying drawings, in which
FIG. 1 illustrates a system for protecting a 3D object according to a preferred embodiment of the present invention;
FIG. 2 illustrates a method for protecting a 3D object according to a preferred embodiment of the present invention; and
FIGS. 3 and 4 illustrate different aspects of 3D object protection according to a preferred embodiment of the present invention.
DESCRIPTION OF EMBODIMENTS
In some 3D content formats, such as for example Virtual Reality Modelling Language (VRML) and X3D, a 3D graphical object (“3D object”) is represented as a first list (or array) of points, wherein each point has a set of specific coordinates, and a second list with information on how to link the points together.
A salient inventive idea of the present invention is to protect a 3D object by performing a cryptographic algorithm, preferably a key-based transformation of the coordinates of the points for at least one dimension in the first list. The transformation results in a creation of a new set of points so that the protected 3D object is still understood by any standard 3D model rendering application, but the resulting display becomes weird and hardly usable to a viewer. In other words, the 3D object is encrypted. The skilled person will appreciate, in particular in view of the description hereinafter, that a difference compared to the solutions in EP 10305692.5 and EP 10306250.1 is that new coordinate values are created according to the present invention.
Authorized users have the means to reverse the transformation to obtain the original points.
FIG. 1 illustrates a system 100 for protecting a 3D object according to a preferred embodiment of the present invention and FIG. 2 illustrates a method for protecting a 3D object according to a preferred embodiment of the present invention. As a non-limitative example, the points correspond to the vertices of the surfaces composing the graphical object and are expressed in 3D coordinates, and the second list comprises information on how to link the vertices together to form lines and surfaces. The transformation may be performed on the static part (Coordinate node in VRML syntax) or the animation part (Coordinatelnterpolator node in VRML syntax), or preferably both. In other words, it is the representation of the 3D object that is protected, which makes the correct rendering of the object impossible.
The system 100 comprises a sender 110 and a receiver 140 , each comprising at least one processor 111 , 141 , memory 112 , 142 , preferably a user interface 113 , 143 , and at least one input/output unit 114 , 144 . The sender 110 may for example be a personal computer or a workstation, while the receiver 120 for example may not only be a personal computer or a workstation, but also a television set, a video recorder, a set-top box or the like.
The sender 110 receives 210 a 3D object 120 to be protected, uses a key to transform 220 at least one of the x-coordinates, the y-coordinates, and the z-coordinates (preferably all three and preferably independently of the other dimensions) of the points of the 3D object 120 to obtain a protected 3D object 130 that is stored or sent 230 to the receiver 140 .
The coordinates are transformed as follows. For each point P=(x,y,z) to be protected, a translation vector (a,b,c) is generated, where (a,b,c)=f(secret) and f is a key-based generator function. The translation vector (a,b,c) is then added to the point P=(x,y,z) to generate a protected point P′=(x′,y′,z). In other words:
( x′,y′,z )=( x+a,y+b,z+c ).
The protected points depend on the translation vectors, which in turn depend on the key-based generator function f(secret).
According to a first variant, f uses a key-based pseudo-random generator with the secret as input parameter. With such a function, the operation is very simple but there is little or no control of the size of the bounding box of the transformed object.
According to a second variant, f uses a key-based pseudo-random generator to generate values respecting additional constraints in order to adjust the impact of the deformation. A first example consists in respecting the bounding box. In this case, the translation is calculated modulo the size of the relevant dimension of the bounding box. In this case, there is no ‘explosion’ of the model; the bounding box of the object does not increase in size. The bounding box and the original point must be specified as additional parameters of the function f.
As an illustration of the second variant, imagine one-dimensional bounding box from 1 to 10 with a point to protect at 8. If the translation vector is, say, 6, then this would result in a point outside the bounding box at 14 . To avoid this, the translation vector is adjusted by the size of the bounding box: 6 (the initial translation vector)−10 (the size of the bounding box)=−4 (the final translation vector). Adding the translation vector to the point gives 8+(−4)=4.
At the receiver, the reverse calculations also result in a point outside the bounding box: 4 (the ‘protected’ point)−6 (the initial translation vector ‘in the opposite direction’)=−2. As this is outside the bounding box, the translation vector is adjusted by the size of the bounding box: 6−10=−4. This value is then subtracted from the ‘protected’ point: 4−(−4)=8, which is the initial value. Another way of seeing this is that the size of the bounding box (10) is added to the value of the point outside the bounding box, i.e. −2+10=8, which is the same result.
A second example is to limit the impact of the deformation by controlling the values of the translation vector within a preferably predetermined range. The range may be expressed as one or more additional input parameters, i.e. lower and upper bounds or a certain percentage of the bounding box (that may be different for each dimension). In this case, the ‘explosion’ of the model is controlled.
On the receiving side, the receiver 120 receives 240 the protected 3D object 130 , restores 250 the points by inversing the transformation of the transformed coordinates using the secret (whose distribution to the receiver is beyond the scope of the present invention), and may then display or otherwise use 260 the unprotected 3D object 150 . Put another way, the receiver uses the function f(secret) to generate a translation vector (a,b,c) that is subtracted from the protected point; (x,y,z)=(x=a,y=b,z=c). It should be noted that the initial 3D object 120 and the unprotected 3D object 150 are identical.
As a result, an authorized user will not notice anything out of the ordinary since all objects will be displayed correctly, while an unauthorized user will see the overall scene with the protected object or objects rendered in an incorrect way.
A first computable readable storage medium 160 comprises stored instructions that when executed by the processor 111 of the sender 110 protects the 3D object as described. A second computable readable storage medium 170 comprises stored instructions that when executed by the processor 141 of the receiver 140 unprotects the 3D object as described.
FIGS. 3 and 4 illustrate different aspects of 3D object protection according to a preferred embodiment of the present invention. FIG. 3 shows an unprotected list of points 310 —for example the static part of the object—that after transformation 320 becomes a protected list of points 330 . As an example, only the x-coordinate values have been transformed, while the y-coordinate values and the z-coordinate values remain unchanged. In FIG. 3 , the indices are shown to the left of the set of coordinate values and the translation vector 315 (comprising only the value a and zeroes as only the x-coordinate is transformed) is seen between the unprotected list 310 and the protected list 330 .
It can be seen that the x-coordinates are different in the two lists; for example, for index 1, the original x-coordinate (17) at is added to the x-coordinate of the translation vector ( 124 ), which yields a translated x-coordinate of the protected point ( 141 ). FIG. 4 illustrates the rendering of 3D objects: a rendered unprotected 3D object 410 is shown next to a rendered protected 3D object 420 to enable comparison between them. As can be seen, the rendered protected 3D object 420 only has a faint resemblance to the unprotected 3D object 410 . This is due to the fact that the translation vectors were generated according to the second example of the second variant, i.e. the size of the vectors was limited.
In an alternative embodiment, the points of the 3D graphical object correspond to the mapping of textures on the surfaces composing the graphical object and are expressed in two-dimensional coordinates.
The skilled person will appreciate that user authorization and key management are out of the scope of the present invention.
It may thus be seen that the coordinates are transformed. A traditional approach would be to encrypt vertex data, which at best would result in having random points spread all over the 3D space and overlapping with the other objects of the complete scene; at worst, it would not at all be possible to render the 3D object. With the approach of the present invention, the protected 3D object stays generally gathered together, possibly even within the geometrical limits of the original, i.e. unprotected, 3D object. Therefore, when the user is not authorized to unprotect one object, it is possible that the overall scene is not too confused by the display of this protected object.
While the invention has been described for three dimensions, it may also be applied to protect objects in other dimensions, not only one but also two or any number of dimensions above three.
It will thus be appreciated that the present invention can provide a mechanism for ensuring the confidentiality of 3D models, and that the mechanism can visually differentiate protected and non-protected models for non-authorized users. It will also be appreciated that the protected 3D object (and the scene comprising the 3D object) can always be rendered, although it will be more or less recognizable, depending on the limitations constraints used for the key-based generator.
Each feature disclosed in the description and (where appropriate) the claims and drawings may be provided independently or in any appropriate combination. Features described as being implemented in hardware may also be implemented in software, and vice versa. Reference numerals appearing in the claims are by way of illustration only and shall have no limiting effect on the scope of the claims. | A 3D object is protected by a first device that receives the 3D object, generates translation vectors that are added to the points of the 3D object to obtain a protected 3D object, and outputs the protected 3D object. The protected 3D object is unprotected by a second device by receiving the protected 3D object, generating translation vectors that are subtracted from the points of the protected 3D object to obtain an unprotected 3D object, and outputting the unprotected 3D object. Also provided are the first device, the second device and computer readable storage media. | 6 |
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to an apparatus and method for monitoring and reflecting the legality of a motor vehicle identity status to outside by using a vehicle-mount microcomputer information system, and belongs to the field of identity anti-fake and automatic identification for a motor vehicle.
DESCRIPTION OF THE RELATED ART
[0002] The legality of a motor vehicle identity is a broad conception and generally comprises the following aspects: whether the license plate itself is true or false and whether it is in conformity with the vehicle; whether the main configuration, appearance and color of the vehicle are in conformity with those of in legal enrollment and registration; whether the vehicle has passed the verification and check with respect to stipulated items on schedule; whether the source and usage of the vehicle are legal, and the like.
[0003] The identification of legality of a road vehicle identity is a difficulty not solved for a long time both domestically and abroad. If the difficulty can not be resolved properly, illegal vehicles, for example including the situations of false license plate, inconformity between the license plate and the vehicle, illegal repack, illegal operation, counterfeiting of a specific identity, evasion of stipulated fees, theft of vehicles, verification and check period overrun, etc., cannot be forbidden, and vehicle-related crimes can not be prevented effectively.
[0004] The current methods for detecting the identity legality of a road vehicle may be classified into the following two categories.
[0005] 1. Direct detection. In this type of method, a vehicle is stopped and the license plate, the vehicle and related certificates are synthetically detected. This is a standard method with accuracy and thoroughness, but it is mainly manually operated, is time consuming and toilsome and thus has low efficiency. This method is particularly prone to being restricted by various subjective and objective factors and thus generally cannot be efficiently implemented. Therefore, this kind of method cannot be the mainstream method, except for being at special places or in special conditions.
[0006] 2. Indirect detection. In this type of method, the legality of the driving vehicle is indirectly judged by monitoring the license plate (or logo, the same below). Since this kind of method is suitable for automatic identification, more and more countries and regions regard the method as a mainstream technology for monitoring the vehicle. However, since the this kind of method only monitors the license plate but not detect the vehicle and related certificates, and current license plate technology does not have the function of reflecting the virtual status of the vehicle identity, judging the defects of the vehicle depending on such kind of method can only obtain uncertain conclusions, particularly cannot confirm that the identity of the vehicle is legal. Moreover, this kind of method has high demands for ground detection system, and thus, in the regions being incompletely provided ground detection apparatus, this type of method will not obtain any effect, and the defection cannot be implemented without omission. For example, a radio frequency communication system is disclosed in Chinese Patent Application No. CN1305911A, published on Aug. 1, 2001 and entitled “automobile electronic license plate system”, and the system comprises automobile electronic license plate apparatus and automobile electronic license plate detection apparatus. According to the descriptions of the specification of the application, said system has the function of quickly identifying and finding remarkable features of the vehicle, as well as the function of automobile logo anti-fake. However, as can be seen from the technical solution, this system also has the similar difficulty as mentioned above, and can not make sure to accurately identify and find the vehicle. This system especially can not confirm that the identify of the vehicles is legal, and does not have the anti-fake function with respect to the vehicle and the logo. Said system cannot obtain any effect in regions having no ground detection apparatus.
[0007] At present, the illegal vehicle on road cannot be detected or prevented and a variety of detecting methods cannot resolve the problem of vehicle identification, the reasons lie in that the vehicle has not anti-fake design and the appearance and license plate of the vehicle do not have the function of reflecting the virtual status of the vehicle identity.
SUMMARY OF THE INVENTION
[0008] In order to resolve the difficulty of judging the identity legality of a road vehicle, it is needed to design a new technical solution to eliminate the source of the difficulty. The present invention exactly solves the above difficulty. According to the present invention, a device is mounted on the vehicle for automatically monitoring, analyzing and judging the vehicle itself, the license plate and related certificates and providing to outside the resulting information of the above said self detection, wherein the administrative institution input in advance the electronic archives of the vehicle identity into a microcomputer of said device. The present invention thus achieves the anti-fake of the vehicle identity, and makes the appearance and license plate of the vehicle have the function of reflecting the virtual status of the vehicle identity and makes the illegal vehicles be exposed automatically.
[0009] The technical solution of the present invention is described as follows.
[0010] 1. The anti-fake apparatus for motor vehicle identity comprises four parts: member anti-fake means, a microcomputer, information displays and communicators. The power supply for the system operation directly comes from the vehicle power supply.
[0011] The microcomputer comprises a microprocessor, a memory and a group of communication interfaces, which microcomputer is mounted on the vehicle or the license plate.
[0012] Each of the member anti-fake means is a means containing identification information. The license plate and respective members of the vehicle legally enrolled and registered according to stipulations of the administrative institution are respectively provided with at least a member anti-fake means. Respective member anti-fake means is in signal connection with respective communication interface of the microcomputer, respectively. Two types of member anti-fake means can be used. One type is the member anti-fake means that is in wired signal connection with the microcomputer, and the other type is the member anti-fake means that is in wireless connection with the microcomputer. The microcomputer monitors the status of the identify information of respective member anti-fake means, so as to make judgment on the status of the identity of the license plate or members of the vehicle on which the respective member anti-fake means mounted.
[0013] The informal displays are mounted on the license plate or members of the vehicle, and connected to the communication interfaces of the microcomputer by wires. The information displays can employ colorful light information display, acoustic information display or screen display. The function of these information displays is to convert the signal transmitted from the microcomputer and reflecting the legality of the status of the vehicle identity to information expressing modes, for example the colorful light, the acoustic information or graphics and text that can be identified directly by sense of human being.
[0014] The communicators are wireless bidirectional communication apparatus and mounted on the vehicle or the license plate, and the number of the communicators is at least one.
[0015] The communication interface of the communicator is connected to the communication interface of the microcomputer by wires. The communicator is used for intercommunion between the motor vehicle identity anti-fake apparatus and the outside administrative institution.
[0016] A vehicle-mount information system for monitoring and reflecting the legality of the status of the vehicle identity is formed by means of the signal connections among the microcomputer, the respective member anti-fake means, the information displays and the communicator.
[0017] 2. Each of the member anti-fake means being in wired signal connection with the microcomputer is a IC chip means, comprising a data input/output interface and a memory for storing identification information, wherein the data input/output interface is connected to the communication interfaces of the microcomputer by wires.
[0018] 3. Each of the member anti-fake means being in wireless signal connection with the microcomputer is a noncontact IC card chip, and is in signal connection with said microcomputer through a noncontact IC card read/write unit, wherein said noncontact IC card read/write unit is mounted on the vehicle or the license plate and is in signal connection with said concontact IC card chip in a radio frequency communication manner. The communication interface of said noncontact IC card read/write unit is connected to said communication interface of said microcomputer by wires.
[0019] 4. The member anti-fake means are fixed on the license plate or respective members of the vehicle in a sticking or covering seal manner.
[0020] 5. The colorful light information displays are electrical light-emitting means, and there are at least three colorful light information displays with at least two different colors. The input ports of respective colorful light displays are connected to the communication interfaces of the microcomputer by wires, respectively.
[0021] 6. The electrical light-emitting means are light-emitting diodes.
[0022] 7. The acoustic information display is an electrical sounding means, and there is at least one acoustic information display. The input port of the acoustic information display is connected to the communication interface of the microcomputer by wires.
[0023] 8. The screen information display is an electronic screen information display means having a communication interface. There is at least one screen information display. The screen information display is mounted in the cab of the vehicle, and the communication interface of the screen display is connected to the communication interface of the microcomputer via wires.
[0024] 9. The colorful light information displays and acoustic information display are connected to the microcomputers, respectively, via an acoustooptic controller, and each of the acoustooptic controller is a microcomputer system having an acoustooptic drive module, and comprises CPU, ROM, RAM, I/O, a communication interface, an acoustooptic drive module and an output port.
[0025] The communication interface of each of the acoustooptic controller is connected to the communication interface of the microcomputer via wires. The output port of respective acoustooptic controller is directly connected to the input port of respective colorful light information displays or the acoustic information display, and the connection ports and the acoustooptic controller are packaged into an integral closed body by insulating material.
[0026] 10. The member anti-fake means, colorful information displays, acoustic information display, microcomputer and communicator are mounted and packaged into the body of the license plate; the body of the license plate serves as the base and casing of these components. The body of the license plate is made from insulating material, and the front face of the license plate body is provided with windows through which the colorful light information displays radiate color light signal to outside.
[0027] 11. The microcomputer, information displays and communicator are packaged into a cartridge which is mounted inside the cab of the vehicle.
[0028] 12. The motor vehicle identity anti-fake apparatus automatically detects the status of the vehicle identity, displays or communicates in wireless manner the detection results according to pre-configurations of the administrative institution or to the real-time wireless remote control instructions issued by the administrative institution.
[0029] The administrative institution loads in advance in the microcomputer operation management software, and writes into the microcomputer the archive information of the vehicle and identify identification information of respective member anti-fake means and the position on which the respective member anti-fake means are located. After completing the above said configurations, the motor vehicle identity anti-fake apparatus starts to operate automatically under the control of the microcomputer.
[0030] According to the predetermined program, the microcomputer makes detection and judgment automatically with respect to the following five aspects based on the detection demand, time information, current image feature information of the vehicle, the identity feature information of the illegal vehicles which are required to be particularly looked up, issued by the administrative institution in wireless manner and received by the communicator.
[0031] (1)Judging the legality of the license plate or members of the vehicle.
[0032] The microcomputer extracts information from respective member anti-fake means and compares the extracted information with the feature information of the respective member anti-fake means previously stored in the microcomputer. If all the features are consistent with each other, it indicates that the identity of the license plate and members are legal; if the feature information of one or more of the member anti-fake means is inconsistent or does not exist, it means that the identity of the vehicle is illegal.
[0033] (2) Judging whether the motor vehicle has passed the verification and check with respect to stipulated items on schedule.
[0034] The microcomputer retrieves contents of the items which have passed the verification and check and the period of validity from vehicle archive information stored in advance in the memory of the microcomputer, and makes judgment to determine whether or not said items are still within said period of validity. If all the items fall within the period of validity, it means that the vehicle has passed the verification and check with respect to the stipulated items on schedule; otherwise, it means that the identity of the vehicle is illegal.
[0035] (3) Judging whether the motor vehicle has special usages or not:
[0036] The microcomputer retrieves and judges information on usage of the vehicle and period of validity of the usage from the vehicle archive information stored in advance in the memory of the microcomputer. If there exists some special usages which should be registered in the administrative institution and such special usages fall within the period of validity, it means that the vehicle has such special usages; otherwise, it means that the vehicle has no such special usages.
[0037] (4) Judging to determine whether the vehicle belongs to an illegal vehicle particularly tracked by related enforcement organ.
[0038] The communicator receives the identity feature information issued in wireless manner by the administrative institution about the illegal vehicle that needs to be particularly tracked, and stores immediately such information into the microcomputer. The microcomputer compares the received feature with the feature of the present vehicle as stored in advance . If the features are consistent with each other, it means that the present vehicle belongs to the illegal vehicle particularly tracked by the related enforcement organ.
[0039] (5) Judging whether the appearance and color are in conformity with those of in the enrollment and registration.
[0040] The communicator receives the feature information about the real-time image of the present vehicle transmitted by the external detection station, and stores immediately the received feature information into the microcomputer. The microcomputer compares the received information with the image feature of the present vehicle in the vehicle archive information stored in advance. If the comparison result is consistent, it means that the vehicle is legal in terms of the appearance and the color ; otherwise, it means that the vehicle identity is illegal.
[0041] The microcomputer stores at any moment the detection and judgment conclusions in terms of the above five aspects into the memory, and at the same time controls the display modes and contents of the information displays according to the property of the detection and judgment conclusions, as well as controls the transmission timing and contents of the communicators according to the instructions as issued by the administrative institution in a wireless communication manner.
[0042] 13. The method performed by the microcomputer to control the transmission timing and contents of the communicators according to the instructions as issued by the administrative institution in a wireless communication manner is described as follows. The receiver of the communicator is always in operation status under the management of the microcomputer. Upon the microcomputer finds that the communicators receive the calling information of the management center or the detection station, the microcomputer stores the set of information into the memory, and makes judgment from this set of information to determine whether there exists a detection demand of the administrative institution for checking and detecting the present vehicle. If there exists such a detection demand, the microcomputer furthers determines the authority of the detecting party. If the detection demand is legal, according to a predetermined program, the microprocessor of the microcomputer selects information within the authority of the detecting party from the information stored in the memory, and organizes and generates reply information and controls the transmitter of the communicator to transmit the reply information.
[0043] The present invention substantively supplements and improves the function of the license plate, or provides an intellectual “ID card” of a vehicle, or is an “electronic police” accompanying the vehicle. The present invention not only enables the license plate itself to possess the function of anti-fake, but also ensures the reliable correspondence between the license plate and the vehicle, and thus making the license plate or the appearance of the vehicle has the function of reflecting the legality status of the vehicle identity.
[0044] Since the present invention radically resolves the problem of anti-fake identification of the basic information of the vehicle and possesses various information representation modes, it plays an important role in traffic management, vehicle management of state road and other fields related with the identification of vehicle identity. More specifically, the present invention at least has the following three remarkable effects.
[0045] (1) The present invention provides a precondition for resolving the difficulty of identification of the vehicles on road. Since the present invention outputs to outside the detection conclusion information directly, it can make the current license plate technology be updated and developed to the vehicle identification technology. The administrative institution can detect or observe the vehicle by using simpler detection apparatus, and even just by eyeballing, without stopping the vehicle, thus obtaining good effects similar to that of in the method of “stopping the vehicle for detection”. Moreover, as compared with existing various automatic license plate identification technology, the demand for the external detection system is simple, and the management cost is largely reduced. In particular, the visual identification by naked eye is simply implemented, and these exists no detection omission nationwide.
[0046] (2) The present invention changes the passive situation in which the administrative institution can not master the basic information of the driving vehicles, and thus provides a precondition to achieve intelligentization, informatization and real-time of the road vehicle and traffic managements.
[0047] (3) The present invention achieves the policy of “give first rank to prevention”. Since the illegal vehicles are always in the status of exposure, people who drive the illegal vehicles are heavily deterred, so that the illegal vehicles are prevented from occurring and being driven on road, thereby vehicle-related crimes will be reduced markedly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] FIG. 1 is a principle chart of the configuration of the motor vehicle identity anti-fake apparatus according to the present invention.
[0049] FIG. 2 is a principle chart of each of the member anti-fake means 3 - 1 and 3 - 2 which is in wired signal connection with the microcomputer according to an embodiment as shown in FIG. 4 .
[0050] FIG. 3 is a principle chart of each of the member anti-fake means 3 - 3 and 3 - 4 which is in wireless signal connection with the microcomputer according to the embodiment as shown in FIG. 4 .
[0051] FIG. 4 is a principle chart of the motor vehicle identity anti-fake apparatus according to an embodiment.
[0052] FIG. 5 is a principle chart of each of the acoustooptic controller 5 according to the embodiment as shown in FIG. 4 .
[0053] FIG. 6 shows six window positions of the front license plate body 7 according to the embodiment as shown in FIG. 4 .
[0054] FIG. 7 is a main flow chart of the operation program of the microcomputer 1 according to the embodiment as shown in FIG. 4 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0055] The present invention is further described in details as follows in association with figures and embodiments.
[0056] FIG. 1 is a principle chart of the configuration of the motor vehicle identity anti-fake apparatus according to the present invention. The anti-fake apparatus for motor vehicle identity comprises four parts: member anti-fake means 3 , a microcomputer 1 , information displays 4 and communicators 2 . The power supply for the system operation directly comes from the vehicle power supply.
[0057] Functions of Respective Components
[0058] (1) The member anti-fake means 3 is integrated with the license plate or the members, serving as the feature signs for identifying the license plate or the members.
[0059] (2) The communicators 2 communicate with the external management center and the detection station by wireless manner. At least a set of communicator is indispensable, preferably two sets, wherein one set performs short distance radio communication with the roadside detection station, and the other set performs long distance wireless communication directly with the management center within a range of certain region.
[0060] (3) The information displays 4 are used to intuitively display the information reflecting the current status of the vehicle identity. There are three types of information displays that can be selected. The colorful light information displays 41 represent specific information associated with the legal status of the vehicle identity using different position relation, color or flicker of light. The acoustic information display 42 represents that the identity of the vehicle currently exists an illegal status using sound signal. The screen display 43 represents information on the legality of the vehicle identity using graphics and text.
[0061] (4) The microcomputer 1 is a center for storing and processing information, and controlling operation of the motor vehicle identity anti-fake apparatus. .
[0062] FIG. 2 is a principle chart of each of the member anti-fake means 3 - 1 and 3 - 2 which is in wired signal connection with the microcomputer according to the embodiment as shown in FIG. 4 .
[0063] Each of the member anti-fake means 3 - 1 and 3 - 2 comprises a data input/output interface 302 , a memory 301 containing identity identification information.
[0064] FIG. 3 is a principle chart of each of the member anti-fake means 3 - 3 and 3 - 4 which is in wireless signal connection with the microcomputer according to the embodiment as shown in FIG. 4 .
[0065] Each of the member anti-fake means 3 - 3 and 3 - 4 adopts a noncontact IC card chip, comprising a memory 310 , an encryption and decryption module 303 , a rectifying and voltage-modulating module 304 , a data encoding and transmitting module 305 , a signal and clock extracting module 306 , a high-frequency signal receiving and transmitting module 307 , an antenna 308 , a microprocessor and monitoring program 309 .
[0066] FIG. 4 is a principle chart of an embodiment of the motor vehicle identity anti-fake apparatus.
[0067] The anti-fake means 3 comprises four member anti-fake means 3 - 1 , 3 - 2 , 3 - 3 , 34 , which four member anti-fake means are respectively stuck and sealed with epoxy resin onto the front license plate, the car frame, the engine and the back surface of the rear license plate. The data input/output interface of the member anti-fake means 3 - 1 is connected to the communication interface 13 - 1 of microcomputer 1 via wires, the data input/output interface of the member anti-fake means 3 - 2 is connected to the communication interface 13 - 2 of microcomputer 1 via wires.
[0068] Noncontact IC card read/write unit 8 and read/write unit 9 are respectively stuck and sealed with epoxy resin on a position within 10 cm in the vicinity of the member anti-fake means 3 - 3 and 3 - 4 . The communication interface of read/write unit 8 is connected to the communication interface 13 - 3 of microcomputer 1 via wires, and the communication interface of read/write unit 9 is connected to the communication interface 13 - 4 of microcomputer 1 via wires.
[0069] Microcomputer 1 comprises a microprocessor 11 , a memory 12 , communication interfaces 13 , and is mounted within the body 7 of the front license plate. The microprocessor 11 operates at a clock frequency of 1 GHz. The memory 12 comprises a memory for storing programs and data, and a random access memory. The interfaces 13 has 15 independent communication interfaces indicated respectively as communication interfaces 13 - 1 , 13 - 2 , 13 - 3 , 134 , 13 - 5 , 13 - 6 , 13 - 7 , 13 - 8 , 13 - 9 , 13 - 10 , 13 - 11 , 13 - 12 , 13 - 13 , 13 - 14 and 13 - 15 , and all these communication interfaces employ serial communication interface RS232.
[0070] A peripheral communication socket 6 is connected to the communication interface 13 - 9 of microcomputer 1 and mounted on the side face of the front license plate body 7 , and is used to supply wired connection communication between the computer of the management center and microcomputer I whenever necessary.
[0071] The communicators 2 comprise communicators 2 - 1 and 2 - 2 . The communicator 2 - 1 is a radio frequency communicator, and it adopts an “electronic label” radio frequency communication circuit. The controller of the communicator 2 - 1 is provided with a RS232 communication interface which is connected to the communication interface 13 - 6 of microcomputer 1 . The communication between said communicator 2 - 1 and the detection station on the roadside is controlled by the microcomputer 1 . The communicator 2 - 1 is fixed and sealed in the front license plate body 7 . The communicator 2 - 2 adopts a miniature ultrashort wave transceiver having a communication interface. The communication interface of the communicator 2 - 2 is connected to the communication interface 13 - 5 of microcomputer 1 , and the communication between said communicator 2 - 2 and the management center is controlled by the microcomputer 1 .
[0072] The colorful light information displays 41 comprise six colorful light information displays indicated respectively as 41 - 1 , 41 - 2 , 41 - 3 , 41 - 4 , 41 - 5 and 41 - 6 , which six colorful light information displays employ light-emitting diodes. The single acoustic information display 42 employs an electronic speaker.
[0073] The acoustooptic controllers 5 comprise seven controllers indicated respectively as 5 - 1 , 5 - 2 , 5 - 3 , 5 - 4 , 5 - 5 , 5 - 6 and 5 - 7 . The output ports of the seven controllers are respectively connected to the input ports of the colorful light information displays 41 - 1 , 41 - 2 , 41 - 3 , 414 , 41 - 5 , 41 - 6 and acoustic information display 42 , and the respective connection ports and the acoustooptic controller chips are stuck and sealed by epoxy resin as a whole body which is then mounted into the front license plate body 7 . The communication interfaces of acoustooptic controllers 5 - 1 , 5 - 2 , 5 - 3 , 5 - 4 , 5 - 5 , 5 - 6 and 5 - 7 are respectively connected to the communication interfaces 13 - 10 , 13 - 11 , 13 - 12 , 13 - 13 , 13 - 14 , 13 - 15 and 13 - 8 of microcomputer 1 .
[0074] The screen display 43 adopts a crystal liquid display, and its communication interface is connected to the communication interface 13 - 7 of microcomputer 1 .
[0075] The screen display 43 and the communicator 2 - 2 are packaged into a cartridge which is mounted on the operating board in front of the driver inside the vehicle.
[0076] FIG. 5 is a principle chart of each of the acoustooptic controller 5 according to the embodiment as shown in FIG. 4 . Each of the acoustooptic controller 5 is a microcomputer system having an acoustooptic drive module, and comprises MPU, ROM, RAM, I/O, a communication interface 501 , an acoustooptic drive module 502 and an output port 503 .
[0077] The acoustooptic controllers provide drive power for the information displays, and more importantly, they prevent the pseudo control signal from entering the information displays by means of the close connection and seal between the acoustooptic controllers and the input ports of the information displays.
[0078] FIG. 6 shows six window positions of the front license plate body 7 according to the embodiment as shown in FIG. 4 .
[0079] The front license plate body 7 is provided with six windows on the surface, indicated respectively as windows 71 , 72 , 73 , 74 , 75 , 76 , and colorful light information displays 41 - 1 , 41 - 2 , 41 - 3 , 414 , 41 - 5 and 41 - 6 are respectively mounted inside these windows for radiating colorful light to outside. The colorful light information displays 41 - 1 , 41 - 2 , 41 - 3 , 41 - 4 , 41 - 5 are light-emitting diodes which emit green light. When the colorful light information display 41 - 1 emits light, it means that the license plate, the car frame and the engine are legal; when the colorful light information display 41 - 1 does not emit light, it means that the license plate or the car frame or the engine are illegal. When the colorful light information display 41 - 2 emits light, it means that the vehicle has passed the verification or check with respect to all stipulated items on schedule; when the colorful light information display 41 - 2 does not emit light, it means that the vehicle has failed to pass the verification or check with respect to some of the stipulated items. When the colorful light information display 41 - 3 emits light, it means that the appearance and the color of the vehicle are in conformity with those on in the enrollment and registration; when the colorful light information display 41 - 3 does not emit light, it means that the appearance and the color of the vehicle are not in conformity with those of in the enrollment and registration. When the colorful light information display 41 - 4 emits light, it means that the present vehicle does not belong to the vehicle particularly tracked by related enforcement organ; when the colorful light information display 414 does emit light, it means that the present vehicle belongs to the vehicle particularly tracked by related enforcement organ. The vehicle particularly tracked are the vehicles that are looked for or controlled by the related enforcement organ for some reasons, for example, the particularly tracked vehicles include the robbed cars and stolen cars. When the colorful light information display 41 - 5 emits light, it means that the vehicle has some special usages; when the colorful light information display 41 - 5 does not emit light, it means that the vehicle does not have some special usages. The special usage is defined by the administrative institution, for example including the police car, the taxi, or the like. The colorful light information display 41 - 6 is a light-emitting diode which emits red light. When the colorful light information display 41 - 6 emits light, it means one of the identity of the vehicle is illegal; when the colorful light information display 41 - 6 does not emit light, it means nothing.
[0080] FIG. 7 is a main flow chart of the operation program of the microcomputer 1 according to the embodiment as shown in FIG. 4 .
[0081] The operation of each step is described sequentially in details as follows:
[0082] 1. the vehicle being powered on, and the motor vehicle identity anti-fake apparatus and the microcomputer 1 immediately starting to work ( 600 );
[0083] 2. making check to determine whether or not the communicators 2 - 1 and 2 - 2 receive legal calling information ( 601 );
[0084] 3. if a legal call is received, writing this set of information having the legal call into the memory 12 ( 602 );
[0085] 4. making check to determine whether or not the information written into the memory 12 has a detection command or questioning query information of the management center or the detection station ( 603 );
[0086] 5. if there exists a detection command or questioning query information, determining the authority of the management center or the detection station ( 604 );
[0087] 6. organizing reply information according to the authority of the management center or the detection station, and controlling the communicator 2 - 1 or 2 - 2 to transmit the reply information and writing the operation records into the memory 12 ( 605 );
[0088] 7. making check to determine whether or not the information newly written into the memory 12 has the vehicle image feature information transmitted from the detection station ( 606 );
[0089] 8. if there exists the vehicle image feature information, comparing said vehicle image feature information with the present vehicle image feature in the vehicle archive information stored in the memory, and writing the comparison result into the memory 12 ( 608 );
[0090] 9. if said comparison result is consistent, transmitting an instruction of switching on the colorful light information display 41 - 3 to the acoustooptic controller 5 - 3 , controlling the screen display 43 to describe in graphics and text that the appearance and the color of the vehicle are consistent with those of in the enrollment and registration, and writing the operation records into the memory 12 ( 609 );
[0091] 10. if said comparison result is inconsistent, transmitting an instruction of switching off the colorful light information display 41 - 3 to the acoustooptic controller 5 - 3 ; transmitting an instruction of switching on the colorful light information display 41 - 6 to the acoustooptic controller 5 - 6 ; transmitting an instruction of switching on the acoustic information display 42 to the acoustooptic controller 5 - 7 ; controlling the screen display 43 to describe in graphics and text that the appearance and the color of the vehicle being inconsistent with those of in the enrollment and registration, and writing the operation records into the memory 12 ( 610 );
[0092] 11. making check to determine whether or not the information newly written into the memory 12 has standard time information ( 611 );
[0093] 12. if there exists standard time information, setting said standard time as the present time of the inner clock of the microcomputer 1 itself ( 612 );
[0094] 13. making check to determine whether or not the information newly written into the memory 12 has the name of the present vehicle particularly tracked by the management center ( 613 );
[0095] 14. if there exists the name of the present vehicle particularly tracked by the management center, transmitting an instruction of switching on the colorful light information display 41 - 6 to the acoustooptic controller 5 - 6 ; transmitting an instruction of switching off the colorful light information display 41 - 4 to the acoustooptic controller 5 - 4 ; transmitting an instruction of switching on the acoustic information display 42 to the acoustooptic controller 5 - 7 ; controlling the screen display 43 to describe in graphics and text that the vehicle belongs to vehicle particularly tracked by the related enforcement organ; writing the operation records into the memory 12 ( 614 );
[0096] 15. judging to determine whether or not the vehicle has passed the verification and check with respect to stipulated items on schedule, and writing the judging result into the memory 12 ( 615 );
[0097] 16. if the vehicle has passed the verification and check with respect to stipulated items on schedule, transmitting an instruction of switching on the colorful light information display 41 - 2 to the acoustooptic controller 5 - 2 ; controlling the screen display 43 to describe in graphics and text that the vehicle has passed the verification and check with respect to stipulated items on schedule ( 616 );
[0098] 17. if the vehicle has not passed the verification and check with respect to stipulated items on schedule, transmitting an instruction of switching off the colorful light information display 41 - 2 to the acoustooptic controller 5 - 2 ; transmitting an instruction of switching on the acoustic information display 41 - 6 to the acoustooptic controller 5 - 6 ; transmitting an instruction of switching on the acoustic information display 42 to the acoustooptic controller 5 - 7 ; controlling the screen display 43 to describe in graphics and text that the vehicle has not passed the verification and check with respect to stipulated items on schedule ( 617 );
[0099] 18. judging to determine whether or not the vehicle has some special usages, and writing the judging result into the memory 12 ( 618 );
[0100] 19. if the vehicle has some special usages, transmitting an instruction of switching on the colorful light information display 41 - 5 to the acoustooptic controller 5 - 5 ; controlling the screen display 43 to describe in graphics and text the special usages that the vehicle has ( 619 );
[0101] 20. if the vehicle has no special usage, transmitting an instruction of switching off the colorful light information display 41 - 5 to the acoustooptic controller 5 - 5 ; 21 . checking the read/write unit 8 - 621 ;
[0102] 22. if there exists identification information of the read/write unit 8 , checking the member anti-fake means 3 - 3 ( 622 );
[0103] 23. if there exists identification information of the member anti-fake means 3 - 3 , controlling the screen display 43 to describe in graphics and text that the identity of the vehicle engine is legal; transmitting an instruction of switching on the colorful light information display 41 - 1 to the acoustooptic controller 5 - 1 if the operation records contain the identification information of the other three member anti-fake means 3 - 1 , 3 - 2 and 3 - 4 at the same time; writing the monitoring operation records into the memory 12 ( 623 );
[0104] 24. if there does not exist identification information of the member anti-fake means 3 - 3 , transmitting an instruction of switching off the colorful light information display 41 - 1 to the acoustooptic controller 5 - 1 ; transmitting an instruction of switching on the colorful light information display 41 - 6 to the acoustooptic controller 5 - 6 ; transmitting an instruction of switching on the acoustic information display 42 to the acoustooptic controller 5 - 7 ; controlling the screen display 43 to describe in graphics and text that the identity of the vehicle engine is illegal, and writing the monitoring operation records into the memory 12 ( 624 );
[0105] 25. if there does not exist identification information of the read/write unit 8 , transmitting an instruction of switching off the colorful light information display 41 - 1 to the acoustooptic controller 5 - 1 ; transmitting an instruction of switching on the colorful light information display 41 - 6 to the acoustooptic controller 5 - 6 ; transmitting an instruction of switching on the acoustic information display 42 to the acoustooptic controller 5 - 7 ; controlling the screen display 43 to describe in graphics and text that the identity of the vehicle engine is illegal, and writing the monitoring operation records into the memory 12 ( 626 );
[0106] 26. checking the read/write unit 9 ( 627 );
[0107] 27. if there exists identification information of the read/write unit 9 , checking the member anti-fake means 3 - 4 ( 628 );
[0108] 28. if there exists identification information of the member anti-fake means 3 - 4 , controlling the screen display 43 to describe in graphics and text that the identity of the rear license plate of the vehicle is legal; transmitting an instruction of switching on the colorful light information display 41 - 1 to the optical controller 5 - 1 if the operation records contain the correct information of the other three member anti-fake means 3 - 1 , 3 - 2 and 3 - 3 at the same time; writing the monitoring operation records into the memory 12 ( 629 );
[0109] 29. if there does not exist identification information of the member anti-fake means 3 - 4 , transmitting an instruction of switching off the colorful light information display 41 - 1 to the acoustooptic controller 5 - 1 ; transmitting an instruction of switching on the colorful light information display 41 - 6 to the acoustooptic controller 5 - 6 ; transmitting an instruction of switching on the acoustic information display 42 to the acoustooptic controller 5 - 7 ; controlling the screen display 43 to describe in graphics and text that the identity of the rear license plate of the vehicle is illegal, and writing the monitoring operation records into the memory 12 ( 630 );
[0110] 30. if there does not exist information of the read/write unit 9 , transmitting an instruction of switching off the colorful light information display 41 - 1 to the acoustooptic controller 5 - 1 ; transmitting an instruction of switching on the colorful light information display 41 - 6 to the acoustooptic controller 5 - 6 ; transmitting an instruction of switching on the acoustic information display 42 to the acoustooptic controller 5 - 7 ; controlling the screen display 43 to describe in graphics and text that the identity of the rear license plate of the vehicle is illegal, and writing the monitoring operation records into the memory 12 ( 632 );
[0111] 31. checking the member anti-fake means 3 - 1 ( 633 );
[0112] 32. if there exists identification information of the member anti-fake means 3 - 1 , controlling the screen display 43 to describe in graphics and text that the identity of the front license plate of the vehicle is legal; transmitting an instruction of switching on the colorful light information display 41 - 1 to the optical controller 5 - 1 if the operation records contain the correct information of the other three member anti-fake means 3 - 4 , 3 - 2 and 3 - 3 at the same time; writing the monitoring operation records into the memory 12 and member anti-fake means 3 - 1 ( 635 );
[0113] 33. if there does not exist identification information of the member anti-fake means 3 - 1 , transmitting an instruction of switching off the colorful light information display 41 - 1 to the acoustooptic controller 5 - 1 , and transmitting an instruction of switching on the colorful light information display 41 - 6 to the acoustooptic controller 5 - 6 ; transmitting an instruction of switching on the acoustic information display 42 to the acoustooptic controller 5 - 7 ; controlling the screen display 43 to describe in graphics and text that the identity of the front license plate of the vehicle is illegal; and writing the monitoring operation records into the memory 12 ( 637 );
[0114] 34. checking the member anti-fake means 3 - 2 ( 638 );
[0115] 35. if there exists identification information of the member anti-fake means 3 - 2 , controlling the screen display 43 to describe in graphics and text that the identity of the car frame is legal; transmitting an instruction of switching on the colorful light information display 41 - 1 to the optical controller 5 - 1 if the operation records contain the correct information of the other three member anti-fake means 3 - 4 , 3 - 1 and 3 - 3 at the same time; writing the monitoring operation records into the memory 12 and member anti-fake means 3 - 2 ( 640 );
[0116] 36. if there does not exist identification information of the member anti-fake means 3 - 2 , transmitting an instruction of switching off the colorful light information display 41 - 1 to the acoustooptic controller 5 - 1 , and transmitting an instruction of switching on the colorful light information display 41 - 6 to the acoustooptic controller 5 - 6 ; transmitting an instruction of switching on the acoustic information display 42 to the acoustooptic controller 5 - 7 ; controlling the screen display 43 to describe in graphics and text that the identity of the car frame is illegal, and writing the monitoring operation records into the memory 12 ( 642 );
[0117] 37. checking the acoustooptic controller 5 - 1 ( 643 );
[0118] 38. if there exists identification information of the acoustooptic controller 5 - 1 , writing the monitoring operation records into the memory 12 ( 645 );
[0119] 39. if there does not exist identification information of the acoustooptic controller 5 - 1 , transmitting an instruction of switching on the colorful light information display 41 - 6 to the acoustooptic controller 5 - 6 ; transmitting an instruction of switching on the acoustic information display 42 to the acoustooptic controller 5 - 7 ; controlling the screen display 43 to describe in graphics and text that the colorful light information display 41 - 1 is illegal; and writing the monitoring operation records into the memory 12 ( 647 );
[0120] 40. checking the acoustooptic controller 5 - 2 ( 648 );
[0121] 41. if there exists identification information of the acoustooptic controller 5 - 2 , writing the monitoring operation records into the memory 12 ( 650 );
[0122] 42. if there does not exist identification information of the acoustooptic controller 5 - 2 , transmitting an instruction of switching on the colorful light information display 41 - 6 to the acoustooptic controller 5 - 6 ; transmitting an instruction of switching on the acoustic information display 42 to the acoustooptic controller 5 - 7 ; controlling the screen display 43 to describe in graphics and text that the colorful light information display 41 - 2 is illegal; and writing the monitoring operation records into the memory 12 ( 652 );
[0123] 43. checking the acoustooptic controller 5 - 3 ( 653 );
[0124] 44. if there exists identification information of the acoustooptic controller 5 - 3 , writing the monitoring operation records into the memory 12 ( 655 );
[0125] 45. if there does not exist identification information of the acoustooptic controller 5 - 3 , transmitting an instruction of switching on the colorful light information display 41 - 6 to the acoustooptic controller 5 - 6 ; transmitting an instruction of switching on the acoustic information display 42 to the acoustooptic controller 5 - 7 ; controlling the screen display 43 to describe in graphics and text that the colorful light information display 41 - 3 is illegal; and writing the monitoring operation records into the memory 12 ( 657 );
[0126] 46. checking the acoustooptic controller 5 - 4 ( 658 );
[0127] 47. if there exists identification information of the acoustooptic controller 5 - 4 , writing the monitoring operation records into the memory 12 ( 660 );
[0128] 48. if there does not exist identification information of the acoustooptic controller 5 - 4 , transmitting an instruction of switching on the colorful light information display 41 - 6 to the acoustooptic controller 5 - 6 ; transmitting an instruction of switching on the acoustic information display 42 to the acoustooptic controller 5 - 7 ; controlling the screen display 43 to describe in graphics and text that the colorful light information display 41 - 4 is illegal; and writing the monitoring operation records into the memory 12 ( 662 );
[0129] 49. checking the acoustooptic controller 5 - 5 ( 663 );
[0130] 50. if there exists identification information of the acoustooptic controller 5 - 5 , writing the monitoring operation records into the memory 12 ( 665 );
[0131] 51. if there does not exist identification information of the acoustooptic controller 5 - 5 , transmitting an instruction of switching on the colorful light information display 41 - 6 to the acoustooptic controller 5 - 6 ; transmitting an instruction of switching on the acoustic information display 42 to the acoustooptic controller 5 - 7 ; controlling the screen display 43 to describe in graphics and text that the colorful light information display 41 - 5 is illegal; and writing the monitoring operation records into the memory 12 ( 667 );
[0132] 52. checking the acoustooptic controller 5 - 6 ( 668 );
[0133] 53. if there exists identification information of the acoustooptic controller 5 - 6 , writing the monitoring operation records into the memory 12 ( 670 );
[0134] 54. if there does not exist identification information of the acoustooptic controller 5 - 6 , transmitting instructions of switching off the colorful light information display 41 - 1 , 41 - 2 , 41 - 3 , 41 - 4 to the acoustooptic controllers 5 - 1 , 5 - 2 , 5 - 3 , 5 - 4 ; transmitting an instruction of switching on the acoustic information display 42 to the acoustooptic controller 5 - 7 ; controlling the screen display 43 to describe in graphics and text that the colorful light information display 4 f- 6 is illegal; and writing the monitoring operation records into the memory 12 ( 672 ); p 55. checking the acoustooptic controller 5 - 7 ( 673 );
[0135] 56. if there exists identification information of the acoustooptic controller 5 - 7 , writing the monitoring operation records into the memory 12 ( 675 );
[0136] 57. if there does not exist identification information of the acoustooptic controller 5 - 7 , transmitting an instruction of switching on the colorful light information display 41 - 6 to the acoustooptic controller 5 - 6 ; controlling the screen display 43 to describe in graphics and text that the acoustic information display 42 is illegal; and writing the monitoring operation records into the memory 12 ( 677 );
[0137] 58. checking the communication interface 13 - 9 to determine whether there exists a legal instruction signal from the computer of the management center ( 678 );
[0138] 59. if there exists a legal instruction signal from the computer of the management center, the microcomputer accepting the control of the computer of the management center and making operation records ( 679 );
[0139] after the communication between the computer of the management center and the microcomputer 1 has finished, microcomputer 1 restarting a work cycle;
[0140] if there exists no legal instruction signal of the computer of the management center, microcomputer 1 entering the next cycle. | The present invention discloses a motor vehicle identity anti-fake apparatus and method. The motor vehicle identity includes a microcomputer ( 1 ), communicators ( 2 ), member anti-fake apparatus ( 3 ) and information displays ( 4 ). The motor vehicle identity anti-fake apparatus is installed on vehicle license and members of the vehicle. The apparatus monitors, analyzes and judges the vehicle and the license plate and certificates thereof automatically under the control of the preloaded software or the wireless management of the administrative institution, and provide information of the self-detection to outside. The present invention is used for anti-fake of motor-vehicle-identity-status and provides to the enforcement organ for recognizing the legal status of motor-vehicle-identity. | 1 |
BACKGROUND OF THE INVENTION
There is disclosed in U.S. Pat. No. 3,752,097 issued Aug. 14, 1973, in the names of George A. Fuller, Jr. et al improved mechanism for performing automatically the edge finishing of workpieces, notably those of flexible fabric having peripheries including both straight and curved portions. According to the invention therein set forth an over-edging machine of known type, for instance, is provided with an automatic corner turning mechanism whereby a swing finger and cooperative rotary clamp are operative in response to an external work edge sensor to enable the over-edging machine to progress rapidly over a margin of a rectilinear path, about a convex "corner", and thence along another straight line path. The guidance sensor controls movement of the swing finger and clamp in response to the position of successive peripheral operating points solely along the external margin of the work.
The indicated guidance control has been found to be commercially satisfactory in dealing with such items as most face cloths, small towels, and the like. Some workpieces, however, require a different mode of automatic guidance in determining their ultimate peripheral configuration. One example is conveniently afforded by face cloths and the like which initially have a pile or terry spaced inwardly from a woven margin that is thinner and free of terry material, but which are to be produced wholly free of such margins. That is to say the edge processing such as overedging is to occur directly along the inner edge of terry material. In edge finishing such work it is desirable to automatically guide the work in a manner whereby the terry edge will be progressively relieved of the non-terry material and progressively bound as by overedging. This entails a need for guidance sensing in two modes, as herein shown, not from the initially external perimeter or raw outside edge of the work, but from discriminating the inner demarcation or inner contour provided by the limit of the upstanding loops of terry. At present guidance of flexible workpieces having margins distinctive from their interior is largely manual, relatively slow, and the results not entirely uniform, especially about the convex "corners" of a multisided periphery.
SUMMARY OF THE INVENTION
In view of the foregoing it is an object of this invention to provide an automatic machine for edge finishing workpieces the non-pile margins of which are to be removed to expose its raw pile marginal edges and then simultaneously and progressively finishing these edges.
Another and more specific object of this invention is to provide an automatic guidance mechanism for an overedging machine or the like having conventional work feeding means whereby, when a terry-type workpiece has a relatively thin margin extending along more than one side thereof, the machine can proceed in substantially continuous manner to trim off the marginal edges, impart rounded corner portions, and simultaneously secure as by stitching the terry material along its periphery.
To these ends, and in accordance with a feature of the invention, an overedging machine or the like having an operating tool such as a needle and trimming means such as a reciprocable cutting blade, and a terry edge guide, is provided with control means including a sensing means responsive to the terry material of a workpiece to distinguish it from its non-terry margin, and work turning mechanism including circuitry having a switch responsive to the sensing means. As herein illustrated the sensing means may alternatively be pneumatic or electronic in character. The edge guide is adapted for cooperating with the edge of the terry material for rectilinear guidance thereby. The sensing means is adapted to signal appropriately for corner turning between adjacent angularly related work edges. Since in the manufacturing of terry material, for instance, the line of demarcation between the terry and the non-terry of the margins is commonly well delineated, a reliable and useful control signal is derived to produce quality products in rapid manner. The invention thus extends the utility and versatility of conventional overedging machines without burdening an operator.
While as herein shown the invention is embodied in a machine having swingable arm type corner turning mechanism such as disclosed in the cited Fuller et al patent, it will be understood that the invention may also be employed in combination with other suitable automatic corner turning means.
It will be appreciated that application of the invention is not limited to the operation on pile-type four-cornered fabric workpieces, but may likewise have utility on any multi-sided, margin-carrying flexible workpiece of leather, paper, or plastic sheet material required to be marginally trimmed i.e. have its external border eliminated and then edge treated as by sewing and/or some other function such as bonding, printing, embossing, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features of the invention together with novel details in construction will now be more particularly described in connection with two illustrative embodiments, and with reference to the accompanying drawings thereof, in which:
FIG. 1 is a prespective view of an edge finishing machine of the type disclosed in the above mentioned U.S. Pat. No. 3,752,097, modified by pneumatic guidance mechanism as herein described to enable non-terry margins of multi-sided workpieces to be removed, and the outer edges of terry material to be secured as by overedging along the terry edge;
FIG. 2 is a view in side elevation, and on a larger scale, of a pile pneumatic sensor and control shown in FIG. 1 for actuating corner turning of a partly pile workpiece and energizing corner counting mechanism embodied in the machine of FIG. 1;
FIG. 3 is an enlarged plan view taken on the section III--III of FIG. 2 (corresponding largely to FIG. 8 of the U.S. Pat. No. 3,752,097) showing a substituted pile edge guide and a pile sensor control as disposed relative to stitching means and corner turning means;
FIG. 4 is a view in side elevation of the mechanism shown in FIG. 3;
FIG. 5 is a plan view indicating the pile edge guide and relative operating positions of a trimming knife, needle operating point, and the sensor control of FIG. 2;
FIG. 6 is a section taken on the line V--V of FIG. 3 and showing initial presentation of the workpiece;
FIG. 7 is a view similar to FIG. 6, the work now being guided on its pile edge;
FIG. 8 is a plan view corresponding to a part of FIG. 3, showing counter-clockwise corner turning of the workpiece;
FIG. 9 is a view generally similar to FIG. 1 but showing an alternative and generally preferred arrangement embodying electronic sensing for corner turning control;
FIG. 10 is an enlarged view of the corner turning control means shown in FIG. 9;
FIG. 11 is a view in front elevation of portions of the sensing means shown in FIG. 10, in both operative and inoperative positions; and
FIG. 12 is a schematic functional block diagram of an electrical circuit controlling corner turning in the FIG. 9 arrangement.
DESCRIPTION OF PREFERRED EMBODIMENTS
Unless hereinafter indicated it may be assumed that construction of the illustrative embodiments now to be explained generally corresponds to that fully disclosed in the cited U.S. Pat. No. 3,752,097. Distinguishing features will now be explained in detail, referring first to the embodiment shown in FIGS. 1-8 inclusive. Like parts in the alternative embodiments bear the same reference characters.
An edge finishing machine 10 (FIG. 1) which may, for instance, be an overedging machine of commercially available type is secured to a plate 12 bolted onto a table 14. A work supporting bed 16 secured to the plate 12 is cut away to accommodate a finishing tool such as a reciprocable needle 18 (FIGS. 3, 5, and 8) of the machine, and usual rectilinear feed dog and presser foot mechanism 20 (FIGS. 3 and 8). Additionally, the machine includes an adjacent pair of margin trimming shears 22, 22 (FIG. 8). Further, the present machine arrangement comprises a suitable corner turning mechanism generally designated 24 (FIGS. 1 and 3) which may, as hitherto disclosed, include a work swinging finger 26 and yieldable rotary clamp 28 cooperative to determine a fixed turning center about which the workpiece will be swung as the margin trimming and overedging operations progress, preferably with no decrease of speed. A corner counting mechanism (not herein shown) preferably is provided together with an automatic kick-out mechanism 29 (FIG. 1) of the type disclosed in said patent for automatically ejecting work at the end of a completed cycle of edging operations.
Control of the corner turning mechanism 24 in the present invention, instead of being responsive to a light beam interruptible by the workpiece as hitherto, resides in a sensing means competent to distinguish the presence of thicker, i.e. pile vs. non-pile material and is herein shown in one form as a pneumo-electric sensor generally designated 30 (FIGS. 1 and 2). This sensor 30 is fixedly mounted and has its lower end receivable in, and extending through, an opening in a vertically movable work-spreading plate 32 overlying the work bed 16. Preferably, and as shown in FIGS. 3, 5, and 8, the sensor 30 later to be described is initially disposed for operation inwardly of a workpiece margin and just ahead of an edge guide generally designated 34 (FIGS. 3, 5, and 8) now to be explained.
The guide 34 is normally arranged to overlie the bed 16 in alignment with the rectilinear path of feed effected by the mechanism 20, and is adapted to provide work guidance as afforded by the rectilinear edge of the pile or terry material, herein designated T, as distinguished from the non-terry marginal material designated NT to be removed. For this purpose the guide 34 preferably has its forward end portion undercut as shown at 35 in FIG. 6 to permit all non-terry margin material to be removed regardless of its width and comprises 2 or more gages in the form of balls 36 (three herein shown) respectively nested in vertical sockets or bores 38 (FIGS. 6 and 7). Each bore 38 threadedly receives an adjustable stop 40. The arrangement is such that margin material NT, being thinner, can slide under the balls 36 when they are in cooperative relation to the work supporting bed 16, but the terry material T is too thick to slide under the balls which are then prevented from sufficient upward displacement by the adjusted stops 40.
As in the patented arrangement, the rearward end of the guide 34 is desirably connected to sew-off actuating means 42 (FIG. 3) operable in response to a signal from the mentioned corner counting mechanism, for thrusting the guide forwardly against a return spring after the last work corner has been processed. This action urges the margin of the work forwardly from beneath the presser foot and hence enables the kick-out mechanism 29 to then free the work from the machine.
The control sensor 30 (FIG. 2) is herein shown as fluid pressure actuated, but it will be appreciated alternative sensor types may be substituted therefor. Air under pressure from a source (not shown) is continuously admitted via a tube 44 (FIG. 2) to the sensor 30 and is vented from an escape orifice formed in a sensing head 46 adapted to distinguish terry material T from the non-terry NT. For this purpose the non-terry can ineffectually influence air flow upon sliding beneath a workengageable ball 48 loosely nested in the head 46, but when the thicker edge of terry material T engages the ball 48 to displace it upwardly, the entering air from the tube 44 is backed up through a passageway 50 extending from the head 46 to a pilot valve 52 housing a piston (not shown) for actuating an electrical switch 54. Accordingly the restriction of the escape orifice by the terry builds back pressure adequate to shift the valve and hence actuate the switch 54. Though not herein shown, means preferably is provided whereby the edge guide body 34 is adjustable heightwise relative to the work support 16 to accommodate different ranges of thicknesses of work material.
The arrangement is such that the workpiece W is initially presented to the edge guide 34 as shown in FIG. 5, a straight edge of the terry T being guided by the balls 36, and the terry T then engaging the control sensor ball 48 as indicated in FIG. 3 and thereby causing closure of the electrical switch 54. Slightly inward of the line of balls 36, another ball 55 (FIGS. 3 and 4) is disposed to serve as a fixed stop or guard preventing excessive inward movement of the work. When relative linear movement of the work W has resulted in trimming and overedging along the straight edge of the terry T to the extent that the sensor ball 48 rides off the terry and onto the non-terry margin NT, or completely off the work as shown is FIG. 8, air can escape from the head 46 at a higher rate, and the pilot valve piston will automatically shift to open the switch 54. Air is then admitted into 1 of 2 inlets 56 (only one is shown in FIG. 2). As a consequence a signal is transmitted to effect operation of the corner turning clamp 28 and the swing finger 26 counterclockwise as seen in FIG. 8. Without interruption of the overedger 10, the work W is thereby swung counterclockwise about the turning center at the axis of the clamp 28, and trimming and stitching proceed along a circular path, usually a 90° arc or "corner," at the terry edge. The trimming precedes the overedging at all times as indicated in FIG. 5. The radius of the work corners to be finished is determined by the spacing of the turning center of the clamp 28 from the line determined by the terry work contact points of the guide balls 36.
It will be apparent that each operation of the corner turning mechanism 24 is effective, through control circuitry substantially as disclosed in the mentioned patent, to bring the terry material T again under the control sensor ball 48 whereupon the resultant air restriction causes the switch 54 to be closed and work turning to be terminated. Rectilinear work feeding, trimming, and overedging accordingly now resume along a straight path determined by the next straight edge of terry to be processed and the guide 34 cooperating therewith.
In the manner indicated the successive non-pile side margins of pile-type workpieces are removed by the shears 22 and the remainder overedged along a pile or terry edge including the interconnecting rounded corners of selected curvature which are produced by the corner turning mechanism 24. In some instances the latter will derive its signal for operation from change in the material beneath the ball 48 from terry material to a non-terry margin, and at other times, because of the nature of the original workpiece, such signal will occur upon a terry portion (already extending to a work edge) passing under the ball 48 and no margin contacting the ball 48. It will be apparent that inclusion of the corner counting and/or the kick-out features are not necessary to usage of this invention, but their application is found particularly convenient in combination with the guide 34 and the control sensor 30 for automatically edge finishing large numbers of workpieces.
As an alternative to the pneumatic sensing means above explained, an electronic arrangement often preferred for controlling corner turning will next be described with reference to FIGS. 9-12 inclusive. An electronic sensor responsive to a beam from a light source, for instance a photo-coupler 60 (FIGS. 9, 10 and 12) responsive to a light beam emitted along an axis X--X by a suitable source 62, is provided. For this purpose the sensor and beam source are supported on an angular arm 64 pivotally mounted on a horizontal pin 63 carried by a vertical plate 66 secured by pins 68,68 to the machine frame. when a start lever 70 (FIGS. 9 and 12) is manually actuated to operate a switch 72, a piston rod 74 (FIGS. 9, 10 and 12) is deactivated, allowing a thickness sensing finger 76 (FIGS. 9-12) to be pivoted independently on the pin 63 (counterclockwise as seen in FIG. 11) by a spring 78 so that a lower, sometimes rounded (and sometimes flat depending on surface texture) end 80 of the finger may yieldingly contact the presented terry material, i.e. be shifted from the dash line position shown in FIG. 11 to the lower full line operating position indicated. This finger is then ready to sense the first work "corner" as it approaches the operating instrumentalities. The piston rod 74 is vertically operable against spring return in an air cylinder 82 held by a clamping block 84 secured to the plate 66. A tension spring 81 connected to a pin projecting from the plate 66 yieldingly maintains the arm 64 in contact with the lower end of a vertically adjustable stop screw 83 threaded through the block 84 thereby enabling the detecting mechanism to be suitably adjusted for different thicknesses of pile material.
It will be understood from the foregoing that, when the work contacting end 80 is in normal work contacting position, i.e. engaging the work surface at its effective level, an opposite end 86 of the finger 76 is disposed just beneath the beam axis X--X. As soon as the finger end 80 under influence of the spring 78 drops off the edge of the terry material T, or more precisely the terry pile moves away from the end 80, the change is detected by the photo-coupler 60 by reason of the mentioned opposite end 86 of the finger rising to block the beam X. As a consequence of this beam interception an output signal from the photo-coupler 60 is sent to an amplifier 88 (FIG. 12) and also fed, as amplified, to an adjustable turn start timer 90 and a test circuit 92. This circuit 92 checks to determine at the start and end of each corner turning operation if a "no terry material" condition exists by "looking" at the state of the terry sensor 76 after a predetermined interval on the order, for instance, of 0.4 seconds. If the sensor 76 then indicates a "no terry material" condition exists at that time a stop cycle signal is generated at block 93 (FIG. 12) as a safety measure. When the delay of the start timer 90 expires, effective operation of the corner turning mechanism 24 commences rotating the workpiece in a manner similar to that indicated in FIG. 8. Simultaneous with the mentioned signal from the photo-coupler 60, its output is employed to activate the cylinder 82 and advance its rod 74 downwardly whereby the finger sensing end 80 is lifted to permit the workpiece corner portion to be swung without interference therefrom. As herein shown (FIG. 9) the sensing finger 76 is movable into and out of work contact by extending into and out of the same slot in the plate 32 that receives the swing finger 26.
The duration of corner turning is adjustable in novel manner in this electronic mode of control to properly allow for the different degree of stretchiness (and possibly difference in handling characteristic) encountered in almost all fabric materials when proceeding with the warp or the woof of a woven fabric of given weight. For this purpose the time of corner turning at the first and third corners of the washcloth, for instance, will be determined by a variable time delay 94, and similarly the corner turning time in which the mechanism 24 is operative at the second and fourth work corners (assuming 90° arcs) will be determined by a variable time delay 96. At termination of each corner turning and accompanying edge finishing, the cylinder 82 is again deactivated to allow the finger end 80 to contact the work on its terry surface in readiness to sense arrival of a next "corner". A corner counting mechanism 98, which may be of the type disclosed in an earlier U.S. Pat. No. 3,722,441, for instance, is provided to determine the last corner to be processed whereupon the workpiece will be sewn off automatically, for example, by actuation of the sew-off actuating means 42, and then ejected by the kick-out mechanism 29 (FIG. 1). The illustrative machine may be provided with automatic work stacking means (not shown) such as the type disclosed in U.S. Pat. No. 3,848,866 based on an application filed Mar. 22, 1972 in the names of G. A. Fuller et al, and wherein the cycles of operation of the machine are coordinated with those of the stacker. | This invention relates to automatic mechanism for processing the edges of pile type fabrics and the like from which thinner or non-pile margins are to be removed. Fabric edge finishing machines are provided with a means for sensing relative thickness of work piece portions, such as terry material as distinguished from thinner or marginal non-terry portions. Accordingly washcloths and the like, as directed by an edge guide and corner turning mechanism, are under the control of a sensor and are automatically guided through the operating localities of instrumentalities, such as the needle and trimming mechanism of an overedge stitcher, or other edge treating machines, to provide for removal of the non-terry material and processing directly along the edge of the remaining terry material. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS: NONE
[0001] NONE
BACKGROUND OF THE INVENTION
[0002] The present application discloses a method for the preparation of methyl silsesquioxane resin particles. The particles are formed by the hydrolysis and condensation of monomethyltrichlorosilane (also known as methyltrichlorosilane) in HCL followed by separation and drying. By this process, by-products and waste are converted into commercially valuable materials.
[0003] Methyltrichlorosilane is made as a byproduct in the production of dimethyldichlorosilane and in quantities well above current market demands. Current outlets for this material yield an economic return that is little above the breakeven price. Thus it is desirable to develop a product from methyltrichlorosilane that can enhance the value of this material to the producer.
[0004] One such product would be a filler. Such fillers should have a small particle size and a high surface area to have the greatest efficacy. However, when MeSiCl 3 and water are brought into contact with each other, particularly under conditions of little agitation, the resulting hydrolysis product consists of large, hard lumps of siloxane. Such material, even when ground to a fine powder, provides little if any reinforcing character when used as a filler even though it may exhibit surface areas of over 250 m 2 /gm. This lack of reinforcement is believed to be due to the high surface area of the particle resulting from small cracks and pores in the particle which the polymer being reinforced cannot enter, thus causing the particle to act as if it had a very low surface area.
[0005] When the reactants, MeSiCl 3 and water are brought together under very dilute conditions, the resulting hydrolysate tends to be of a low molecular weight that is generally soluble in a solvent. Such lower molecular weight resins can be used in coatings or as ingredients of coating products, but they generally do not find application as a filler.
[0006] The present inventors have produced a methyl silsesquioxane (MeSiO 3/2 ) that not only is of a high molecular weight, which gives it high temperature stability, but particles derived from such material also have a high surface area that makes them attractive for filler applications in sealants, rubbers, and the like.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention comprises a method for the preparation of particles having a large surface area from methyltrichlorosilane. The method comprises first reacting methyltrichlorosilane with aqueous HCl to form a liquid phase and a solid phase. The solid phase is separated from the liquid and dried to form high surface area particles.
DETAILED DESCRIPTION OF THE INVENTION
[0008] The method of the invention essentially comprises hydrolyzing and condensing methyltrichlorosilane to form resin particles followed by separating the resin particles and drying them. The silicone resin forming the silicone resin particles comprises methyl silsesquioxane resin expressed by the unit formula MeSiO 3/2 .
[0009] The medium in which the hydrolysis and condensation reactions of the methyltrichlorosilane compound or other silane compounds is aqueous HCl. The HCl should generally be at a sufficient concentration to inhibit the formation of low molecular weight species. In one embodiment, the HCl is at a concentration greater than 10 wt. %. In an alternative embodiment, the HCl is at a concentration greater than 20 wt. %. In an alternative embodiment, the HCl is at a concentration greater than 30 wt. %. In an alternative embodiment, the HCl is at a concentration greater than 35 wt. %. In yet an alternative embodiment, the HCl is at a concentration of about 37 wt. %.
[0010] In one embodiment, the methyltrichlorosilane is added to a solution of the aqueous HCl with agitation. In another embodiment, the HCl is added to a solution of the methyltrichlorosilane with agitation. If desired, the methyltrichlorosilane can be diluted in a solvent for the reaction.
[0011] In an alternative embodiment, the reaction of the methyltrichlorosilane and the aqueous HCl can be run by bubbling gaseous methyltrichlorosilane through aqueous HCl. If desired, the gaseous methyltrichlorosilane can be diluted with a material that doesn't react with it. For example, the gaseous methyltrichlorosilane could be diluted with nitrogen and this gaseous mixture then bubbled through the aqueous HCl.
[0012] The rate of addition in either of the above processes is not critical. For example, it can be added quickly (e.g., over a period of a few seconds to a few minutes, for example 5 seconds to 5 minutes), provided the reaction medium is contained within the reaction vessel. In another example, the methyltrichlorosilane and aqueous HCl can be mixed more slowly over a period of several minutes to several hours (e.g., 5 minutes to 24 hours) by, for example, dropwise addition or slow gaseous addition.
[0013] The ratio of aqueous HCl to methyltrichlorosilane used in the reaction can vary over a wide range. For example, the ratio of HCl:methyltrichlorosilane can be a molar ratio of 100:1 to 1:100. In another embodiment the ratio can be 1:25 to 1:75. In another embodiment, the ratio can be a molar ratio of 5:1 to 1:5.
[0014] The temperature of the reaction medium in which the methyltrichlorosilane is subjected to the hydrolysis and condensation reaction, is in the range from 0 to 100° C. or, in an alternative embodiment, from 0 to 40° C. An aqueous medium at a temperature lower than 0° C. will result in slower reaction rates. When the temperature of the reaction medium is too high, the reactant rate will be very fast and may result in larger particles.
[0015] If desired, small amounts of others silanes can be included in the reaction media. These can include, for example, dimethyldichlorosilane, silicon tetrachloride, trimethylchlorosilane, methyhydrogendichlorosilane, and trichlorosilane. These which may be in the methyltrichlorosilane as a by-product or impurity or they may be intentionally added to slightly alter the composition of the final resin. In one embodiment, the other silanes can be included in a weight percentage of less than 10%, alternatively in a weight percentage of less than 1%, and alternatively in a weight percentage of less than 0.1%.
[0016] Once the hydrolysis and condensation reactions occur, a solid phase is formed. This can be in the form of solid particles, foam or the like. According to the process of the present invention, the solid phase is removed from the liquid phase and dried to form the particles. If desired, however, the reaction product can be manipulated to form a variety of particles before it is dried. For example, the mixture of the solid phase and the liquid phase can be blended to form smaller particles.
[0017] In one embodiment of the invention, the reaction product comprising the solid phase and the liquid phase is also diluted with water prior to the separation. This dilutes any remaining acid and allows for ease in further processing. The amount of water added in this step is not critical.
[0018] The solid phase is then removed from the liquid phase. This can be accomplished by known techniques such as heating under normal or reduced pressure, gravity settling of the particles, fluidization of wet particles in a hot air stream, spray drying of the dispersion or a conventional solid-liquid separation procedure such as filtration, centrifugation, decantation and the like to remove at least a part of the aqueous medium.
[0019] The particles are typically further dried by mechanical means, heat or the like (for example, an oven or a microwave). When the thus dried resin particles are in the form of loose cakes, it is usual that the cakes are disintegrated into discrete particles by using a conventional disintegrator such as jet mills, ball mills, hammer mills and the like.
[0020] If desired, the solid phase can be further washed or flushed with water or alternative diluents. This may improve the purity of the material.
[0021] While the silicone resin particles basically comprise the methylsilsesquioxane, the silicone resin may further comprise other types of siloxane units including other trifunctional units of the formula R 1 SiO 3/2 , difunctional units of the formula R 1 2 SiO 2/2 , monofunctional units of the formula R 1 3 SiO 1/2 and tetrafunctional units of the formula SiO 4/2 , in which each R 1 is independently a hydrogen or a hydrocarbon group of 1-20 carbon atoms, such as, for example, an alkyl, an alkenyl, an aryl and the like. In one embodiment the molar fraction of trifunctional units is at least 80%.
[0022] The resultant particles generally have a surface area greater than about 100 m 2 /g, alternatively greater than about 150 m 2 /g, alternatively greater than about 200 m 2 /g.
[0023] The following examples are included to demonstrate preferred embodiments of the invention. It should be appreciated by those of skill in the art that the techniques disclosed in the examples which follow represent techniques discovered by the inventor to function well in the practice of the invention, and thus can be considered to constitute preferred modes for its practice. However, those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments which are disclosed and still obtain a like or similar result without departing from the spirit and scope of the invention. All percentages are in wt. %.
EXAMPLE 1 (COMPARATIVE)
[0024] 105.3 grams of MeSiCl 3 and 804.5 grams of n-pentane were mixed in a 3.8 liter jug. A magnetic stirring bar was added and the jug contents were agitated with a magnetic stirrer as 8.4 grams of water was added drop wise over a one hour period of time. The jug contents were then stirred overnight. The drop wise addition of water was continued until 17.4 more grams of water was added as the jug contents were stirred with the magnetic stirrer. The jug contents were then stirred for one hour with no additions. Agitation was then stopped and the jug contents allowed to separate. The pentane phase was poured off and about a half gallon of water was added to the remaining gels. White gels separated from the aqueous phase in the jug. After agitating briefly, the jug contents were dumped and the gels separated and placed on paper towels to dry. After drying to a powder the gels were analyzed for surface area using a BET technique after outgasing under helium purge at 250° C. overnight. A surface area of 193.7 square meters per gram was determined.
EXAMPLE 2: (COMPARATIVE)
[0025] 74 grams of MeSiCl 3 and 567.2 grams of pentane were added to a 2-liter 3-neck flask then water was added drop wise with vigorous stirring with a magnetic stirrer over a four hour period during which 54.5 ml of water was added. During this time 83 grams of additional MeSiCl 3 was added in three equal aliquots. At the end of the 4 hour period 347 grams of additional water was added and the flask contents were stirred for an additional 10 minutes. The flask contents were then emptied into a separatory funnel where the solid resin material was separated from the aqueous phase and pentane. The resin was allowed to air dry and then analyzed for surface area as in example 1. The surface area was 79.0 square meters per gram.
EXAMPLE 3: (COMPARATIVE)
[0026] 133 grams of MeSiCl 3 and 762.4 grams of pentane were added to a 2-liter 3-neck flask. 9.2 gram of water was slowly added over a 34 minute period of time with vigorous mixing. The resulting slurry was then allowed to stir for 187 minutes. Twenty-five ml of additional water was slowly added over an 80 minute period of time. The flask contents were allowed to stir overnight then 1 liter of water was added and stirring was continued for 100 minutes. The solids were separated from the aqueous phase and the pentane was allowed to air dry. After air drying the resin was heated in a 1000 watt microwave oven for six minutes to drive off moisture. The surface area of the resulting dry white powder was 147 square meters per gram as measured by the process of Example 1.
EXAMPLE 4
[0027] 1961 grams of 37% aqueous HCl were put in a 4 liter open top vessel and agitated using a magnetic stirrer. 550 grams of MeSiCl 3 were added as quickly as possible without generating so much foam that it overflowed the vessel (about 5 minutes). About 4 liters of water was then added to dilute the acid. The solids were filtered from this slurry using a 5 micron polyester felt filter bag. The filtered resin was slurried in water and the slurry placed in a household blender for about 1 minute to reduce particle size. This blended slurry was again filtered using the same filter bag. The solids were further washed by pouring approximately 10 liters of water over the resin in the filter bag. The resin in the bag was pressed dry then placed in a 150° C. oven for several hours then heated in a 1000 watt microwave oven for 12 minutes. The solids content of the dried resin powder were 99.3 wt % and the HCl content was 280 ppm. Surface area of the dried resin was 227 square meters per gram as measured by the process of Example 1.
EXAMPLE 5
[0028] 2.5 liter of 37% aqueous HCl were added to a 18.93 liter plastic pail and, while agitating the acid with a plastic rod, MeSiCl 3 was slowly added. When the resulting slurry became difficult to stir, water was added to dilute it. A total of about 3 liters of MeSiCl 3 was added. This slurry was diluted 50:50 in water and then the resin filtered out with a 5 micron polyester felt filter bag. The filtered resin was again slurried with water and the slurry mixed in a blender for 30 seconds to reduce particle size. Following filtering again of the slurry and air drying, the resin was taken to dryness using a 1000 watt microwave oven. The dried resin was 99.5 wt % solids, contained 150 ppm HCl and had a surface area of 147.5 square meters per gram as measured by the process of Example 1. A five gram sample of this resin was placed in a 350° C. oven for 23 hours and the surface area was measured again to be 284.2 square meters per gram as measured by the process of Example 1. Upon retesting 24 hours later the same sample was measured to be 282.7 square meters per gram as measured by the process of Example 1, showing that the increase in surface area obtained upon heating to 350° C. was retained.
Foam Reactor Examples
EXAMPLE 6
[0029] Nitrogen was bubbled through MeSiCl 3 at about 0.6 liter/min and the resultant nitrogen/MeSiCl 3 fed into a reactor. Concentrated aqueous HCl was also fed into the reactor at a rate of 18 ml/min. The nitrogen/MeSiCl 3 vapor stream entered the reactor through a spherical gas dispersion stone. Over 6.5 hours, 433 grams of MeSiCl 3 was fed. The methyl silsesquioxane foam and excess acid spilled out of the reactor and was collected in a collection vessel. The methyl silsesquioxane foam was separated from the acid by phase separation, collected in a filter bag, washed with water, spread out on an absorbent surface, and allowed to dry at room temperature. About 95 grams of a white powder was left after drying which was 98.8 wt % solids and contained 426 ppm HCl. The surface area of the powder was 260.9 square meters/gm as measured by the process of Example 1.
EXAMPLE 7
[0030] A reaction ran in the same apparatus as described in Example 6 for several hours at rates similar to Example 6. At the end of this time care was taken to wash the foam gently and separate the methyl silsesquioxane which remained as a foam from the methyl silsesquioxane which mixed with the aqueous acid in the foam collection vessel. After drying each portion of product, 25 grams of methyl silsesquioxane which had remained in the foam phase was collected and 48 grams of methyl silsesquioxane was collected which had been filtered from the aqueous acid phase. The methyl silsesquioxane from the foam was 98.5 wt % solids and had 788 ppm HCl with a surface area of 203.9 square meters/gram as measured by the process of Example 1. The methyl silsesquioxane from the aqueous acid phase was 99 wt % solids, had 630 ppm HCl and had a surface area of 247.8 square meters/gram as measured by the process of Example 1.
EXAMPLE 8
[0031] Nitrogen was bubbled through MeSiCl 3 in an 800 ml stainless steel cylinder at about 2 liters/min and the resultant nitrogen/MeSiCl 3 was fed into a 7.62 cm diameter, 30.38 cm tall reactor. Concentrated aqueous HCl was fed into the reactor at about 20 ml/min. The nitrogen/MeSiCl 3 vapor stream entered the reactor through a spherical gas dispersion stone. The methyl silsesquioxane foam and excess acid spilled out of the reactor and was collected in a collection vessel. A total of 690 grams of MeSiCl 3 was fed over 6 hours and 20 minutes. The foam was collected, washed, collected in a Buchner vacuum funnel using a water aspirator to pull a vacuum, and allowed to dry at room temperature. 134 grams of dry powder were collected which were 98.6 wt % solids, 677 ppm HCl and had a surface area of 237.2 square meters/gram as measured by the process of Example 1.
EXAMPLE 9
[0032] The apparatus as described in Example 8 was used with a reactor that was 2.54 cm in diameter and 30.48 cm tall. The nitrogen flow rate was about 1 liter/min and the acid flow rate was about 20 ml/min. The nitrogen/MeSiCl 3 vapor stream entered the reactor through a spherical gas dispersion stone. Over a 4½ hour period 311 grams of MeSiCl 3 was fed. The foam was collected, washed, and dried at room temperature as in example 8.72 grams of dry powder were collected which were 98.9 wt % solids, 648 ppm HCl, and had a surface area of 249.5 square meters/gram as measured by the process of Example 1.
EXAMPLE 10
[0033] Nitrogen was bubbled through MeSiCl 3 in an 800 ml stainless steel cylinder at about 2 liters/min and the resultant nitrogen/MeSiCl 3 was fed into a 7.62 cm diameter, 30.38 cm tall reactor. Concentrated aqueous HCl was fed into the reactor at about 100 ml/min. The nitrogen/MeSiCl 3 vapor stream entered the reactor through a spherical gas dispersion stone. Over a 4.5 hour period 958 grams of MeSiCl 3 was fed. The methyl silsesquioxane foam and excess acid spilled out of the reactor and was collected in a collection vessel. The excess acid was recycled to the reactor at the prescribed rate. The foam was collected, washed, collected in a Buchner vacuum funnel using a water aspirator to pull a vacuum, and allowed to dry at room temperature. 264 grams of dry powder was collected which was 98.5 wt % solids, 1140 ppm HCl and had a surface area of 262.5 square meters/gram as measured by the process of Example 1.
EXAMPLE 11
[0034] HCl was bubbled through MeSiCl 3 in an 800 ml stainless steel cylinder which was heated to maintain a consistent temperature of 25° C. at about 4.3 liters/min and the resultant HCl/MeSiCl 3 was fed into a 3.81 cm diameter, 60.96 cm tall reactor. Concentrated aqueous HCl was fed into the reactor at about 100 ml/min. The HCl/MeSiCl 3 vapor stream entered the reactor through a spherical gas dispersion stone. Over a 3 hour period about 300 g of MeSiCl 3 was fed. The methyl silsesquioxane foam and excess acid spilled out of the reactor and was collected in an 18.93 liter collection vessel. The excess aqueous acid was recycled to the reactor at the prescribed rate. HCl gas was sent to a scrubber. The foam was collected, washed, collected in a Buchner vacuum funnel using a water aspirator to pull a vacuum, and allowed to dry at room temperature. The final resin was 97.9 wt % solids, had 1875 ppm HCl and had a surface area of 192.9 square meters/gram as measured by the process of Example 1.
EXAMPLE 12
[0035] This experiment was run in the same apparatus as described in Example 11 with the exception of using a differently sized reactor. A 10 molar % SiCl 4 in MeSiCl 3 mixture was prepared. The SiCl 4 /MeSiCl 3 mixture was loaded into the 800 ml stainless steel cylinder which was heated to maintain a temperature of 20° C. and the reactor was about 5.08 cm in diameter and about 66.04 cm tall. The HCl flow was set at about 2 liters/min and the concentrated aqueous acid flow was about 137 ml/min. The HCl/SiCl 4 /MeSiCl 3 vapor stream entered the reactor through a spherical gas dispersion stone. Over a 2.75 hour period about 300 grams of SiCl 4 /MeSiCl 3 mixture was fed to the reactor. The foam was collected, washed, collected in a Buchner vacuum funnel using a water aspirator to pull a vacuum, and allowed to dry at room temperature. The final resin was 97.9 wt % solids, had 920 ppm HCl and had a surface area of 219.6 square meters/gram as measured by the process of Example 1.
EXAMPLE 13
[0036] This experiment was run in the same apparatus as described in Example 12. A 10 molar % Me2SiCl2 in MeSiCl 3 mixture was prepared. The Me 2 SiCl 2 /MeSiCl 3 mixture was loaded into the 800 ml stainless steel cylinder which was heated to maintain a temperature of 20° C. The HCl flow was set at about 2 liters/min and the concentrated aqueous acid flow was about 137 ml/min. Over a 2.5 hour period about 300 grams of Me 2 SiCl 2 /MeSiCl 3 mixture was fed to the reactor. The foam was collected, washed, collected in a Buchner vacuum funnel using a water aspirator to pull a vacuum, and allowed to dry at room temperature. The final resin was 98.8 wt % solids, had 572 ppm HCl and had a surface area of 106.8 square meters/gram as measured by the process of Example 1. | The invention discloses a method for the preparation of high surface area methylsilsesquioxane resin particles. The particles are formed by the hydrolysis and condensation of methyltrichlorosilane followed by separation and drying. By this process, by-products and waste are converted into commercially valuable materials. | 2 |
This is a continuation-in-part of application Ser. No. 20,635, filed Mar. 2, 1987, now abandoned.
BACKGROUND OF THE INVENTION
Rolls of toilet tissue that are several times larger than normal size rolls are being sold for institutional use in special dispensers. Such rolls, which typically have a diameter between about 20 to 30 centimeters, are referred to as jumbo rolls. The disposition of the rolls when part of the tissue has been consumed is currently a problem. Discarding the partially spent roll, which is called a stub or remnant roll, is wasteful while leaving the roll in the dispenser incurs the risk that the tissue will be depleted without another source of tissue being available. This invention provides a convenient solution to the problem.
SUMMARY OF THE INVENTION
This invention provides a dispenser having, in addition to a first spindle for receiving the jumbo roll, a second spindle for receiving the stub roll. The rolls are secured by means that discourage pilferage of the rolls but permit access to them by an attendant when the rolls are changed. This invention also provides a special roll of tissue for use in such a dispenser. Unlike a conventional jumbo roll of tissue, which is either all perforated or all unperforated, the initial section (i.e., the section closest to the core) of the roll of this invention is perforated to a predetermined size. The remaining (terminal) section is unperforated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an embodiment of the dispenser of this invention shown in the closed (locked) position.
FIG. 2 is a perspective view of the dispenser of FIG. 1 shown in the open position.
FIG. 3 is a front view of another embodiment of the dispenser of this invention.
FIG. 4 is an exploded perspective view of still another embodiment of the dispenser of this invention.
FIG. 5 is an exploded perspective view of the preferred embodiment of the dispenser of this invention.
FIG. 6 is a perspective view of the second spindle of the dispenser shown in FIG. 5.
FIG. 7 is an exploded perspective view of means for discouraging pilferage of a stub roll borne by the second spindle.
FIG. 8 is a sectional view of the second spindle taken along line 8--8 in FIG. 5.
FIGS. 9 and 11 are sectional views of the second spindle taken along line 9--9 in FIG. 8.
FIGS. 10 and 12 are sectional views of the second spindle taken along line 10--10 in FIG. 8.
DETAILED DESCRIPTION
Referring to FIGS. 1 and 2, the dispenser comprises a base 10 adapted to be secured to a wall. A first spindle 11 extends from the base 10 for supporting a jumbo roll of tissue 12. A second spindle 13 is mounted on the base 10 for supporting a stub roll 14. A housing 15, which is adapted to enclose the first spindle 11 and the jumbo roll 12, but not the second spindle 13 or the stub roll 14, is hinged by means of a bar 16 to the base 10. The bar 16, which supports the housing 15 and extends from it, is adapted to engage the free end of the second spindle 13. A locking mechanism 17 mounted on the bar 16, or other lock means, is employed to secure the bar 16 to the second spindle 13. When the mechanism 17 is locked, as shown in FIG. 1, the jumbo roll 12 and the stub roll 14 cannot readily be removed. When the mechanism 17 is unlocked, the bar 16 and the housing 15 can be swung open, as shown in FIG. 2, to permit access to the first and second spindles for replacing the rolls.
The housing 15 has a serrated edge 18, as is conventional, to facilitate tearing of the roll supported by the first spindle. A serrated edge is not necessary to facilitate tearing of the roll supported by the second spindle because, in accordance with this invention, the initial section of the jumbo roll of tissue is perforated. The length of the perforated section is about equal to the length of a normal size roll of tissue, i.e., a length corresponding to a roll diameter between about 10 and 15 centimeters, or between about 40 to 60 percent of the diameter of the jumbo roll.
Initially, with the locking mechanism 17 unlocked, a restroom attendant swings open the housing 15, places a jumbo roll of toilet tissue on first spindle 11, and closes the housing 15, which locks the locking mechanism 17. After a period of time, depending on the frequency of use, the attendant checks the amount of toilet tissue remaining on the roll in the housing. If the roll is down to the perforated section, the attendant unlocks the locking mechanism 17 such as with a key (not shown), transfers the stub roll from the first spindle 11 to the second spindle 13, places a new jumbo roll of tissue on the first spindle 11, and closes the housing 15, which locks the locking mechanism 17. The steps of transferring the stub roll 14 to the second spindle 13 and placing the jumbo roll 12 on the first spindle 11 are indicated by arrows in FIG. 2. The situation resulting after completion of the steps and closing of the housing 15 is shown in FIG. 1.
In the embodiment shown in FIG. 3, a bar 16' is slidably mounted on the housing 15 and engages the free end of the second spindle 13 by sliding into a groove at the end of the spindle. Sliding movement of the bar 16' is controlled by a locking mechanism 17', which is mounted at the center of the housing 15. When the mechanism 17' in unlocked, such as by inserting a key and turning it clockwise, the bar 16' slides in the direction shown by the arrow, thereby permitting the housing 15 to be swung open to enable the attendant to access the rolls.
In the embodiment shown in FIG. 4, the bar 16" and a tongue 19 supporting the second spindle 13' are readily detachable from the housing 15' and the base 10', respectively, and are adapted to engage the housing 15' and base 10' so that they can be mounted on either the left hand or the right hand side of the dispenser. The tongue 19 terminates in an aperture 20 that is adapted to slip over the first spindle 11'. Means are provided for detachably securing the tongue 19 to the base 10'. These means may be a pair of detents 21 and 22 on the base 10' that are adapted to engage slots 23 and 24, respectively, in the tongue 19, and one or more detents 25 on the first spindle 11' that are adapted to engage an arcuate tab 26 extending from the tongue 19 toward the center of the aperture 20. The housing 15' has a slot 27, 28 on each side for receiving the bar 16". Means are provided for detachably securing the bar 16" to the housing 15' such as detents 41, 42 on the inner surface of the housing 15' that are adapted to engage a slot 29 in the bar 16", and a slot 30, 31 on each side of the housing to engage a tab 32 extending from the bar 16". To support the bar 16", the second spindle 13' has a recess 33 for receiving a male fitting 43 extending from the bar 16". Extending from the first spindle 11' is a first latch 34 adapted to engage the housing 15' through hole 35 and thereby lock the dispenser. The dispenser may be unlocked by inserting a key (not shown) into keyholes 36, 37 in the housing 15' and first spindle 11', respectively. Extending from each side of the housing 15' is a journal pin 38 that is supported by bearings 39, 40 formed in the base 10'. When the dispenser is unlocked, the housing 15' can be tilted down to permit access to the first and second spindles. A particular advantage of the embodiment shown in FIG. 4 is that the elements supporting the stub roll can readily be switched from one side of the dispenser to the other. Also, if desired, the elements can readily be removed to provide a dispenser supporting only the jumbo roll.
The embodiment shown in FIG. 5 differs from the embodiment shown in FIG. 4 in that there is no bar, the housing does not have slots and other features for receiving the bar, and the second spindle is different. The second spindle 13" has a pivotable retaining element 44 that extends from the end of the spindle in a direction substantially perpendicular to the axis of the spindle when the spindle bears the stub roll in order to discourage pilferage of the roll. To permit access to the stub roll, the retaining element 44 is pivoted so that it extends beyond the end of the spindle, as shown in FIG. 6.
As best seen in FIGS. 8, 10 and 12, the retaining element 44 is connected to a latch 46 that extends though the interior of the second spindle 13". As shown in FIGS. 9 and 10, the latch 46 engages a latch plate 47 when the retaining element 44 extends beyond the circumference of the spindle to secure the stub roll borne by the spindle. The latch plate 47 has an aperture 48 by which the latch plate is mounted to the base of the spindle for pivotal movement (as shown by arrow A in FIG. 7). The latch plate 47 is normally out of view (hidden from potential pilferers) but is accessible to an attendant by a recess at the base of the spindle. When the stub roll is depleted, the attendant pushes up on the lower end of the latch plate 47 (as shown by the arrow in FIG. 11) to release the latch 46. The released latch 46 retracts (as shown by arrow B in FIG. 8) as the attendant pivots the retaining element 44, as shown by arrow C in FIG. 7 and arrow D in FIG. 8. This enables the attendant to remove the depleted stub roll and replace it with a new stub roll removed at the same time from the first spindle. When the new stub roll has been placed on the second spindle, the attendant pivots the retaining element 44 back into the position where it secures the roll as the latch 46 engages the latch plate 47. Because the second spindle 13" is inverted when it is mounted on the other side of the dispenser, the latch plate 47 is adapted to engage the latch 46 in the inverted position as well. For example, the end of the latch 46 that engages the latch plate 47 preferably has the profile of an arrow head. Another movable retaining element, such as a push button, may be substituted for the pivotable retaining element 44. Similarly, means other than a latch may be employed for locking the retaining element in the extended position and for releasing the retaining element from the locked position. | A jumbo roll of toilet tissue wherein the initial section of the roll is perforated and the remainder is unperforated is dispensed from a dispenser having, in addition to a first spindle for supporting the jumbo roll, a second spindle for receiving the preceding roll of tissue after most of the tissue has been consumed. The spindles are secured by means that discourage pilferage of the rolls but permit access to them by an attendant when the rolls are changed. The second spindle is readily detachable and can be mounted on either side of the dispenser. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing of U.S. Provisional Patent Application Ser. No. 61/981,857 filed on Apr. 21, 2014 entitled “The Solar Jet Turbofan Aircraft Engine” and the disclosure of which is incorporated herein by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] One of the problems that the world faces is how to reduce its usage of fossil fuel due to its inevitable exhaustion, the expense of manipulating it and its effect on the environment. One of the many things that contribute to air pollution and global warming is the exhaust of jet fumes.
[0005] A separate invention has incorporated the usage of electrical power within a jet engine (U.S. Pat. No. 8,727,271 B2) however the majority of the time the engine burns fossil fuel. This new embodiment of a jet engine does not require the use of fossil fuel in order to operate thereby reducing the cost of operation and eliminating the emission of harmful gas fumes into the atmosphere.
BRIEF SUMMARY OF THE INVENTION
[0006] The Solar Jet Turbofan Aircraft Engine is a revolutionary process that changes the type of fuel necessary to power a jet engine. The power of the sun is harnessed through solar panels. The solar panels are located on top of the aircraft. This solar power is converted to electricity which is stored in a battery, used to start the compressor fan and/or used to super heat electrical elements within a heating chamber. The primary compressor fan that is started by an electric motor sets into motion a process that creates jet power. This fan spins at a high rpm and sends the air through a stator that guides the flow of the air through the nacelle and the heating chamber that ultimately force the air through the nozzle creating thrust that propels the aircraft.
[0007] In a Turbofan design the annular compression fan is larger than the radius of the heating chamber's air input opening. This process makes the fan more economical than a Turbojet design where the compressor fan is the same size as the opening of the heating chamber. The airflow from the fan is compressed due to the resistance of the turbine. Thus there is not an “even flow” of air exiting the turbine.
[0008] This compressed air is forced into the “heating chamber” where a high powered electrical element (or series of electrical elements) can super heat the air. This process increases the pressure of the air which increases the speed that the turbine turns and thereby the force of the thrust is increased since the turbine is connected by a shaft to the primary compressor fan.
[0009] Traditionally, a jet engine's power is increased by the combustion of oxygen and fossil fuel within the combustion chamber of the jet engine. In this invention the traditional fossil fuel (e.g. Jet A) that is combined with oxygen and lit with an igniter is replaced by an electrical heating element.
[0010] The compressed air is forced into a combination of compressor blades (fans) and stator blades which guide the high velocity air towards the turbine. The turbine is connected with a shaft (or a combination of shafts) to the compressor fan which turns the fan in tandem with the turbine. The shaft extends through the compressor fan and turns the generator/alternator which is covered by a nose cone that protects the generator/alternator and also diverts the incoming air.
[0011] The electricity that is generated is sent to the electrical heating elements, the battery or other parts of the aircraft as needed via a Master Control Unit. The increase or decrease of this heat within the heating chamber is what controls the speed of the aircraft. Another embodiment of the invention is to add additional compressor blades as needed in order to further compress the air into the heating chamber.
[0012] Yet another embodiment of the invention is to add an additional heating chamber which serves as an “afterburner”. The compressed air is sent through the first phase of the heating chamber and then it is reheated again in the “afterburner”. The purpose of the afterburner is to increase the thrust of the aircraft temporarily if needed for take-offs, landings and other vital maneuvers. The afterburner is an alternative embodiment of the jet engine design.
[0013] The air exhaust is forced through a nozzle which concentrates the air and creates a powerful force that propels the aircraft forward. A moveable and/or adjustable thrust controller can be incorporated within the nozzle such that it directs the exhaust air thereby guiding the aircraft. This is an optional modification. A thrust reverser is attached to the nozzle that enables the thrust to be utilized to slow or stop the aircraft.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0014] There are four configurations of the design that are viewed.
[0015] FIG. 1 is with series of compressor fans and stator blades with an afterburner.
[0016] FIG. 2 is with a series of compressor fans and stator blades without an afterburner.
[0017] FIG. 3 is with a single compressor fan and with an afterburner.
[0018] FIG. 4 is with a single compressor fan and without an afterburner.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The Solar Panel ( 16 ) transforms solar energy into electrical energy. This electricity is then sent to the Master Control Unit ( 17 ) where it is directed to the battery ( 18 ) to store the energy, the Compressor Fan ( 3 ) to start the process, the Electric Heating Elements ( 19 ) to super heat the compressed air in the Primary Heating Chamber ( 5 ) and/or the Secondary Heating Chamber/Afterburner ( 8 ) in order to increase or decrease the speed of the aircraft. It also is directed to other parts of the aircraft as needed (e.g. cockpit).
[0020] The Electricity Generator ( 1 ) can be an Alternator (Direct Current) and/or a Generator (Alternating Current); its function is to generate electricity via the spinning of the shaft ( 13 ) and then send it to the Master Control Unit ( 17 ) where a decision is made to route the electricity to the battery ( 18 ) and/or the Heating Element ( 19 ) and/or other parts of the aircraft. The Air Input ( 2 ) is where the air flows into the engine's Nacelle ( 14 ). The Nacelle ( 14 ) encloses the aircraft engine parts.
[0021] The Compressor Fan ( 3 )—forces air into the Air Bypass Chamber ( 15 ) and the Primary Heating Chamber ( 5 ) and compresses it due to the resistance caused by the Turbine ( 7 ) and the heating of the air. This Fan ( 3 ) is started electrically with energy from the Solar Panel ( 16 ) and/or the Battery ( 18 ). The Primary Stator Blade ( 4 ) is a stationary device that directs the air into the proper flow towards the Nozzle ( 9 ). The Primary Heating Chamber ( 5 ) then superheats to further expand the compressed air inside the Heating Chamber ( 5 ). Another embodiment of the invention is to add additional compressor blades ( 20 ) and stator blades ( 6 ) that are attached to the shaft as needed in order to further compress the air into the heating chamber.
[0022] The Stator Blade ( 6 ) directs the air into the proper flow towards the Turbine ( 7 ). The Turbine ( 7 ) turns as a result of the compressed super heated air being forced into the heating chamber and exiting through the chamber. This compressed air spins the Turbine ( 7 ). The Turbine ( 7 ) is connected to a Shaft ( 13 ) that turns the Compressor Fan ( 3 ). The shaft ( 13 ) extends through the Compressor Fan ( 3 ) and turns a generator and/or alternator ( 1 ). The shaft can be comprised of low pressure and high pressure spools.
[0023] The Secondary Heating Chamber or “Afterburner” ( 8 ) reheats the exhaust air causing it to expand further as it is forced out the back of the Nacelle ( 14 ) through the Nozzle ( 9 ) creating additional thrust. The Thrust Reversal Unit ( 10 ) is a moveable device connected to end of the Nozzle ( 9 ) in order to redirect the thrust forward in order to slow the vehicle. The Nozzle ( 9 ) can be adjustable and maneuverable to any angle in order to guide the aircraft as necessary. The Nozzle ( 9 ) is mandatory while the adjustability and maneuverability aspect of the Nozzle ( 9 ) is optional.
[0024] The Air Exhaust ( 11 ) is the compressed heated air combined with the cooler air generated by the primary Compressor Fan ( 3 ) that bypasses the heating chamber and is forced out the back of the Nacelle ( 14 ) through the Nozzle ( 9 ) creating the thrust and force that propels the aircraft. The Nozzle ( 9 ) concentrates the thrust of the exhaust air flow. The Thrust Reversal Unit ( 10 ) deflects the exiting exhaust air forward in order to slow the speed of the aircraft when necessary.
[0025] The Nose Cone ( 12 ) is a pointed cone that deflects incoming air and protects the Electrical Generator/Alternator ( 1 ) from excessive air pressure from incoming air at high speeds.
[0026] The Stator Blades ( 4 , 6 ) direct the air into the proper flow towards the Turbine ( 7 ) and the Nozzle ( 9 ). The Shaft ( 13 ) connects to the Turbine ( 7 ), the Compressor Fan ( 3 ) and the Generator and/or Alternator ( 1 ). The Air Bypass Chamber ( 15 ) sends excess air from the Compressor Fan ( 3 ) through the chamber that surrounds the Heating Chambers ( 5 and 8 ). It has a larger diameter than the Heating Chamber ( 5 ) and creates the majority of the thrust. It also cools the outside of the Heating Chambers ( 5 and 8 ). The Air Bypass Chamber ( 15 ) sends excess air from the Compressor Fan ( 3 ) through this chamber that surrounds the Primary Heating Chamber ( 5 ) and the Secondary Heating Chamber ( 8 ) where the air merges with the heated compressed air and is forced through the nozzle creating thrust that propels the aircraft forward.
LIST OF REFERENCE NUMERALS
[0000]
1 . Electricity Generator
2 . Air Input
3 . Compressor Fan (Electric Starter)
4 . Stator (stationary) Blade
5 . Primary Heating Chamber
6 . Stator (stationary) Blade
7 . Turbine
8 . Secondary Heating Chamber (Afterburner)
9 . Nozzle
10 . Thrust Reversal Unit
11 . Air Exhaust
12 . Nose Cone
13 . Shaft
14 . Nacelle
15 . Air Bypass Chamber
16 . Solar Panel
17 . Master Control Unit
18 . Battery
19 . Electric Heating Element
20 . Compressor Blades | The Solar Jet Turbofan Aircraft Engine is a system and method for utilizing electrical heating elements to heat compressed air within a jet engine's “Heating Chamber” in order to increase or decrease thrust. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of Provisional Application Ser. No. 61/979,714 entitled “PLASMA TREATED SEMICONDUCTOR DICHALCOGENIDE MATERIALS AND DEVICES THEREFROM”, filed on Apr. 15, 2014, which is herein incorporated by reference in its entirety.
FIELD
Disclosed embodiments relate to semiconductor transition metal dichalcogenide (TMDC) materials and devices including such materials.
BACKGROUND
While graphene has a very high carrier mobility, the lack of a bandgap limits the application of graphene in nanoelectronic and optical devices. Recently single layer and few layer MoS 2 sheets have been receiving significant attention due to their tunable band gap from 1.2 eV in the bulk to 1.8 eV in a single layer.
Field effect transistors (FETs) based on single layer MoS 2 have shown fast current switching with a mobility of about 250 cm 2 /Vs. In addition, phototransistor, chemical sensor, photovoltaic devices, and integrated circuits have been demonstrated based on MoS 2 .
Significant progress has been made in modifying and controlling the intrinsic properties of MoS 2 . The ability to modulate the electronic and optical properties further widen the applications of 2D MoS 2 and may open up a new era in solid state electronics and opto-electronics. However, such modification of physical properties is of significant challenge as it requires controllably tuning the material properties.
SUMMARY
This Summary is provided to introduce a brief selection of disclosed concepts in a simplified form that are further described below in the Detailed Description including the drawings provided. This Summary is not intended to limit the claimed subject matter's scope.
Disclosed embodiments include plasma oxidation methods for selectively oxidizing a single layer or a few layer 2D semiconductor transition metal dichalcogenide (TMDC) material to reduce its electrical conductivity. As defined herein, a semiconductor is a material having an electrical conductivity between that of an electrical conductor such as the metal copper and that of an electrical insulator (or dielectric) such as a silica, with a 25° C. resistivity of between 10 7 and 10 −3 ohm-cm.
In one particular embodiment, a MoS 2 flake material is changed by plasma processing from a semiconductor to insulator (dielectric). Although the TMDC material is described herein as being MoS 2 , the TMDC material can be other materials provided they are semiconductors and can be oxidized by disclosed plasma processing including oxygen to raise the resistivity of the material to that of an insulator. For example, the TMDC can also generally comprise MoSe 2 , WS 2 , WSe 2 , In 2 Se 3 , or GaTe.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a cross sectional schematic diagram of an example back-gated field effect transistor (FET) that includes a disclosed oxidized dielectric TMDC layer, according to an example embodiment.
FIG. 1B shows the output characteristics of a FET including a single layer of oxidized dielectric MoS 2 at different back gate voltages (V G ) ranging from −60V to 40V with a voltage interval of 20 V, while FIG. 1C shows transfer characteristics of the single layer MoS 2 device.
FIG. 2A shows gate dependence of the source drain current (I DS ) for an example MoS 2 -based FET, where the curve corresponds to plasma exposure times of 0, 2, 3, 4, 5, 6, and 7 sec, respectively. FIG. 2B shows the effect of plasma exposure on the ON current (at V G =40V) and mobility of few layers MoS 2 -based FET.
FIG. 3A is an I DS vs. V DS characteristics curve for the few layers MoS 2 -based FET at different plasma exposure. FIG. 3B shows the resistance of the FET as a function of plasma exposure time. The line shown is the linear fit of the logarithmic electrical resistance as a function of exposure duration.
FIG. 4A is a Raman spectra of pristine MoS 2 and plasma etched MoS 2 obtained with a 532 nm excitation wavelength. While MoS 2 modes were conserved, new Raman peaks corresponding to Mo—O bonds in MoO 3 were measured in the flake after exposure. FIG. 4B shows PL spectra of the flake showing strong response of the monolayer and total PL quenching after plasma treatment.
FIG. 5 is a X-ray photoelectron spectroscopy (XPS) spectrum of Mo (3d) and S(2 s) core levels for pristine (lower panel) and plasma treated (upper panel) MoS 2 flakes.
FIG. 6A shows a structural model of electrical property tuning via defect engineering in MoS 2 single layer as a function of oxygen plasma exposure time, while FIG. 6B shows the change in energy band diagram of multilayer MoS 2 -based FET with plasma exposure time.
FIGS. 7A-D show the effect of plasma exposure time on the mobility with FIG. 7A for 1 layer, FIG. 7B for 4 layers, and FIG. 7C for an 8 layer MoS 2 device. FIG. 7D is a plot of Mobility/Layer vs. Plasma time/Layer for 1 layer, 4 layer and an 8 layer FET and it was found that the curves for the different devices essentially collapse into same line.
DETAILED DESCRIPTION
Disclosed embodiments are described with reference to the attached figures, wherein like reference numerals, are used throughout the figures to designate similar or equivalent elements. The figures are not drawn to scale and they are provided merely to illustrate aspects disclosed herein. Several disclosed aspects are described below with reference to example applications for illustration. It should be understood that numerous specific details, relationships, and methods are set forth to provide a full understanding of the embodiments disclosed herein.
One having ordinary skill in the relevant art, however, will readily recognize that the disclosed embodiments can be practiced without one or more of the specific details or with other methods. In other instances, well-known structures or operations are not shown in detail to avoid obscuring aspects disclosed herein. Disclosed embodiments are not limited by the illustrated ordering of acts or events, as some acts may occur in different orders and/or concurrently with other acts or events. Furthermore, not all illustrated acts or events are required to implement a methodology in accordance with this Disclosure.
Notwithstanding that the numerical ranges and parameters setting forth the broad scope of this Disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, all ranges disclosed herein are to be understood to encompass any and all sub-ranges subsumed therein. For example, a range of “less than 10” can include any and all sub-ranges between (and including) the minimum value of zero and the maximum value of 10, that is, any and all sub-ranges having a minimum value of equal to or greater than zero and a maximum value of equal to or less than 10, e.g., 1 to 5.
Mechanisms are described below that are believed to explain the observed phenomena provided by disclosed embodiments. Although the mechanisms described herein are believed to be accurate, disclosed embodiments may be practiced independent of the particular mechanism(s) that may be operable.
Disclosed embodiments recognize for semiconductor TMDC materials such as MoS 2 to be used as a building block for lateral devices such as lateral FETs, it is necessary to develop a technique for the fabrication of tunable electrical insulator regions that can be rendered “on demand” tunnel region(s). Disclosed plasma oxidation methods provide a relatively simple approach enabling the fabrication of lateral FETs where a controllable (selectable) dielectric TMDC region can be created on the surface of a two-dimensional (2D) semiconductor TMDC material, in contrast to known heterostructures in a vertical geometry where 2D materials of different bandgaps are placed on top of each other. The 2D TMDC material is generally a layer that is one (1) to eight (8) atomic layers thick, and disclosed plasma treating generally oxidizes regions in all the layer(s) of the TMDC material. For MoS 2 1 atomic layer corresponds to about 0.9 nms thick, and 8 atomic layers corresponds to about 6 nms thick.
MoS 2 is a 2D TMDC material representing a new classes of materials, generally having good electrical, mechanical and optical properties. Disclosed embodiments include oxygen plasma techniques for tuning the electrical properties of the layer(s) of TMDC materials such as MoS 2 flakes from being a semiconductor to an insulator. Such controlled changes to the electrical properties of TMDC materials such as MoS 2 is expected to be of significant importance for a variety of nano-electronic device applications such as FETs, sensors, diodes and quantum devices.
In one embodiment, a single layer or multilayer MoS 2 -based FET device is formed using disclosed methods. In one specific embodiment, MoS 2 deposited unto a substrate is then exposed to an oxygen plasma (e.g., O 2 :Ar mixture of 20%:80% by volume) treatment for different time durations. It has been shown that the mobility, ON current and electrical resistance of a single layer and multilayer MoS 2 FET varies exponentially by up to four orders of magnitude with the plasma exposure time. Raman and XPS study of the MoS 2 flakes that were exposed to O 2 plasma reveal dominant MoO 3 peaks. It is believed while exposed to oxygen plasma, energetic oxygen molecules interact with MoS 2 to create MoO 3 rich defect regions which are insulating (dielectric). The area coverage of the defect region increases with increasing exposure time. This effect can be exploited in fabricating lateral TMDC-based FETs without the need to pattern the TMDC layer.
FIG. 1A is a cross sectional diagram of an example back-gated FET (FET) 100 including an oxidized dielectric TMDC layer 116 including defects regions (defects) 116 a therein comprising molybdenum trioxide, MoO 3 , according to an example embodiment. The TMDC layer 116 that is not shown as defects 116 a provides the active layer for HFET which has the geometry of a conventional lateral FET. FET 100 comprises a TMDC layer 116 on a gate dielectric layer 122 on an electrically conductive substrate 112 . The gate dielectric layer 122 may comprise silicon nitride (SiN), silicon dioxide (SiO 2 ), Boron Nitride (BN), aluminum oxide (Al 2 O 3 ), or hafnium oxide (HfO 2 ), among other suitable insulators.
As the substrate 112 is used as a back-gate for the FET 100 , the substrate 112 may comprise highly doped (n+ or p+) Si, typically doped to at least 5×10 18 cm −3 , or another electrically conductive substrate material. Contacting respective sides of the oxidized dielectric TMDC layer 116 is a source contact 114 and a drain contact 115 which each provide a low resistance Ohmic contact. The source contact 114 and a drain contact 115 may also be on the oxidized dielectric TMDC layer 116 . The source contact 114 and drain contact 115 can comprise a metal or metal alloy, such as gold (Au), Nickel (Ni), or Scandium (Sc).
Regarding operation of FET 100 , a gate bias (Vg) is applied to the substrate 112 relative to the source. A source-drain bias (Vds) is then applied between source contact 114 and a drain contact 115 , such as Vds=100 mV. A positive gate voltage induce charges in TMDC 116 and changes the current (Id). The oxygen plasma create defects 116 a being MoO 3 regions, which create bottlenecks for current flow. FET 100 is turned ON and OFF by applying a bias to the substrate 112 acting as a back gate. At Vgs=0, the FET 100 may not be fully OFF as shown in FIG. 1C described below.
A method of fabricating TMDC-based lateral FET can include the following steps. A TMDC layer (e.g. MoS 2 ) 116 is deposited on an electrically conductive substrate 112 by mechanical exfoliation, chemical vapor deposition (CVD) or an epitaxial processes. In mechanically exfoliation a bulk TMDC crystal is exfoliated to generate flakes that are deposited onto the substrate 112 . Another approach for depositing the TMDC layer is using an atomic layer deposition (ALD) process at about 300° C., such as a CVD process, but process control for the ALD process may be limited as compared to exfoliation. Then metal (ohmic) source and drain contacts 114 and 115 are formed on opposite ends of the TMDC layer 116 for providing the source and drain contact. The device is then exposed to a disclosed oxygen gas plasma and a defect induced oxidized dielectric TMDC layer 116 is formed including defects 116 a.
EXAMPLES
Disclosed embodiments of the invention are further illustrated by the following specific Examples, which should not be construed as limiting the scope or content of this Disclosure in any way.
Device Fabrication:
Example devices were fabricated using single layer MoS 2 flakes that were mechanically exfoliated from a commercially available crystal of molybdenite (SPI Supplies Brand, Natural Molybdenite) using an adhesive tape micromechanical cleavage technique and deposited on a highly doped Si substrate capped with a thermally grown 250 nm thick layer of SiO 2 . Before MoS 2 deposition, the Si/SiO 2 wafers were cleaned using oxygen plasma followed by rinsing in acetone and isopropyl alcohol.
An atomic force microscopy (AFM) height profile indicated a MoS 2 thickness of 0.9 nm, corresponding to a single layer. The number of MoS 2 layers was further confirmed by a Raman study. Laser power was kept below 1 mW in order to avoid any damage to the MoS 2 flake and on the other hand sufficient to obtain a good signal to noise ratio. Two prominent peaks at E2g and A1 g corresponding to in-plane and out-of-plane vibrations of atoms were identified separated by a Raman shift Δ=19.46 cm −1 confirms the single layer nature of the flake. Standard electron beam lithography (EBL) was used to pattern metal contacts corresponding to source contact 114 and drain contact 115 on the MoS 2 flakes. Other metal contact techniques can also be used such as optical lithography.
For the fabrication of a MoS 2 FET. first a double layer electron beam resist, methyl methacrylate/poly(methyl methacrylate) (MMA/PMMA), was spun on the substrate and baked, followed by e-beam exposure and development in (1:3) methyl isobutyl ketone:isopropyl alcohol (MIBK:IPA). After defining the electrodes (source contact 114 and drain contact 115 ), 35 nm Au was deposited by thermal evaporation, followed by liftoff in acetone.
The electron transport measurements of the MoS 2 FET were performed in a probe station at ambient condition using a Keithley 2400 source meter and a DL instruments 1211 current preamplifier interfaced with LabView program. The measurements were performed before and after each oxygen plasma treatment. The plasma treatment on the MoS 2 FETs was carried out using a commercial (Plasma Etch, PE-500) plasma chamber at a power of 100 W operating at 50 kHz. During plasma exposure, the pressure within the plasma chamber was held at 1 Torr and a gas mixture of Oxygen (20%) and Argon (80%) flow at a constant rate of 15 sccm. Each time, the sample was exposed for 5 sec and the electron transport measurements were repeated.
Results and Discussions:
FIG. 1B shows the output characteristics (I D vs. V DS ) for different back-gate voltages (V BG ) for FET 100 varying from −20 to 40 V (bottom to top) with a step size of 10 V. An increase of drain current with gate voltage indicates n-type FET behavior. FIG. 1C shows the transfer characteristics (drain-current I DS as a function of back-gate voltage V G ) for FET 100 measured at a fixed source-drain bias voltage V DS =100 mV for the as-fabricated FET 100 . The I DS increased by several orders of magnitude with the increase V G , demonstrating n-type FET behavior. The current ON-OFF ratio of the device was found to be ˜10 4 . The field effect mobility of FET 100 can be calculated using the relation μ=(L/WC G ×V DS ) (dI DS /dV G ), μ=(L 2 /C G ×V DS )×(dI D /dV C ) where L is the channel length, W is the channel width and C G =∈ 0 ∈ r /d is the capacitance between the substrate 112 (gate) and gate dielectric 122 (SiO 2 ), C c =(2π∈L)/ln(2 h/r) with ∈ r ˜3.9∈ 0 being the effective dielectric constant of SiO 2 , and d (=250 nm) is the silicon oxide thickness. The mobility of the FET 100 was calculated to be 6 cm 2 /Vs.
FIG. 2A shows the transfer characteristic at VDS=100 mV of FET 100 after each plasma exposure. Several interesting behaviors can be seen from this transfer characteristic curve. First, the drain current at all gate voltages decreases with an increase of oxygen plasma exposure. This can be more clearly seen in FIG. 2B (right axis) where there is a plot of the ON-current at V G =40 V in a semi-log scale. The drain current was ˜285 nA for the as fabricated sample, which decreased exponentially with time to value of less than 20 pA, a drop of more than four orders of magnitude, after only a total of 6 s plasma exposure time. After a 6 s exposure, the current become negligibly small. The rapid drop of current with oxygen plasma exposure evidences electrons are getting trapped in defect regions of the MoS 2 and the trapped states are increasing with increasing plasma exposure. The mobility of the device after each plasma exposure is calculated from the I−V G curves in FIG. 2A and is plotted in FIG. 2B (left axis) in a semi-log scale. Like the ON-current behavior, the mobility also drops exponentially from 6 cm 2 /Vs for as fabricated sample to 4×10 −4 cm 2 /Vs, after a 6 s plasma exposure. Similar to ON-current, the decrease of mobility is also more than four orders magnitude with plasma exposure.
FIG. 3A shows the dependence of current-voltage FET characteristics upon plasma exposure time. The I DS −V DS graph of the device at V G =40 V is plotted in FIG. 3A for different plasma exposure times. It is observed that at all exposure time the I DS −V DS curves are linear around the zero bias representing Ohmic behavior. FIG. 3B demonstrates the dependence of resistance on the plasma exposure time. A large variation in resistance is observed after plasma exposure. The linear fit of the logarithmic resistance as a function of time indicates that the resistance increases exponentially upon plasma exposure. Similar changes in resistance were also observed for other gate voltages.
Similar device characteristics were obtained on two other single layer FETs. To explore the physical mechanism responsible for the observed change in electronic transport properties, Raman spectroscopy, X-ray photospectroscopy (XPS) and photoluminescence (PL) characterization of the pristine and plasma treated MoS 2 flakes were performed. Raman spectroscopy is a powerful tool to investigate changes in composition of 2D materials. The Raman signature of the pristine flake and the plasma treated monolayer were compared.
FIG. 4A shows the Raman spectra of a representative single layer MoS 2 flake before and after 6 s of oxygen plasma treatment. The two Raman peak corresponding to E 2g 1 (˜385 cm −1 ) and A g 1 (˜410 cm −1 ) modes, characteristic of MoS 2 observed in the pristine flake, clearly decrease in amplitude after treatment. Interestingly, E 2g 1 (in plane) is severely affected as a result of the treatment, while A g 1 shifts only of 3 cm −1 with a strong amplitude decrease (6 times) and a significant broadening. Finally the disappearance of the LAM mode at 450 cm −1 also confirms the disruption of the MoS 2 lattice during oxygen plasma treatment. On the other hand, the apparition of other peaks observed in the 150-400 rel. cm −1 range indicate the formation of Mo—O bonds in the system at 180 cm −1 corresponding to the B 2g vibrational mode of MoO 3 , 225 cm −1 corresponding to the B 3g mode.
Hence the electronic properties were explored using PL spectroscopy. As a result of oxygen plasma treatment, the PL of MoS 2 is fully quenched after 6 s of treatment (see FIG. 4B ). Photoluminescence involves exciting excess electron-hole pairs optically with energy of the incident photons higher than the band gap of the semiconductor sample. The emitted radiation is a result of the radiative recombination in the sample. For single layer MoS 2 , the PL distribution is centered around 1.84 eV (often referred to as exciton A 1 ), with a second peak with lower amplitude around 1.0 eV (often referred to as exciton B 1 ). A decrease in PL intensity, as seen in FIG. 4B indicates competing non-radiative processes removing excess carriers in the system. The results are indication of a reorganization of the excess carriers in presence of MoO 3 .
FIG. 5 show the XPS spectra of pristine MoS 2 and plasma treated MoS 2 respectively. Three prominent peaks were observed at energies 227 eV, 229.7 eV, and 233.1 eV in pristine MoS 2 sample, origin of which has been attributed to binding energy of S 2 s, Mo 3d 5/2 and Mo 3d 3/2 electrons in Mo—S bond of the MoS 2 crystal respectively. All these peaks were also found at same binding energies for the plasma treated sample, however an additional peak at energy 236.4 eV could be observed, corresponding to the higher oxidation state Mo +6 . This new peak further confirms the presence of MoO 3 in the plasma treated sample.
Based on the Raman, XPS and PL study, the following mechanism is proposed to explain the electrical property evolution of MoS 2 due to disclosed plasma treatment. During plasma treatment high energetic charge particles bombard on MoS 2 surface. Since S has much smaller mass compared to Mo, they move from the lattice site and lattice vacancies are created. Because of the excess oxygen supplied by the plasma, oxidation takes place at the defect sites in the surface. The oxidation process can be described as 2MoS 2 +70 2 =2MoO 3 +4SO 2 . The work function of MoO 3 is ˜6.8 eV which is larger than that of MoS 2 (4.5 to 5.2 eV). As a result of this large work function difference, electron transfer can occur from MoS 2 to MoO 3 resulting in hole doping in MoS 2 . In addition, MoO 3 has a bandgap of 3.2 eV-3.8 eV, making it electrically insulating in nature. Therefore, the creation of MoO 3 in MoS 2 hinders the charge transport. An exponential increase in resistance ( FIGS. 3A , B) is indicative of percolation conduction mechanism in MoS 2 upon plasma exposure. This evidences that with increase of plasma exposure time, MoO 3 rich region increases in MoS 2 which creates significant distortion of lattice ( FIG. 6A ). Those lattice distortions create tunnel barriers (see FIG. 6B ) inside the 2D materials which reduces the charge carrier transport through the device. The tunnel barrier height increases with the exposure time, and for high exposure of time completely cease the transport.
In order to investigate whether or not similar electronic property tuning can occur in multilayered MoS 2 flakes, devices were fabricated with 4 layer and 8 layer MoS 2 flakes. The results are summarized in FIGS. 7A-D ( FIG. 7A for 1 layer, FIG. 7B for 4 layers and FIG. 7C for 8 layers). It can be seen that the plasma exposure time needed to see changes in mobility (also in current) increases with increasing MoS 2 thickness. For example, in single layer sample, a mobility of less than 0.001 cm 2 /Vs was achieved in 6 sec while similar mobility change occurred in 8 layer sample in 60 sec. It was found that the time required to see changes in mobility linearly scale with the number of layer. This is shown in FIG. 7D where there is a plot the mobility/layer with time/layer. This demonstrates that a controlled tuning of electronic properties from single layer and multilayer TMDC sample such as MoS 2 is possible in a predictive way.
While various disclosed embodiments have been described above, it should be understood that they have been presented by way of example only, and not as a limitation. Numerous changes to the disclosed embodiments can be made in accordance with the Disclosure herein without departing from the spirit or scope of this Disclosure. Thus, the breadth and scope of this Disclosure should not be limited by any of the above-described embodiments. Rather, the scope of this Disclosure should be defined in accordance with the following claims and their equivalents.
Although disclosed embodiments have been illustrated and described with respect to one or more implementations, equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. While a particular feature may have been disclosed with respect to only one of several implementations, such a feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. | A plasma-based processing method includes depositing a transition metal dichalcogenide (TMDC) material onto a substrate. The TMDC material is plasma treated in an oxygen containing ambient to oxidize the TMDC material to form oxidized dielectric TMDC material. The oxidized dielectric TMDC material has a higher electrical resistivity as compared an electrical resistivity of the TMDC material before the plasma treating, typically >10 3 times greater. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation of U.S. application Ser. No. 12/501,225, filed Jul. 10, 2009, now U.S. Pat. No. 8,251,986, which is a continuation of U.S. application Ser. No. 11/106,835, filed Apr. 15, 2005, now U.S. Pat. No. 7,938,824, which is a continuation of U.S. application Ser. No. 09/931,672, filed Aug. 17, 2001, now U.S. Pat. No. 6,892,099, which claims priority to U.S. provisional application Ser. No. 60/267,106, filed Feb. 8, 2001 and to U.S. provisional application Ser. No. 60/225,775, filed Aug. 17, 2000, all of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to electroporation of tissues and, specifically, to apparatus and methods for reducing subcutaneous fat deposits, performing virtual face lifts, and body sculpturing.
BACKGROUND OF THE INVENTION
“Cosmetic surgery” is a phrase used to describe broadly surgical changes made to a human body with the usual, though not always, justification of enhancing appearance. This area of medical practice constitutes an ever-growing industry around the world. Obviously, where such a procedure fails to deliver an enhanced appearance, the procedure fails to meet the desired goal. One of the reasons that the majority of current procedures fail to deliver upon their promise is that, for the most part, current procedures are invasive, requiring incisions and suturing, and can have serious and unpleasant side effects, including but not limited to scarring, infection, and loss of sensation.
One of the more common forms of cosmetic surgery is the “face-lift.” A face-lift is intended to enhance facial appearance by removing excess facial skin and tightening the remaining skin, thus removing wrinkles. A face-lift is traditionally performed by cutting and removing portions of the skin and underlying tissues on the face and neck. Two incisions are made around the ears and the skin on the face and neck is separated from the subcutaneous tissues. The skin is stretched, excess tissue and skin are removed by cutting with a scissors or scalpel, and the skin is pulled back and sutured around the ears. The tissue tightening occurs after healing of the incisions because less skin covers the same area of the face and neck and also because of the scars formed on the injured areas are contracting during the healing process.
Traditional face-lift procedures are not without potential drawbacks and side effects. One drawback of traditional cosmetic surgery is related to the use of scalpel and scissors. The use of these devices sometimes leads to significant bleeding, nerve damage, possible infection and/or lack of blood supply to some areas on the skin after operation. Discoloration of the skin, alopecia (boldness), is another possible side effect of the standard cosmetic surgery. The overall quality of the results of the surgery is also sometimes disappointing to the patients because of possible over-corrections, leading to undesired changes in the facial expression. Additionally, face-lift procedures require a long recovery period before swelling and bruising subside.
The use of lasers to improve the appearance of the skin has been also developed. Traditional laser resurfacing involves application of laser radiation to the external layer of the skin—the epidermis. Destruction of the epidermis leads to rejuvenation of the epidermis layer. The drawback of the laser resurfacing procedure is possible discoloration of the skin (red face) that can be permanent.
Another laser procedure involves using optical fibers for irradiation of the subcutaneous tissues, such as disclosed in U.S. Pat. No. Re36,903. This procedure is invasive and requires multiple surgical incisions for introduction of the optical fibers under the skin. The fibers deliver pulsed optical radiation that destroys the subcutaneous tissues as the tip of the fiber moves along predetermined lines on the face or neck. Debulking the subcutaneous fat and limited injury to the dermis along the multiple lines of the laser treatment results in contraction of the skin during the healing process, ultimately providing the face lift. The drawback of the method is its high price and possibility of infection.
Electrosurgical devices and methods utilizing high frequency electrical energy to treat a patient's skin, including resurfacing procedures and removal of pigmentation, scars, tattoos and hairs have been developed lately, such as disclosed in U.S. Pat. No. 6,264,652. The principle drawback of this technology is collateral damage to the surrounding and underlying tissues, which can lead to forming scars and skin discoloration.
Other forms of cosmetic surgery are also known. One example is liposuction, which is an invasive procedure that involves inserting a suction device under the skin and removing fat tissues. As with other invasive surgical procedures, there is always a risk of infection. In addition, because of the invasive nature of the procedure, physicians usually try to minimize the number of times the procedure must be performed and thus will remove as much fat tissue as possible during each procedure. Unfortunately, this procedure has resulted in patient deaths when too much tissue was removed. Assuming successful removal of excess fat tissue, further invasive surgery may be required to accomplish desired skin tightening.
The prior art to date, then, does not meet the desired goal of performing cosmetic surgery in a non-invasive manner while causing minimal or no scarring of the exterior surface of the skin and at the same time resulting in the skin tightening.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide an apparatus and method which uses electroporation to cause necrosis of cells in the subcutaneous layer of fat and the interior side of the dermis, resulting in the contraction and tightening of the skin. In particular, it is an object of the present invention to provide method and apparatus for performing face and neck lift and others similar procedures on the face in a non-invasive manner.
Another object of the present invention is to provide an apparatus and method for significant bulk reduction of the number of subcutaneous fat cells in the body, resulting in a significant weight loss.
Still another object of the present invention is to provide non-invasive apparatus and method for cosmetic and weight loss procedures.
Still another object of the invention is to provide an apparatus and method for selective removal of fat in different areas to enable changing the shape of the body, or body sculpturing.
SUMMARY OF THE DISCLOSURE
The present invention provides an apparatus and method for creation of a controlled injury or alteration to the subcutaneous tissue and/or underside of the dermis, with the following healing process leading to the contraction of the skin; and/or to the controlled destruction of fat cells, leading to their permanent loss. In the present invention the damage to the subcutaneous tissue, underside of the dermis, and/or fat cells is caused by electroporation.
An apparatus in accord with the current invention comprises a voltage pulse generator, an applicator with two or multiple electrodes of different shapes and sizes and a cable connecting the electrodes to the pulse generator. The pulse generator produces set of high voltage pulses of predetermined amplitude, duration and number to cause necrosis in a treated area of subcutaneous tissues.
A method in accord with the current invention comprises application of electrical pulses to the electrodes positioned on the skin in a treatment area. For a face lift, flat and needle-like electrodes are used, the last one providing a strong and non-uniform electric field predominantly normal to the surface of the skin. The amplitude, duration and number of applied pulses are selected to cause necrosis of fat cells to a predetermined depth in the subcutaneous tissue and a limited necrosis of the underside of the dermis. A number of lines of predetermined pattern are exposed to electroporation. Later, during the healing process the skin on the treated area contracts. The injury to the tissues made by electroporation is very gentle and selective; it does not produce scars on the epidermis, the most external layer of the skin.
A method of weight loss and body sculpturing in accord with the present invention comprises application of electroporation pulses to a significant volume of fat tissue. In this case both electrodes are flat and attached to the arms of a forceps. The electrodes are moveable towards and away from each other and are capable of pinching skin with underlying subcutaneous fat and electroporating it. Application of flat, parallel electrodes produces a electric field is uniform in the tissue that effects only fat cells.
For weight loss a voltage generator coupled to multiple needle type electrodes may be used.
In another embodiment of the present invention, an electroporation apparatus for bulk weight loss may comprise apparatus for production of a pulsed magnetic field and its application to the area to be treated. In this embodiment of the present invention, a curl electric field for the electroporation of subcutaneous fat is created by the pulsed magnetic field. Curl electric field causes eddy currents in the tissue and at an appropriate amplitude above kills the fat cells.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and advantages of the present invention will be appreciated from the following specification when read in conjunction with the accompanying drawings wherein:
FIG. 1 is a schematic illustration of an apparatus with an applicator having an array of symmetric electrodes shown during electroporation treatment.
FIG. 2 is a schematic illustration of an apparatus with an applicator having one flat electrode and one a needle like electrode shown during electroporation treatment.
FIG. 3 is a schematic illustration of different applicators of the present apparatus wherein FIG. 3 a illustrates an applicator with two needle like electrodes; FIG. 3 b illustrates an applicator having an array of needle like electrodes; and FIG. 3 c illustrates applicator having one flat electrode and one needle like electrode.
FIG. 4 a is a perspective view of a forceps type applicator with two flat electrodes in an open position.
FIG. 4 b is a schematic illustration of the forceps flat electrodes in closed position shown during electroporation treatment.
FIG. 5 is a schematic illustration of an apparatus for electroporation treatment for weight loss with electrodeless applicator.
FIG. 6 is a frontal view of a human head with schematically shown electroporation treatment for removal of the forehead wrinkles and glabellar frown lines.
FIG. 7 is a lateral view of a human head with schematically shown electroporation treatment for a neck lift.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The term “electroporation” (EP) refers to the use of electric field pulses to induce microscopic pores in the cell membranes called “electropores”. Depending on the parameters of the electric pulse, an electroporated cell can survive the pulse or die. The cause of death of an electroporated cell is believed to be a chemical imbalance, resulting from the fluid communication with the extra cellular environment through the pores. The number and size of electropores created depends on the product of the amplitude E and duration t of the pulse. Below a certain limit, no electropores are induced at all. This limit is different for different cells and depends, principally, on their sizes. The smaller the cell, the higher the product of the amplitude and duration must be to induce pores. Above the lower limit the number of pores and their effective diameter increases with the product Et. Until an upper limit is achieved, cells survive pulsing and restore their viability thereafter. Above the upper limit the pores diameters and number become too large for a cell to survive. It cannot repair itself by any spontaneous or biological process and dies. As noted, a cell's vulnerability to an electric field depends on its size: the larger the cell, the lower the electric field required for killing it. If cells of different sizes are exposed to the same electric field, the largest cells are the first to die. Thus, application of an electric field having preselected parameters can result in selectively killing particular cells.
A desirable target for cell death using the present invention is adipose tissue, commonly called fat. Adipose cells do not proliferate in adults. Their number is fixed at a very early age. Adipose cells can change their size by accumulating or loosing lipids and be responsible for significant, up to two-fold increase in the body weight. Cutting down in the number of large adipose cells results in a significant weight loss in the fat tissue and the whole body. If fat cells are destroyed by any means, their content is metabolized by the body, i.e., scavenged by macrophages, and their number is not restored. The loss of adipose cells, then, is permanent.
Adipose tissue consists of lipid-filled cells ranging in size from 25 to 200 microns. An applied electric field affects the various sized cells differently as previously mentioned. For example, if an electric field, equal to the upper electroporation limit for 100 micron cells (about 10-20 V/mm) is applied to a fat tissue, all cells with sizes from 100 micron and above, will die. The dead cells will be disposed later by macrophages, and the body will metabolize the lipids stored in these cells. Small adipose cells, for which the applied electric field is below the upper electroporation limit, survive any number of electric pulses without any morphological or functional damage.
Pulsed electric fields can be applied to fat deposits inside the body by different methods. In a first method two electrodes are applied to the skin over the fat tissue at some distance from each other and electric microsecond pulses are applied by the electrodes to the tissue. The pulse electric field, created by these two electrodes is non-uniform; it is higher near the electrodes and decreases with the depth. The electric field at the fat deposits should reach several tens of volts per mm to be able to kill adipose cells of large diameters. At the skin level the non-uniform electric field will be significantly higher. To be harmless for the skin cells, the field should not exceed the value of the upper electroporation limit for skin cells. The cells in the epidermic basal layer of the skin, which is responsible for the mitotic division and continuous rejuvenation of the skin, have dimensions of about 10 microns or less (6-10 microns). This is 10 or more times less than that of the targeted adipose cells, which is about 100 microns and larger as noted earlier. The upper electroporation limit for the skin cells in accordance with their size is therefore about 10 times higher than that of adipose cells of 100 microns diameter.
A second method of applying an electric field to the subcutaneous adipose tissue or the skin is by applying short magnetic pulses preferentially normally to the skin. The transient magnetic field creates curl electric field in the skin and the underlying tissues. This curl electric field causes eddy currents in the cells. If the magnitude of this transient electric field reaches the upper electroporation limit for the cells, it will kill them exactly as does the potential electric field created by charged electrodes.
The depth of penetration of the electric field in the skin and the fat tissue under it depends on the distance between the electrodes, their shape and size. The larger the size of electrodes and the distance between them, the deeper the penetration will be. If the electrodes are small enough and the distance between them is short, the electric field penetrates only into the skin and does not reach the underlying tissues.
If pulsed electric field penetrates only in the skin and its amplitude is high enough to kill skin cells (several hundred volts per mm), electroporation can be used for selective cell killing. The dead cells are removed by macrophages and the skin shrinks during the healing process. This skin shrinkage can be planned in advance both in terms of directions and degree. By selecting a number, direction and length of the electroporation “cuts” the operator can control the future shrinks. This method can be used for correcting wrinkles and skin pouches on the face, the neck, and on the upper and lower eye lids.
The skin electroporation treatment together with fat reducing electroporation treatment can be used as alternative to cosmetic surgery for the face lift, the upper and lower eye lid surgery, the forehead lift and body sculpturing practically in all parts of the human body.
An electroporation treatment presents several notable advantages over present cosmetic surgery procedures. First, an electroporation treatment is sterile. The most upper layer of the skin, comprising horny dead cells, is very resistant to any damage from an electroporation treatment; it protects the lower layers of the skin from infection.
The electroporation virtual facelift and body sculpturing can be performed in step by step fashion in a multi-session process. This method allows taking into account actual results of previous sessions and directs process of reshaping of the face or body to desired objectives. The treatment can be performed by a medical professional or by the patient him/herself.
With the foregoing generalized explanation of the present invention, apparatus in accord therewith may be described. Referring to FIG. 1 , an electroporation system 10 in accord with the invention is schematically shown with a cross section of a piece of skin 12 with subcutaneous tissue 14 during electroporation treatment. Electroporation system 10 includes a power supply 16 for generating high voltage pulses that are sent though an appropriate electrical connector 18 to an applicator 20 . Applicator 20 includes electrodes 22 and 24 that engage skin 12 and will be appropriately insulated to ensure safe handling. Additionally, the applicator will preferably be configured so as to ensure ease of handling, and thus could take many forms. The electrodes 22 and 24 may take the form of needle electrodes. The electric field created between the electrodes 22 and 24 is depicted with field lines 26 and is applied to the skin 12 and subcutaneous tissue or fat 14 . In the areas close to the electrodes the electric field has an amplitude exceeding the upper electroporation limit, thus causing death to fat cells. This area of fat cell necrosis is indicated at 28 .
In FIG. 2 an alternative embodiment 40 of the present invention is shown with an applicator having two members: a needle-like electrode 42 and a flat electrode 44 . If desired, the system 40 may include an insulating handle 46 configured to be held by an operator to facilitate the manual manipulation of the electrode 42 . The high voltage pulse power supply 16 is connected to the applicator electrodes 42 and 44 by appropriate electrical connectors 48 . Both electrodes 42 and 44 are engaged with skin 12 . Electric field lines 26 depict an electric field between the electrodes 42 and 44 . The area 28 , where the electric field is the highest, is the treatment area where the amplitude of the electric field exceeds the upper electroporation limit and causes cell death.
In FIG. 3 different versions of applicators are schematically shown. FIG. 3 a illustrates an applicator 60 with two needle-like electrodes 64 . FIG. 3 b shows an applicator 64 with an array of needle-like electrodes 64 . FIG. 3 c depicts an applicator 66 like that shown in FIG. 2 and comprising a needle-like electrode 42 and a flat electrode such as electrode 44 .
FIGS. 4 a and 4 b illustrate another embodiment 80 of an electroporation system in accord with the present invention useful for bulk fat reduction. System 80 includes an applicator 82 comprising a body or support member 84 supporting calipers or forceps apparatus 86 . The calipers apparatus 86 includes a pair of pivotable arms 88 mounted at the distal end thereof. The arms 88 support a pair of electrodes 90 and 92 . Applicator 82 may include a pistol grip 94 mounted on a proximal end of the elongated tubular support member 84 for enabling ease of manipulation of same. The electrodes 90 and 92 are mounted on a moveable linkage so that the electrodes are moveable toward and away from each other. A power supply 16 and electrical connectors 48 are also included within a system 80 to provide pulse electrical power to the electrodes 90 and 92 .
FIG. 4 b schematically illustrates an electroporation treatment utilizing system 80 . As shown in the figure, a “fold” of skin 12 with underlying subcutaneous tissue—fat— 14 is compressed between arms 88 and thus electrodes 90 and 92 . A uniform electric field 26 is applied to the skin 12 and subcutaneous tissue 14 clamped between electrodes. Only the large fat cells are killed in this field configuration because the cells of the dermis are spared death because of their small size.
FIG. 5 schematically illustrates another embodiment of the present invention including an electrodeless system 100 . System 100 includes a high pulse current power supply 16 and an appropriate electrical connector 18 extending to an applicator 102 . Applicator 102 comprises a housing 104 and an electromagnetic coil 106 disposed therein. Coil 106 generates a magnetic field 108 that is applied to the skin 12 and the subcutaneous tissues 14 . The pulsed magnetic field 108 in the tissue exists only about 10 microseconds. The energy of rapidly changing magnetic field transforms into a curl electric field 110 , which creates eddy currents in tissue and provides the electroporation treatment for killing the fat cells in the tissue 14 . Preferably, the curl electric field generated in the subcutaneous tissue is in the range of 30 to 50 Volt/mm, and the duration of the pulses is 5 to 20 microseconds.
FIG. 6 schematically illustrates a frontal view of human head 120 with glabellar frown lines 122 and forehead wrinkles 124 . An embodiment of the present invention Such as system 40 is shown in application. Electrode 44 is shown applied to the forehead and the needle electrode 42 is moved over the skin where treatment is desired. Moving the electrode tip along the skin creates a line of necrotic subcutaneous fat cells, which later are metabolized by the body. An exemplary line of treatment 126 is shown in the Figure. Multiple applications of the electrode along predetermined lines on the face or neck create shrinkage of the skin and the subcutaneous fat volume underlying the treated area.
FIG. 7 depicts a lateral view of a human head 130 during a neck lift electroporation procedure using an electroporation system in accord with the present invention such as system 40 . The figure illustrates an exemplary line of electroporation treatment 132 .
The present invention having thus been described, other modifications, alterations, or substitutions may now suggest themselves to those skilled in the art, all of which are within the spirit and scope of the present invention. It is therefore intended that the present invention be limited only by the scope of the attached claims below. | A method of treating a human body by destroying tissue cells is provided. The method involves positioning an electric field generating element near a target area containing tissue cells to be killed in the human body, and treating the human body by applying electrical pulses through the positioned electric field generating element in an amount above an upper limit of electroporation to irreversibly open pores in membranes of the tissue cells in the target area, thereby killing the tissue cells in the target area. | 0 |
This is a continuation of International Application No. PCT/AT2004/000362, filed on Oct. 21, 2004.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method for quality assurance of preferably finger-jointed long timber, produced in series and having a predetermined minimum length, in particular of structural solid wood, as well as to a device for carrying out the method.
2. Description of the Related Art
In order to manufacture from tree trunks a high-quality long timber as used, for instance, as structural timber, thereby ensuring a reasonably uniform quality, the tree trunks are cut or formatted, respectively, to the desired dimension, and, if the blanks thus broken down exhibit defective spots also known as weak points such as loose branches etc., those defective spots or weak points, respectively, are removed and the remaining blank pieces are glued together to form a long timber by means of finger joints on the front side. In this way, glue-laminated timber is produced which is formed from several layers of longitudinally jointed boards glued together and exhibiting finger joints in an offset manner. Laminated squared timber is manufactured from two to three beams glued together longitudinally, which optionally are likewise comprised of sections connected by finger jointings.
A specific problem arises with regard to the processing of strong timber, meaning trees which, at breast height, have a diameter of more than approx. 50 cm. If such strong timber is processed into structural solid wood, it has the advantage of a higher yield. However, the timber properties are very heterogeneous, i.e., the strong timber involves higher selection efforts. In addition, a wet core or a heart shake may cause problems. Strong branches likewise cause poorer mechanical properties. For this reason, long timber manufactured from strong timber can only rarely be cut from a tree trunk in one piece; mostly, it is necessary to cut out weak points and to glue the sections together by finger jointing, as mentioned above, in order to form a long timber.
It is known to carry out this process in a more or less automated fashion, with the wood first passing through a quality sorting plant in which it is examined for moisture, tree-ring density, quality of colour and texture, branches etc., which can either be done visually or by electric resistance measurement (for humidity measurement) or using laser cameras. X-ray or computer-tomography or ultrasonic technology is used for detecting hidden branches. Cutting out the defective spots and sticking together the finger jointing is usually performed in automatically controlled installations.
In order to assure the quality of finger jointings manufactured in such installations, destruction tests are carried out, wherein, in a bend test provided for such a destruction test, no breakage is allowed to occur in the region of the finger jointing.
It has been shown that, if long timber manufactured in this manner is used, unexpected breaks—caused, for example, by compressive breaks e.g. in wind fallen wood, gluing errors, tooth forming errors, internal cracks etc.—may occur despite automated error detecting methods and despite a subsequent intensive visual inspection so that there are attempts to exclude structural solid wood from wooden constructions in which timber has a supporting function. This is disadvantageous especially since, due to this, an inexpensive utilization as a squared timber made of strong timber would no longer be possible, i.e., the strong timber would also have to be processed into multilayered glue-laminated timber or laminated squared timber, wherein hidden or undetected defective spots or weak points, respectively, in individual sections are of less consequence as a result of multilayered gluing.
SUMMARY OF THE INVENTION
It is the object of the invention to provide a method for quality assurance of long timber produced in series, no matter if shaped in the form of glue-laminated timber or laminated squared timber or structural solid wood, laminated chip wood, laminated veneer wood, in order to be able to efficiently use such kind of long timber also for structural parts which are subject to higher stress. In particular, it should be possible to strongly reduce the cross-section surcharges which presently are required due to the timber's inhomogeneity.
Since strong timber is predominant in forests and the amount of strong timber is still increasing, a specific object of the invention is to be able to use just this strong timber also with the required safety for highly stressed structures in which long timber assumes supporting functions, wherein the long timber is shaped as a structural solid wood, i.e., is not formed from individual timber layers glued together longitudinally.
According to the invention, said object is achieved in that each long timber finished within the length, preferably each long timber completely glued together, is loaded with tensile forces engaging the respective ends thereof and increasing to a threshold value below the breaking load of a faultless long timber, and the change in length increasing therewith is determined in at least one section or across the entire length of the long timber and is used as a quality criterion for the use, or the further processing, respectively, of the long timber.
The invention is based on the realization that, in a tensile test for timber, no deterioration of timber properties occurs below the breaking limit due to the strict linearity between the change in length and the tension.
Thereby, in order to determine the change in length, the laser speckle method or a method of differential length measurement is preferably used with a direct measuring method or indirect measuring methods such as, e.g., a resistance change in strain gauges.
If the long timber breaks in the tensile test, the tensile stress determined during the breakage is preferably used for classifying the quality of the broken pieces for further usage or subsequent processing thereof.
A preferred variant is characterized in that, in case an inadmissibly high change in the length of the long timber is determined at a predetermined tensile force, the long timber is eliminated from the production, the weak point of the long timber causing the inadmissible change in length or the weak points of the long timber, respectively, is/are cut out and the remaining parts of the long timber that are free from weak points are assembled by finger jointing into a new long timber, optionally with further long timber parts being added, whereupon the newly produced long timber is again subjected to the method according to claim 1 .
Making use of the above-indicated realization, a tension test can be performed in the production process up to the breaking limit (test for determining the breaking limit). The test report shows the stress at break. If the point of break is removed by lopping after the breakage and the broken pieces are possibly reconnected, for example, by finger jointing, no repeated breakage can occur in a repeat of the tension test up to, at most, the breaking limit (if jointing is correct), since all the other points of the timber have already passed the test without problems. In order to maintain the full material length, a new part of high quality can be inserted after removal of the broken section. In doing so, however, a higher risk of repeated breakage occurs (two jointing points, untested new material). Suitably, the second tension test is carried out with a strongly reduced tensile load but with a loading that is sufficient for the desired strength requirement. With broken pieces having a sufficient size for further processing, the material thus obtained can directly be regarded as thoroughly tested after the broken ends have been lopped off, and a second tensile test can be omitted.
By these measures, it is possible to successfully reintroduce the long timber eliminated during the tensile test into the production process so that an optimum utilization of timber will be provided, with the amount of waste and/or cuttings being as small as possible.
Suitably, the tensile forces are applied to the long timber via clamping jaws provided at the ends of the long timber on two opposing sides.
Advantageously, each tested long timber is provided with a quality mark.
Finish-machining of the long timber such as, for example, by planing, grinding or milling is preferably carried out after the test.
It has turned out to be advantageous that the long timbers are allocated to at least two different quality classes depending on the result of the length change determination, whereby it is possible to provide the product which is most suitable for each specific requirement in terms of strength values and to efficiently use also long timber which does not meet the highest demands.
After a surface analysis, the raw material, being undivided and/or divided into sections, is preferably sorted into quality classes and is subjected in each quality class as an individual long timber to a method for quality assurance according to claim 1 , optionally after finger jointing.
It is a further object of the invention to provide a method by means of which beams and binders, respectively, for wooden constructions made of quality-assured long timber can be manufactured, which beams and binders have very large cross-sections and can thereby fully assume a supporting function which is at least equivalent to that of a glue binder made of glue-laminated timber, and preferably have an even higher load-bearing capacity.
According to the invention, said specific object is achieved in that at least two long timbers tested in accordance with claim 1 , which meet a quality criterion required for an application, are glued together, whereby a beam having an upright glued joint is formed.
In doing so, it is essential that the long timbers were subjected to a quality assurance test according to claim 1 , i.e., have been tested across their entire length, before they are formed into a beam. Thereby, it is possible to use strong timber—with the quality being at least the same as with beams formed, e.g., from boards in a conventional manner.
Particularly good adhesion and gluing, respectively, of the long timbers for forming a beam is ensured if the vertical side faces of the long timbers, which side faces are glued together, are processed by milling prior to gluing.
Depending on the required load-bearing capacity of a beam, three or more long timbers arranged side by side can also be glued together to form a beam.
In order to form a binder from the beams manufactured according to the invention, beams which in each case have an upright glued joint are preferably placed on top of each other and glued together to form a beam binder.
A beam manufactured according to the method of the invention is characterized in that it exhibits at least one upright glued joint and that the side faces forming the glued joint are preferably processed by milling.
A beam binder is suitably formed by two or more beams arranged on top of each other and glued together.
According to the invention, a specific optical advantage is provided for the wooden architecture, particularly since the vertical side faces of a beam or of a beam binder exhibit a speckled texture rather than showing, as with a glue-laminated timber, only narrow boards glued together and comprising the glued joints.
Preferably, a beam or a beam binder, respectively, is characterized in that it is formed from long timbers having a height of more than 100 mm, preferably of up to about 300 mm, and a width of more than 50 mm, preferably of up to 100 mm.
In order to be able to use extra high strength zones of the sapwood area of a tree trunk in the high-stress area of a carrier, a beam or a beam binder, respectively, is characterized according to a preferred embodiment in that it is formed from long timbers having a height of more than 300 mm, preferably of up to 600 mm, and a width of more than 50 mm, wherein long timbers are used the narrow edge regions of which are cut from the sapwood of a strong timber.
In order to ensure a speckled texture also at the bottom side and/or the top side of a beam or beam binder, respectively, a beam or a beam binder is suitably characterized by the arrangement and gluing of at least one long timber at the bottom side and/or top side, which long timber extends across the entire width of the beam or beam binder, respectively, and is likewise tested and exhibits a speckled texture towards the bottom or the top, respectively.
A device for carrying out the test is characterized by a tension testing facility applying tensile forces to a long timber and comprising clamping jaws whose sides engaging the long timber are provided with grooves having an arcuate, preferably circular-arc-shaped, cross-section and running transversely to the direction of loading.
For better power transmission, adjacent grooves have different depths, with adjacent grooves suitably exhibiting cross-sections having different curvatures as well as different widths.
In order to avoid that the long timber to be tested is damaged by the clamping jaws, said clamping jaws are characterized according to a preferred embodiment in that a groove having a larger depth and width and a less pronounced curvature is in each case followed by a groove having a smaller depth and width and a more pronounced curvature, with the grooves advantageously being arranged next to each other.
Furthermore, it is an object of the invention to provide a tension testing device for timber for testing timber pieces produced in series, in particular long timber, no matter if shaped in the form of glue-laminated timber or laminated squared timber or structural solid wood, laminated chip wood, laminated veneer wood, in order to be able to efficiently use such kind of long timber also for structural parts which are subject to higher stress. In particular, it should be possible to strongly reduce the cross-section surcharges which presently are required due to the timber's inhomogeneity.
Since strong timber is predominant in forests and the amount of strong timber is still increasing, a specific object of the invention is to provide a timber tension testing device for said strong timber, wherein the long timber is shaped as a structural solid wood, i.e., is not formed from individual timber layers glued together longitudinally.
According to the invention, said object is achieved by combining the following features:
a test bed, in particular an engine bed, having a length corresponding to the maximum length of the timber piece to be tested, a first tensioning trestle arranged, preferably fixedly arranged, in an end region of the test bed, a second tensioning trestle movable along the test bed and adjustable to the length of the timber piece to be tested, clamping jaws provided at both tensioning trestles which grip and clamp a timber piece brought into the test position from above and from below, a device for the application of force onto a clamped timber piece by means of a tensioning trestle, a cross conveyor for conveying a timber piece from a buffer zone for timber pieces, which is arranged at the side of the test bed, to the test bed and onwards to a storage zone arranged opposite the buffer zone and at the side of the test bed and receiving the tested timber pieces, as well as a centering means for centering a timber piece brought into the test position between the clamping jaws.
In this way, it is possible to test each timber piece as a whole and provide it for a specific use depending on the respective test result, without any risk of breakage as it always exists, for example, in strong timber as presently used.
Thereby, the cross conveyor is preferably formed by several conveyor chains arranged side by side.
According to a preferred embodiment, the centering means comprises two centering arms which are movable, preferably pivotable, from a rest position above the upper clamping jaw into a centering position disposed beside the clamping jaws, wherein the centering arms are advantageously movable synchronously against the timber piece, namely in each case from one side.
A particularly simple device for carrying out a length difference measurement is characterized in that a scanner to be applied to a front surface of a timber piece is provided on each tensioning trestle.
BRIEF DESCRIPTION OF THE DRAWINGS
Below, the invention is illustrated in further detail by way of the drawing, with
FIG. 1 showing a block diagram of the process steps of the manufacturing process according to the invention and
FIG. 2 showing a typical tensile stress curve for a finger-jointed long timber.
FIGS. 3 to 7 illustrate the manufacture and testing of long timbers,
FIG. 8 shows a section through a clamping jaw.
FIGS. 9 to 11 show oblique views of beams according to the invention.
FIG. 12 illustrates a so-called “glue binder” made of glue-laminated timber.
FIG. 13 shows a beam binder according to the invention, again in oblique view.
FIG. 14 shows a strong timber, and
FIG. 15 again shows a beam in oblique view.
FIG. 16 concerns a side view and
FIG. 17 a top view of a tension testing device for timber.
FIGS. 18 and 19 show a tensioning trestle on an enlarged scale, once in side view ( FIG. 18 ) and once in the direction of arrow XIX of FIG. 18 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The timber prepared by natural (open air drying) or technical drying (e.g. in electronically controlled drying chambers) so as to reach a predetermined value such as, e.g., 15%±3% residual moisture is supplied to a solid wood processing plant by means of stackers or other conveying means. Rough wood products having a specified length (e.g. 4 m or also significantly more) and a particular cross-section dimensioning (particular cut dimensions) as well as qualities as comparable as possible usually serve as starting products for a standard squared-timber product.
At first, each piece of said greenware is tested for its moisture content. This is done most precisely by the kiln-drying test, in doing so, the weight loss of a test piece is determined during selective drying in a kiln. The electric resistance measurement (conductivity measurement) by means of probes (ram electrodes) penetrating deeply into the timber at two or more defined points is more practicable. However, capacitive methods (megahertz region) can also be used for a contactless humidity measurement, with the specific inductive capacity depending on the water density in the timber. Infrared measuring methods, chemical measuring methods (e.g. indicator paper), neutron scattering methods can be applied. Microwave measuring methods are also possible for the determination of moisture. Stray field sensors, radiation field sensors or resonators can also be used for the determination of moisture. Besides, there is the possibility to determine the moisture in a drill hole via hygrometers.
The first selection stage consists in moisture testing. Raw material that is too wet is again subjected to drying.
A short first cut at the front surface serves for neatly exposing the cross-sectional structure in order to measure the density of tree rings. The measurement is effected visually by cameras, laser focussing and image processing software or other measuring means. This second stage of selection enables the automatic and computer-assisted classification of tree trunks into various quality classes based on tree-ring widths. The higher the density of the rings and the smaller the distances between tree rings, the higher are the strength and hence the quality. Branches have a strength reducing property, since the tree-ring formation involves imperfections.
A surface analysis with regard to colourings, frequency of branches, cracks and other quality characteristics detectable by camera and electronic image data processing is performed in parallel. The timber elements thus detected and suitable in terms of quality are subsequently cut with saws to the crude cross-section, unless they are thitherto already provided as suitable scattered squared-timber rods exhibiting the irregularities in shape caused by shrinkage on drying. Each scattered rough wood is rough-planed on at least two sides in order to obtain clearly defined reference surfaces for further processing for the jointing technique.
In order to determine the inner timber quality, each timber is subjected to an echo depth sounding test either with X-rays in one or several directions or by computer-tomography technology via ultrasound. The results are processed in a computer-assisted fashion using calculators, computers or processors and are stored for further processing of the timber. Here, all defective spots are detected, for the subsequent lopping, in an automated fashion but also via an additional visual inspection by trained personnel, and the data such as lopping positions, quality levels are used for further control of the machine.
Suitable sections having minimum lengths which result from the limitations brought about by the plant are cut with the lopping saw from the preselected timbers. In case of sufficient suitability, the raw material is subjected to further processing also in an undivided state. Based on the data ascertained from the main selection, the pieces thus formed are sorted into various quality classes and are supplied separately via conveyors to one or several jointing plant(s) such as (a) finger-jointing plant(s).
Normally, the sections are provided with dovetails on the front side using a milling cutter, are glued and pressed together and taken via conveyors to the storage for glue aging, where they will again rest separately according to the quality levels corresponding to the main sorting until the glued joint exhibits the required strength. Alternatively, other jointing techniques can also be used. Long timbers resulting therefrom are stored in different quality classes in a logistically separated way. Each quality level has its specific characteristics such as appearance and strength class. The number of quality classes can be defined arbitrarily.
To provide a simpler explanation, three quality levels will be looked at. Quality A of high grade, strength and suitability for the visible range (e.g. standard class S 13), Quality B with suitability for the invisible range (e.g. standard class S 10) and quality R with visible cracks due to the shrinkage caused by drying. Depending on the respective class and timber dimension, various maximum allowable tensile stress loads occur in a further tensile test.
The long timbers which are finger-jointed or connected otherwise are taken to the final testing via cross and longitudinal conveyors prior to or after planing and chamfering. In doing so, each individual long timber is clamped into the tension testing plant by clamping means, the tensile load is then increased to the preadjusted test load (depending on the cross-section and the quality class) and the change in length is recorded via measuring means (e.g. according to laser speckle). For example, the modulus of elasticity is calculated therefrom. In case of breakage or moduli of elasticity which no longer follow Hooke's law, the test procedure is terminated, the defective spot or weak point, respectively, (e.g. bad finger jointings) is located and removed and the resulting timber pieces are reintroduced into the production cycle and allocated as sections of an inferior or equal quality level. Beforehand, a splitting of the rods or broken pieces might be necessary. In case of inadmissible moduli of elasticity or an excessive change in length, respectively, the timber thus tested is either likewise returned to the working cycle, whereby further presumed weak points are split and lopped off, or the timber is checked for lower quality criteria and allocated to them. If the timber breaks, it always breaks at its weakest point. The point of break is removed (lopped off) when the defective timber is returned to the production process. Thereby, the quality of a long timber produced cyclically in this manner is, in principle, increased from cycle to cycle, using a jointing technology such as finger jointings. In order to avoid damage to plant facilities and for accident prevention, protective means such as protecting caps can be disposed around the test section, which in case of breakage (failure) of the test sample catch parts that are splintering off. Nevertheless, a greater yield can be obtained from the rough wood, in particular strong timber, via this method.
If the product passes the tensile test, it is provided with the test results. This can be done after planing and chamfering directly on the product by embossing, imprinting with coded or uncoded measured values and other data such as manufacturing date, quality class, firm name and the like, or separately on protocols which are applied or added to the subsequent package either with stickers or directly.
FIG. 2 shows a typical stress-strain diagram (solid line) and its derivation (dashed line), the modulus of elasticity, for timber. During the tensile test, the time, force and elongation are recorded. The evaluation software continuously calculates the tension from the force signal and the known initial cross-section.
It is advantageous to classify the greenware piece by piece and section by section after the moisture test and a machine-assisted external and internal optical inspection, for example, as follows: A=top quality; B=minor quality, R=quality showing cracks, with useability. Unusable parts are lopped out and removed from the production process. After this first production stage, the timber pieces are divided according to the above-indicated classes. This is followed by timber jointing. The parts of a respective class or quality level are assembled piece by piece into a string via a jointing technique (e.g. finger jointing). Upon reaching the selected final length, the string is divided into the desired length of the long timber—e.g. 8 m—and the long timbers thus obtained are conveyed into the space for aging the adhesive or glue, respectively, allocated to the respective quality level. This procedure is repeated for all quality levels. Then, the products of the second production stage are already provided separately in terms of quality, but still without a tension test.
After the aging period for the adhesive, the tensile test is carried out in a manner ranked according to product classes.
By way of FIGS. 3 to 7 , it is explained below how to proceed in the test for tensile strength.
A rough-planed long timber 1 formed by two pieces 2 , 3 interconnected by finger jointing 4 is fastened, according to FIG. 3 a , to the two ends or end regions 5 , respectively, by means of clamping jaws 6 arranged in pairs and opposite each other, wherein one pair of clamping jaws 6 is preferably stationary at one end 5 of the long timber 1 and the other pair of clamping jaws 6 clamping the other end 5 of the long timber 1 is movable in the axial direction of the long timber in order to apply a tensile force.
According to FIG. 3 b , a first change in length Δ 1 has occurred after the application of a tensile force onto the long timber 1 . A further increase in the tensile force up to the final test load results in a break of the long timber 1 , as illustrated in FIG. 3 ; the reason for this is a weak point 7 which is formed, for instance, by an internal crack etc. which remained undetected in the preliminary test. Said weak point 7 is cut out as illustrated in FIG. 4 a (cf. FIG. 4 b ), and the two remaining pieces 8 , 9 are provided with dovetails 10 at the cutting surfaces in order to be joined together again.
According to FIG. 5 a , a further piece 11 is inserted between the two pieces 8 , 9 so that the long timber 1 will again reach the original length 12 despite the weak point 7 that has been cut out. This is followed by another tensile test up to the final test load as illustrated in FIG. 5 b . If the change in length Δ 1 1 thereby detected is classified as admissible, the long timber 1 ′ thus provided has passed the test.
It should be noted that the length tested at a full load is limited to the distance Z between the pairs of clamping jaws 6 . The end regions 5 of the long timber 1 , where it is held by the clamping jaws, are not tested under a full load, since, there, the tensile force decreases across the end regions 5 .
In FIG. 6 , three blanks for the production of long timber are illustrated in a rough-planed state after error detection. The areas of the long timbers A, B, C and I include longitudinal cracks 13 , and said areas are interconnected by finger jointings 4 in order to achieve a separate grade of long timber 1 ′, as illustrated on the right-hand side of FIG. 7 , wherein, however, the areas I produce waste material as a result of their short length. The areas D, E, F and G have no detectable defect or weak point, respectively, and are assembled into a long timber 1 by means of finger jointings 4 in order to achieve top quality. The two broken pieces H are eliminated just like the areas I. The long timbers 1 and 1 ′ are then subjected to the tensile test according to the invention.
FIG. 8 shows a clamping jaw 6 in sectional view, as it is perfectly suitable for the application of large tensile forces onto a long timber 1 in order to determine the change in length thereof Transverse grooves, i.e. grooves 15 , 16 transverse to the longitudinal direction of the long timber 1 or to the direction of the tensile forces, respectively, extend across the area 14 coming into contact with the long timber 1 , with the grooves 15 , 16 having different depths t 1 and t 2 . Preferably, a groove 16 of a lower depth t 2 is in each case arranged beside a deeper groove 15 , with the transitions 17 from groove 15 to groove 16 being designed with sharp edges.
Preferably, the cross-sections of the grooves 15 , 16 are shaped in the form of a pitch circle, with the deeper groove 15 having a cross-section of a slightly larger radius R 1 than groove 16 which has a lower depth t 2 . The ratio of the widths a, b of the grooves 15 and 16 , i.e. of width b of groove 16 having a lower depth to width a of the larger groove 15 , ranges between 0.3 and 0.6. The radio of radii R 1 and R 2 preferably ranges between 0.8 and 1.5.
FIGS. 9 to 11 relate to so-called beams 21 , 22 , 23 formed from long timber 1 , 1 ′ tested according to claim 1 . FIG. 9 shows a so-called duo beam 21 , FIG. 10 shows a trio beam 22 , and FIG. 11 shows a quattro beam 23 .
The essential feature of these beams 21 to 23 is the upright glued joint 25 , resulting in side surfaces 26 having a speckled texture 27 . The width 28 of the long timbers 1 , 1 ′ to be glued together preferably amounts to 60 or 70 or 80 mm, resulting in beam widths 29 for a duo beam of between 120 and 160 mm. The height 30 of the long timbers 1 , 1 ′ is preferably between 200 and 300 mm. Glued joints 25 of a particularly high load-bearing capacity are produced if the vertical side faces of the long timbers 1 , 1 ′, which side faces are glued together, are processed by milling prior to gluing.
According to the invention, the beam width 29 always extends across at least two widths 28 of the long timbers 1 , 1 ′; with a duo beam across two, with a trio beam across three, and with a quattro beam across four long timbers 1 , 1 ′.
In FIG. 12 , a conventional “glue binder” 31 is illustrated which is formed from boards 32 as a glue-laminated timber. The height 33 of the individual boards usually amounts to 3 to 4 cm. The width 34 of the boards 32 usually ranges between 120 mm and 200 mm. The production of such a “glue binder” 31 is costly, and a large amount of glue or adhesive is used. The side view thereof shows all glued joints and only a plain texture with regard to the timber.
Instead of such a “glue binder”, a beam binder 35 can be provided according to the invention, which, according to FIG. 13 , is formed, for example, from duo beams 21 each having an upright glued joint 25 , with three of such duo beams 21 placed on top of each other and glued together. The width 36 of such a beam binder likewise ranges between 120 and 200 mm but can also exceed this value, for example, if trio or quattro beams 22 or 23 are placed on top of each other and glued together.
The advantage of such a beam binder 35 over a glue binder 31 formed by boards 32 does not only consist in the optical appearance—in side view, a beautiful speckled texture 27 can be seen—but also in the load-bearing capacity, particularly since it is assembled only from long timbers 1 , 1 ′ tested individually and across the entire length. The fact that it can be formed from strong timber is another essential criterion.
In FIG. 13 , it is indicated by dashed lines that long timbers 1 , 1 ′ can be glued to the bottom and/or top side of the beam binder 35 so that also the bottom and/or top side will in each case have a speckled texture and will hence be optically equivalent to a lower side of a “glue binder” 31 formed by boards 32 .
To be able to take advantage of the special strength of sapwood 37 for beams 21 to 23 and beam binders 35 , respectively, strong timber 38 having diameters of more than 400 mm is split according to the cutting plan illustrated in FIG. 14 . For example, long timbers 1 , 1 ′ of a height 30 of about 500 to 600 mm can thereby be produced, with the narrow edge regions 39 thereof being cut from the outer area, i.e. the sapwood area 37 of a strong timber 38 .
If, for example, two of such long timbers 1 , 1 ′ are glued together to form a beam 21 following a quality inspection performed according to claim 1 , a beam 21 having a particularly high load-bearing capacity is produced, particularly since the tension and pressure zone of the beam is formed by sapwood 38 , which, as mentioned above, has extra high strength, especially extra high tensile strength. A beam 21 of this kind, as illustrated, e.g., in FIG. 15 , also has a lateral speckled texture 27 without any glued joint. A beam of such dimensions is also referred to as a tram binder.
Beams 21 as described above can be produced at particularly low cost. As can be seen in FIG. 14 , the resulting timber loss is only small and, furthermore, only few production steps are necessary for the manufacture thereof.
According to the exemplary embodiment of a tension testing machine as illustrated in FIGS. 16 to 19 , a test bed designed as an engine bed 41 is supported on a foundation 42 . On one end, said engine bed 41 carries a first tensioning trestle 43 fixed or fixable thereto and comprising two clamping jaws 44 and 45 , with one clamping jaw 44 thereof being fastened to the tensioning trestle 43 at the height of a support 46 for the long timber 1 to be tested. The second clamping jaw 45 is arranged opposite said clamping jaw 44 , with said second clamping jaw being clampable against the lower clamping jaw 44 by means of a force device such as a pressure cylinder 48 , whereby the long timber 1 is clamped.
On the front side 49 of the tensioning trestle 41 oriented toward the engine bed 41 , a centering means 50 for the long timber 1 to be tested is provided, which long timber is conveyable to the engine bed 41 via a cross conveyor 51 forming the support 46 and preferably formed by several conveyor chains and/or conveyor belts, respectively, arranged side by side, whereby the end region 52 of the long timber 1 ends up lying between the clamping jaws 44 and 45 , as can be seen in FIG. 18 .
Using the centering means 50 formed by two centering arms 53 pivotably arranged on the upper part of the tensioning trestle 43 , it is possible to align the position toward the tensioning trestle 43 in a precisely centric way. The centering arms 53 are pivotable synchronously by means of an adjusting device such as a pressure cylinder 54 from a rest position R disposed above the clamping jaws 44 and 45 , which is illustrated in FIG. 19 by dashed lines, into a centering position Z, which centering position is illustrated in FIG. 19 by solid lines. The synchronous movement can be realized, for example, by interlocking tooth segments 55 which are connected to the centering arms 53 in a torque proof manner.
A second tensioning trestle 56 which has the same design as the above-described tensioning trestle 43 but is oriented in opposition thereto is provided at the other end region of the engine bed 41 . Said second tensioning trestle 56 can be moved relative to the engine bed 41 (cf. double arrow 57 ) so that it is possible for long timbers 1 of various lengths to be gripped in each case at their end regions 52 by the clamping jaws 44 , 45 of the two tensioning trestles 43 and 56 .
At the side of the engine bed 41 , a buffer zone 58 for long timbers 1 supplied for the test is provided, and on the opposite side thereof a storage zone 59 for long timbers 1 that have already been tested is provided, with the delivery and removal of the long timbers to and from said zones 58 and 59 in each case taking place in the longitudinal direction of the long timbers 1 . After the test, an elimination flap arrangement is preferably provided where long timbers exhibiting a detected weak point are eliminated in order to be returned to the process after lopping, for example.
For applying a tensile force (illustrated by double arrow 60 ) to the long timber 1 after said timber has been clamped onto the two tensioning trestles 43 and 56 , at least one of the tensioning trestles 43 , 56 is moved away from the opposite tensioning trestle by means of a force device, which is not illustrated further in the illustrated exemplary embodiment.
In order to detect a difference in length between the long timber 1 burdened with the test load and the unstressed long timber 1 , scanners 61 mounted to the tensioning trestles 43 and 56 are moved toward the front surfaces 62 of the long timber prior to the application of the test force and are pressed during the test against said front surfaces 62 with a predetermined force. A movement of the scanners 61 as a result of a change in the length of the long timber 1 is determined via suitable measuring means and transmitted to a plotting station.
In the illustrated exemplary embodiment, the engine bed 41 is designed as a box girder manufactured from sheet steel. Of course, it can also be formed by the foundation 42 itself, in which case guide rails are arranged on the foundation 42 for the movable second tensioning trestle 56 , which guide rails are provided on the engine bed 41 in the illustrated exemplary embodiment. | The invention relates to a method for quality assurance in preferably finger-jointed timber ( 1 ), produced in series, with a given minimum length ( 12 ), characterized in that each piece, produced within the length ( 12 ), is loaded with increasing tensile forces at the ends ( 5 ) thereof to a threshold value, below the breaking load for a fault-free timber piece, and the length changes (DELTA 1 ), changing therewith, are determined over a section, or the whole length of the timber piece ( 1 ) and used as a quality criterion for the use, or the further processing of the timber piece ( 1 ). The invention further relates to a device for carrying out said method. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional patent application based on U.S. patent application Ser. No. 10/687,216, which is issued as the U.S. Pat. No. 7,437,553, entitled “Systems and Methods for Providing Autonomous Security” by Alex I. Alten, filed on Oct. 15, 2003.
CROSS REFERENCE TO RELATED APPLICATIONS
The application claims priority from the U.S. provisional application entitled “Secure Autonomous System and Method for the Internet Protocol” filed on Oct. 15, 2002, with Ser. No. 60/418,802, which is herein incorporated by reference.
FIELD OF THE INVENTION
This invention relates to secure computer networking systems in general and in particular to securing autonomous systems that use the Internet Protocol.
BACKGROUND
Security systems and secure communication channels are well known for providing the underpinnings of providing trusted communications among individuals and organizations. Having secure communications between parties is desirable for financial transactions and confidential communications.
The emergence of the Internet Protocol version 4 (IPv4) as the universal datagram routing protocol has provided a common computer networking protocol that enables the world's computers to communicate with one another seamlessly without regard to geography. As the world's society has come to depend on IPv4 for commerce it has become increasingly evident that it needs to be secure, especially with the increased use of subnets using portions of the radio spectrum to transmit and receive network packets.
Traditionally, security systems and methods typically either encapsulate IPv4 within a lower layer security protocol or they use IPv4 to provide routing for a higher layer secure networking protocol.
It would be desirable to have a security system and methods to provide secure communications natively within a common routing protocol such as IPv4.
SUMMARY
Systems and methods for providing autonomous security are configured to modify an original header associated with an original data packet wherein key information is added; encrypt original data associated with the original data packet in response to the key information; and form an encrypted data packet including the modified header and the encrypted data, wherein the encrypted data packet is a same size as the original data packet.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a diagram illustrating a data flow between a sender, a receiver and server according to the invention.
FIG. 2 depicts a diagram illustrating a data flow between a sender, a receiver and server according to the invention.
FIG. 3 depicts a diagram illustrating the Key or Seed Data Structure according to the invention.
FIG. 4 depicts a diagram illustrating unit sizes according to the invention.
FIG. 5 depicts a diagram illustrating random Source Pads according to the invention.
FIG. 6 depicts a diagram illustrating Mixing Keys according to the invention.
FIG. 7 depicts a diagram illustrating Working Keys according to the invention.
FIG. 8 depicts a flow diagram illustrating a process of random nested shuffling according the invention.
FIG. 9 depicts a diagram illustrating a random nested shuffle of a number sequence according to the invention.
FIG. 10 depicts a diagram illustrating an Internet Protocol packet header with modified fields according to the invention.
FIG. 11 depicts a flow diagram illustrating a process of encrypting the data payload of outgoing Internet Protocol packets.
FIG. 12 depicts a flow diagram illustrating a process of decrypting the data payload of incoming Internet Protocol packets.
FIG. 13 depicts a diagram illustrating encryption of a series of Internet Protocol packets according to the invention.
FIG. 14 depicts a diagram illustrating decryption of a series of Internet Protocol packets according to the invention.
FIG. 15 depicts a flow diagram illustrating a half of the first part of the key generation according to the invention.
FIG. 16 depicts a flow diagram illustrating another half of the first part of the key generation according to the invention.
FIG. 17 depicts a flow diagram illustrating the second and final part of the key generation, and encryption or decryption of an Internet Packet data payload, according to the invention.
FIG. 18 depicts a flow diagram illustrating a nested shuffle of a source pad.
FIG. 19 depicts a flow diagram illustrating a rotation and simple shuffle of a working pad.
FIG. 20 depicts a flow diagram illustrating a process of setting up the sender computer and the receiver computer.
DETAILED DESCRIPTION
Specific reference is made in detail to the embodiments of the invention, examples of which are illustrated in the accompanying drawings and following descriptions. While the invention is described in conjunction with the embodiments, it will be understood that the embodiments are not intended to limit the scope of the invention. The various embodiments are intended to illustrate the invention in different applications. Further, specific details are set forth in the embodiments for exemplary purposes and are not intended to limit the scope of the invention. In other instances, well-known methods, procedures, and components have not been described in detail as not to unnecessarily obscure aspects of the invention.
In the following descriptions, the following descriptive names will be used: Key, Seed, Vector, Pad, Value, Card, Pack, Case, Initialization Vector (IV), random number generator (RNG), and pseudo random number generator (PRNG). A Key, Pad, and Value are populated with random bits from the PRNG. A random factorial permutation of a sequence of bytes or numbers will be referred to as a Shuffle. An AES Key or an AES IV is a single 16 byte random value. In the following descriptions, the following acronyms for the Internet Protocol version 4 (Internet Standard RFC 791) will be used: IP and IPv4.
Referring to FIG. 1 , a system ( 100 ) illustrates a secure autonomous system for providing secure communications through the Internet Protocol. The system ( 100 ) consists of several interoperating software components and secured computer networking protocols.
In some embodiments, there is a central Key and Pad Server ( 102 ), also known as a Key Distribution Center (KDC), that supplies all the cryptographic materials necessary used by two communicating computers, a sender computer ( 104 ) and a receiver computer ( 106 ), that are sending and receiving secure IP packets ( 108 ). In some embodiments, the sender computer ( 104 ) and the receiver computer ( 106 ) communicate via network such as the Internet.
In some embodiments, the sender computer ( 104 ) and the receiver computer ( 106 ) maintain key synchronization with separate Key Management (KM) computer networking packets ( 110 ). These KM packets are configured to utilize either IP or UDP packets as transport. In some instances, both the sender computer ( 104 ) and the receiver computer ( 106 ) request and receive cryptographic key and pad materials from the KDC ( 102 ) using a secure, mutually authenticated communications channel ( 112 ), called the Privacy Access Line (PAL).
In some embodiments, the sender computer ( 104 ) contains the following software components; a Layer-2 Driver ( 114 ) that communicates with the Network Interface Card (NIC) ( 130 ), an encryption intermediate driver ( 116 ), a Key Management (KM) Service ( 118 ), a TCP/IP protocol stack ( 120 ) and a sender application ( 122 ).
In some embodiments, the sender application ( 122 ) initiates sending clear data to the TCP/IP Stack ( 120 ). In this embodiment, the TCP/IP stack ( 120 ) formulates a standard IP packet and sends it to the encryption intermediate driver ( 116 ). This driver ( 116 ) communicates with the KM Service ( 118 ) to get any keys and IV's it needs to encrypt IP packet data payloads. In some embodiments, the KM Service ( 118 ) uses either UDP or IP packets to send and receive PAL ( 112 ) packets from the KDC Server ( 102 ). The Sender's KM Service ( 118 ) uses either UDP or IP packets to send KM Packets ( 110 ) to the Receiver's KM Service ( 119 ) to notify it that a series of encrypted IP packets will soon be sent to it and that it will need to get the appropriate encryption materials. Using a Key and an IV the encryption intermediate driver ( 116 ) sends an IP packet with an encrypted payload and a slightly modified header (with a recomputed check sum) to the Layer-2 Driver ( 114 ) that in turn makes the NIC ( 130 ) transmit the encrypted packet onto the communications channel connected to the NIC ( 132 ). The slightly modified header is shown in more detail in FIG. 10 .
In some embodiments, the channel includes any standard IP subnet, like Ethernet, Wi-Fi, ATM, etc. In other embodiments, the sender computer ( 104 ) and receiver computer ( 106 ) can be on the same subnet or on different subnets separated by one or more IP routers.
In some embodiments, the receiver computer ( 106 ) then receives the IP packets with encrypted data payloads with the NIC ( 132 ). The Layer-2 Driver ( 115 ) then takes the IP packets from the NIC ( 132 ) and sends the IP packets to the decryption intermediate driver ( 117 ). This driver ( 117 ) communicates with it's corresponding KM Service ( 119 ) to get any keys and IV's it needs to decrypt IP packet payloads. The KM Service ( 119 ) uses either UDP or IP packets to send and receive PAL ( 112 ) packets from the KDC Server ( 102 ). In some embodiments, the receiver computer ( 106 ) sends acknowledgment packets to the Sender's KM Service ( 118 ) using KM Packets ( 110 ).
In some embodiments, IP packets with encrypted data payloads may arrive at the receiver computer ( 106 ) out of order and some payloads can be missing. In some embodiments, the incoming IP packets have their payloads decrypted and the IP packet with clear data payloads is sent to the TCP/IP Stack ( 121 ) that in turn transmits the data to the application ( 123 ) for processing.
Referring to FIG. 2 , the system 100 benefits from access to a reliable, moderately fast network for key and pad material distribution. In one embodiment, a 10 Mbps Ethernet LAN is utilized for back channel communications with a central Key and Pad Server ( 202 ), which contains a RNG and a PRNG. In one embodiment, the AES cipher itself will support over 100 Mbps encrypted throughput ( 208 ) on an ordinary computer's communication interface, typically either 100 Mbps or 1 Gbps Ethernet, between the two computers, a sender computer ( 204 ) and a receiver computer ( 206 ). In one embodiment, each of these computers shares the identical sets of working keys ( 216 ), rotation values ( 218 ), mixing keys ( 212 ), and source pads ( 210 ), a copy of the key and IV generation algorithm ( 220 ), and a copy of the AES cipher either in software or hardware. The source pads ( 210 ) are periodically refreshed on both computers to maintain the maximum level of security. To extend the life (i.e. keep them secret longer) of the source pads ( 210 ), while they are on both computers, the server will send out Mixing Keys ( 212 ) as needed. More frequently, Rotation Values ( 218 ) and Working Keys ( 216 ) are sent out to each machine to regenerate the actual randomly created pad used to derive AES keys and IV's that are used to encrypt the outgoing IP packet's clear data payload or decrypt the incoming IP packet's cipher data payload ( 208 ). Note that for purposes of this document all communications with the Key & Pad Server are considered secure, i.e. cryptographically mutually authenticated and private. This could also be achieved by having a separate physically secure 10 Mbps LAN dedicated to only distributing Keys, Values and Pads from the Server.
Referring to FIG. 3 , the random control sequence of unique numbers are shown as a key ( 302 ). In one embodiment, the key ( 302 ) is generated from a PRNG. In some embodiments, the key ( 302 ) come in sequences 32 unique numbers randomly shuffled only from the range of values 0 to 31. In this embodiment, the number of active bits per number is 5.
Referring to FIG. 4 , when large sequences of numbers are randomly shuffled, they are broken up into certain sizes in one embodiment. The smallest size is called a card ( 402 ). A card is 1 byte in size. The next larger size is a pack ( 404 ), which consists of 32 cards. The next larger size is a case ( 406 ), which consists of 32 packs. The largest size is the large sequence of numbers to be shuffled, called a pad ( 408 ), which consists of 32 cases.
Referring to FIG. 5 , all keys and IV materials used to encrypt or decrypt IP packet data payloads are typically derived from four (4) random source pads ( 502 ). Each Source Pad ( 504 , 506 , 508 , 510 ) consists of 262,144 random bytes that was generated by the PRNG on the KDC server. The total size is 1 Megabyte of random seed material.
Referring to FIG. 6 , the first stage of creating keys and IV materials used to encrypt or decrypt IP packet data payloads is controlled by mixing keys ( 602 ) from the KDC server. There are twelve (12) mixing keys ( 604 , 606 , 608 , 610 , 612 , 614 , 616 , 618 , 620 , 622 , 624 , 626 ). Each mixing key consists of a randomly mixed set of unique numbers from 0 to 31, one per byte, a total of 32 bytes each. Mixing keys ( 604 , 610 , 616 , 622 ) are used for Level 1 mixing (L1) of each Source Pad. Mixing keys ( 606 , 612 , 618 , 624 ) are used for Level 2 mixing (L2) of each Source Pad. Mixing keys ( 608 , 614 , 620 , 626 ) are used for Level 3 mixing (L3) of each source pad. The total size is 384 bytes.
Referring to FIG. 7 , the second stage of creating keys and IV materials used to encrypt or decrypt IP packet data payloads is controlled by a set of working keys and rotation values from the KDC server. The are two (2) rotation values ( 704 , 706 ), 4 bytes each, and two (2) working keys, 32 bytes each. Each rotation value is a random number generated by the KDC's PRNG. Each working key consists of a randomly mixed set of unique numbers from 0 to 31, one per byte. These will all collectively be referred to as the working keys ( 702 ). Total size is 72 bytes.
The keys and IV materials as described in FIGS. 5 , 6 , and 7 are utilized to illustrate a specific, particular embodiment. Other embodiments can be utilized without departing from the spirit of the invention.
Referring to FIG. 8 , a nested shuffling process is shown by the flow diagram. At block 802 , the 3 mixing keys are received. The 3 mixing keys include case keys, pack keys, and card keys. At block 804 , a shuffling function is performed on each case utilizing a case key for each case, this is a Level 1 shuffle (L1). At block 806 , each of the shuffled cases are divided into multiple packs. At block 808 , a shuffling function is performed on each pack utilizing a pack key for each pack, this is a Level 2 shuffle (L2). At block 810 , each of the shuffled packs are divided into multiple cards. At block 812 , a shuffling function is performed on each card utilizing a card key for each card, this is a Level 3 shuffle (L3).
Referring to FIG. 9 , a nested shuffling of a sequence of cards proceeds as follows. A sequence of cards ( 902 ) divided into cases ( 904 ), which are then shuffled according to a case key ( 916 ), resulting in randomly permuted sequence of cases ( 906 ). A case key is also called a Level 1 Key (L1). Then in turn, these shuffled cases ( 906 ) are subdivided into packs ( 908 ), each case being partitioned identically, which are then shuffled according to a pack key ( 918 ) that is applied once per case to each set of packs contained therein, resulting in identically randomly permuted sequence of packs per case ( 910 ). A pack key is also called a Level 2 Key (L2). Then in turn, these shuffled packs ( 910 ) are subdivided into cards ( 912 ), each pack being partitioned identically, which are then shuffled according to a card key ( 920 ) that is applied once per pack to each set of cases contained therein, resulting in identically randomly permuted sequence of cards per pack ( 914 ). A card key is also called a Level 3 Key (L3).
FIG. 10 reveals a standard IP packet header that has been modified ( 1002 ) to support the encryption of the IP packet data payload that follows it. Two fields of the IP header, the fragment identification and the fragment offset have been replaced by three fields, the mixing key refresh ratio value or ratio 1 ( 1006 ), the working key refresh ratio value or ratio 2 ( 1008 ) and the offset for selecting key and IV values ( 1004 ) from a final pad. Optionally, the first bit of the standard flags field ( 1012 ) is set to 1 to indicate an encrypted IP packet, or the last bit of the type of service field ( 1014 ) may be set to 1 to indicate an encrypted IP packet. In some embodiments, these bits are unused by Internet standards. These bits are not required to be set for successful encryption and subsequent decryption of the IP data payload. After all the fields have been written, the header checksum field ( 1010 ) will need to be recomputed before the IP packet with encrypted data payload is transmitted. The flow diagram as depicted in FIG. 6 is merely one embodiment of the invention.
In use, the modified header ( 1002 ) allows an unencrypted data packet to be encrypted without changing the overall size of the encrypted data packet compared with the unencrypted data packet. By replacing the fragmentation identification and the fragment offset with the ratio 1 value, the ratio 2 value, and the IV values, the overall size of the data packet remains the same.
The flow diagrams in FIGS. 11 , 12 , and 15 - 20 , illustrate one particular use of the invention based on a specific application. In other embodiments, the invention may be utilized with other applications. The blocks within the flow diagrams can be performed in a different sequence without departing from the spirit of the invention. Further, blocks can be deleted, added, or combined without departing from the spirit of the invention.
Referring to FIG. 11 , an exemplary process to encrypt and send IP packets is shown by the flow diagram. When the sender's application sends data to the receiver's application it causes an IP packet to be created by the sender's TCP/IP stack and readied for transmission. When this occurs the sender's KM Service requests key and pad materials from the KDC using a PAL request packet. In many embodiments, PAL protocol packets are secured using any number of well-known techniques. It can be a modified Kerberos protocol, with extensions to allow the receiver to communicate with the KDC. Or it can be like the TriStrata PAL protocol.
In block 1102 , the KDC provides a session identifier both in the clear and encrypted with a key only the KDC knows inside a PAL response packet. In some embodiments, this session identifier will be used by the KDC to keep track what keys and pads have been issued for any given set of encrypted packets flowing between the sender and receiver computers. In some embodiments, the PAL response packets are utilized to transmit the keys securely to the sender computer and the receiver computer.
In block 1104 , the sender's KM Service transmits the encrypted session identifier to the receiver's KM Service using a special KM packet over UDP or IP, this is also known as the session setup packet. In some embodiments, the encryption of the session identifier can be done in any known appropriate method for correctly securing a small piece of important data. For example, in one instance, the session identifier can be encrypted with the AES cipher using a CBC mode with 128-bit key. Additionally, a SHA-2 one-way hash with a 256-bit digest could be computed over the encrypted Session Identifier, encrypted and attached to it.
In block 1106 , the sender's KM Service requests source pads from the KDC.
In block 1108 , a local ratio 1 counter is set to zero. In block 1110 , the mixing keys are requested from the KDC. In block 1112 , a local ratio 2 counter is set to zero. In block 1114 , the working keys and rotation values are requested from the KDC.
In block 1116 , the encryption intermediate driver creates the 16 Kbyte Working Pad. In block 1118 , the local offset value for selecting a AES Key and an IV from the final pad is set to zero. In block 1120 , the IP packet with a clear data payload is delivered by the TCP/IP stack to the encryption intermediate driver.
In block 1122 , using the offset value, the key and IV are extracted from the final pad. For example, in one instance, the encryption of an IP packet's data payload utilizes a 16 byte AES key and a 16 byte IV value, for a total of 32 bytes. There are 512 unique pairs of AES key and IV values that can be extracted from a 16 Kilobyte Final Pad. In some embodiments, each unique pair is associated with an offset value from 0 to 511. Each offset value must be at least 9 bits in size.
In block 1124 , the encryption intermediate driver then encrypts the IP packet's data payload with the extracted AES key and IV values. For example, in one instance, the encryption of the payload could use the AES key and IV with a NIST approved AES counter mode (CTR) to operate as a stream cipher. This allows each byte of the IP packet's data payload to be encrypted without requiring any pad bytes to make it aligned with a block size of 16 bytes.
In block 1126 , the offset value, 9 bits, is written into the unused fragmentation field of the IP packet. In block 1128 , the ratio 1 and ratio 2 values, 8 bits each, are written into the fragmentation identification field. In one embodiment, the ratio 1 and ratio 2 values are replaced by adding an extra bit in the offset value to prevent the rollover of it from 511 to 0 without detection. In one instance, the offset value is larger, and consumes all the available bits in the standard IP fragment identifier and fragment offset fields.
In block 1130 , after modifying the IP header fields, the header checksum is recomputed. In block 1132 , the header checksum is written into the IP header again.
In block 1134 , the encryption intermediate driver gives the IP packet with the modified header and encrypted data payload to the Layer-2 Driver. In block 1134 , the IP packet with the modified header and encrypted data payload is given to the NIC that then transmits it to the receiver computer.
In block 1136 , a value is added to the offset value. In block 1138 , if the offset value is less than 512 then return to the block 1120 . In block 1140 , a value is added to the ratio 2 value. In block 1142 , if the ratio 2 value is less than 512 then return to the block 1114 . In block 144 , a value is added to the ratio 1 value. In block 1146 , if the ratio 1 value is less than 512 then return to the block 1106 .
Referring to FIG. 12 , an exemplary to receive and decrypt encrypted IP packets is shown by the flow diagram. In block 1202 , the receiver KM Service receives an encrypted session identifier from the sender from a special KM packet over UDP or IP, the Setup Packet. In block 1204 , the encrypted session identifier is sent to the KDC Server using a PAL request packet. In block 1206 , the KDC decrypts the encrypted session identifier and responds with the session identifier inside a PAL response packet.
In block 1208 . the receiver's KM Service requests and receives source pads from the KDC. In block 1210 , a local ratio 1 counter is set to zero. In block 1212 , the mixing keys are requested from the KDC. In block 1214 , a local Ratio 2 counter is set to zero. In block 1216 , the working keys and rotation values are requested from the KDC. In block 1218 , either the KDC or the encryption intermediate driver creates the 16 Kbyte working pad. In block 1220 , the local offset value for selecting a key value and an IV value from the final pad is set to zero.
In block 1222 , an encrypted IP packet arrives from the Layer-2 driver and is sent to the encrypted intermediate driver. In block 1224 , it is determined if the ratio 1 and ratio 2 in the IP packet header match the local ratio 1 and ratio 2. If there is not a match, the packet is dropped and return back to the block 1222 . If there is a match, extract the 9 bit offset value from the IP packet's header in block 1226 .
In block 1228 , using the offset value, the key and IV are extracted from the final pad. In block 1230 , the decryption intermediate driver then decrypts the IP packet's data payload with the extracted AES key and IV values. In block 1232 , the IP packet with a clear data payload is delivered to the local TCP/IP Stack. In some embodiments, the ratio 1, ratio 2 and offset values can be optionally cleared from the IP packet header, and the header checksum can be recomputed prior to delivering the IP packet to the TCP/IP Stack.
In block 1234 , a value is added to the offset value. In block 1236 , if the offset value is less than 512, then return back to the block 1222 . In block 1238 , a value is added to the ratio 2 value. In block 1240 , if the ratio 2 value is less than 512, then return back to the block 1240 . In block 1242 , a value is added to the ratio 1 value. In block 1244 , if the ratio 2 value is less than 512, then return back to the block 1206 .
In some embodiments, the use of the ratio 1 value and the ratio 2 value for a given packet indicates which source pad is utilized in encrypting the packet. In some instances, the ratio 1 value and the ratio 2 value also assist in determining the order of the packets once multiple packets arrive at the receiver computer. For example, the packets arrive out of order and the ratio values are utilized to determine the correct order of the packets.
In some embodiments, the offset value is utilized to indicate a location within the source pad that is identified by the ratio 1 value and the ratio 2 value. In some instances, the offset value is utilized to assist in determining the order of the packets once multiple packets arrive at the receiver computer. In this example, the offset value provides additional ordering assistance when the ratio 1 value and the ratio 2 value repeats.
Referring to FIG. 13 , for encryption the cipher machinery ( 1326 ) takes as input two working pads, derived from the four source pads ( 1306 , 1308 , 1310 , 1312 ), two working keys ( 1332 ), two rotation values ( 1334 ), and the 512 IP packets ( 1328 ). The two working pads each comes from one of the two nested shuffle machineries ( 1302 , 1304 ). One machinery ( 1302 ) takes as input two source pads A and B ( 1306 , 1308 ), and two sets of three mixing keys ( 1316 , 1318 ). The other machinery ( 1304 ) takes as input two source pads C and D ( 1310 , 1312 ), and two sets of three mixing keys ( 1322 , 1324 ). The number of IP packets with clear text data ( 1328 ) cannot exceed 512 packets, before requiring a new set of Working Keys and rotation values. The number of IP packets with clear text data cannot exceed 131,072 packets, before requiring a new set of mixing keys. The number of IP packets with clear text data cannot exceed 33,554,432 packets, before requiring a new set of source pads. Every IP packet with clear text data is transformed out into a corresponding IP packet with cipher text data ( 1330 ).
Referring to FIG. 14 , decryption is identical to encryption, except that now the cipher machinery ( 1426 ) takes as input two working pads, derived from the four source Pads ( 1406 , 1408 , 1410 , 1412 ), two working keys ( 1432 ), two rotation values ( 1434 ), and the cipher text data ( 1428 ). The two working pads each comes from one of the two nested shuffle machineries ( 1402 , 1404 ). One machinery ( 1402 ) takes as input two source pads A and B ( 1406 , 1408 ), and two sets of three Mixing Keys ( 1416 , 1418 ). The other machinery ( 1404 ) takes as input two source pads C and D ( 1410 , 1412 ), two substitution keys C and D ( 1420 ), and two sets of three Mixing Keys ( 1422 , 1424 ). The number of IP packets with cipher text data ( 1428 ) cannot exceed 512 packets, before requiring a new set of working keys and rotation Values. Note that within each group of 512 packets, packets can be lost or arrive out of order. Packets delayed by network latency that arrive after a new set of working keys and rotation values have been used, cannot be decrypted and must be thrown away. The number of IP packets with cipher text data cannot exceed 131,072 packets, before requiring a new set of mixing keys. The number of IP packets with cipher text data cannot exceed 33,554,432 packets, before requiring a new set of source pads. Every IP packet with cipher text data is transformed out into a corresponding IP packet with clear text data ( 1430 ).
FIG. 15 reveals an internal view of a half of an initial phase of the cipher machinery. The source pad A of 32 kilobytes ( 1502 ) is nested shuffled ( 1510 ) with the three mixing keys A ( 1506 ) resulting in a shuffled source pad A of 32 kilobytes ( 1514 ). The source pad B of 32 kilobytes ( 1504 ) is nested shuffled ( 1512 ) with the three mixing keys B ( 1508 ) resulting in a shuffled source pad B of 32 kilobytes ( 1516 ). XOR the two resulting pads together ( 1526 ), byte-by-byte, and the result is a 32-kilobyte working pad A ( 1528 ).
FIG. 16 reveals an internal view of another half of the initial phase of the cipher machinery. The source pad C of 32 kilobytes ( 1602 ) is nested shuffled ( 1610 ) with the three mixing keys C ( 1606 ) resulting in a Shuffled Source Pad C of 32 kilobytes ( 1614 ). The source pad D of 32 kilobytes ( 1604 ) is nested shuffled ( 1612 ) with the three mixing keys D ( 1608 ) resulting in a shuffled source pad D of 32 megabytes ( 1616 ). XOR the two resulting pads together ( 1626 ), byte-by-byte, and the result is a 32-kilobyte Working Pad B ( 1628 ).
FIG. 17 reveals an internal view of a final phase of the cipher machinery. The working pad A ( 1702 ) is rotated and then simple shuffled ( 1706 ), using a working key A ( 1710 ) and a rotation value A ( 1714 ), then extract half of each of the cards ( 1718 ), and the result is a 16-kilobyte temporary pad A ( 1722 ). The working pad B ( 1704 ) is rotated and then simple shuffled ( 1708 ), using a working key B ( 1712 ) and a rotation value B ( 1716 ), then extract half of each of the cards ( 1720 ), and the result is a 16-kilobyte temporary pad B ( 1726 ). XOR the two resulting temporary pads ( 1722 , 1726 ) together ( 1724 ), byte-by-byte, and the result is a 16-kilobyte final pad ( 1728 ). This final pad can then be used with a 9-bit offset value ( 1729 ), which is incremented by one for each IP packet, to extract a unique 16-byte AES key and a unique 16-byte IV from each 32-byte position within the final pad. Using the key and IV as inputs into an AES cipher in counter mode ( 1731 ) results in a PRNG stream of bytes to XOR ( 1730 ) with IP packet clear text data payload ( 1732 ), byte by byte, resulting in IP packet cipher text data payload ( 1734 ). Or it can be used with a 9-bit Offset Value ( 1735 ) extracted from IP packet header ( 2039 ) to extract the AES key and IV from a 32-byte position within the Final Pad. Using the key and IV as inputs into an AES cipher in Counter Mode ( 1737 ) results in a PRNG is stream of bytes to XOR ( 1736 ) with IP packet cipher text data payload ( 1738 ), byte by byte, resulting in IP packet clear text data payload ( 1740 ).
Referring to FIG. 18 , the operation to nested shuffle a source pad A or B or C or D of 32 kilobytes each utilizes three mixing keys; a case key ( 1802 ), a pack key ( 1804 ) and a card key ( 1806 ), each having 32 unique 5-bit random numbers. The source pad is partitioned into 32 cases ( 1808 ). The cases ( 1808 ) are all shuffled together randomly ( 1810 ), using the case key ( 1802 ) to determine the shuffle pattern, and results in a random sequence of cases ( 1812 ). Each case is further partitioned into 32 Packs ( 1814 ). The packs ( 1814 ) within each case are shuffled together randomly ( 1816 ), using the pack key ( 1804 ) to determine the shuffle pattern, and results in a random sequence of packs ( 1818 ), identically shuffled per case. Each pack within each case is further partitioned into 32 cards ( 1820 ) of one byte each. The cards ( 1820 ) within each pack are shuffled together randomly ( 1822 ), using the card key ( 1806 ) to determine the shuffle pattern, and results in a random sequence of cards ( 1824 ), identically shuffled per pack. These three levels of shuffling, Level 1 (L1), Level 2 (L2) and Level 3 (L3), result in a randomly shuffled source pad, which has (2 32 ) 3 or 2 96 random permutations, i.e. entropy of 96 bits.
Referring to FIG. 19 , this illustrates the core operation of generating the key and IV for each IP packet. First, a working pad of 32-kilobytes ( 1906 ) is randomly rotated by 4-byte intervals using the random rotation value ( 1904 ). Then, the working pad is sub-divided into 1024 packs ( 1908 ) of which each is further sub-divided into 32 cards ( 1910 ) where a card is 1 byte in size. Using the working key ( 1902 ), the cards are shuffled in the 1 st Pack ( 1912 ). This results in 32 randomly shuffled cards in the first pack ( 1914 ). This is repeated from 2nd to the last pack in the working pad. This results in a 32 kilobyte rotated and shuffled working pad ( 1916 ). Finally we extract the first 16 cards of each pack ( 1918 ) and assemble them into an 16 kilobyte temporary pad ( 1920 ).
This shuffle can be done rapidly since a typical working key and many source pad packs can be brought in the microprocessor's fastest L1 cache. The working key stays in L1 cache, amortizing its load cost from DRAM over all the 1024 packs. Further, performance gains can be made by taking advantage of multiple ALU pipelines in a CPU to process either larger cards or multiple packs simultaneously.
The source pads are considered to be secret, known only to the sender, the receiver, and the KDC server. The three levels of four sets of Mixing Keys, along with the four Source Pads, which themselves are periodically changed, interact to effectively keep the four Source Pads secret for as long as possible. This allows fast local generation of 33,554,432 keys and IV pairs per set of four source pads.
FIG. 20 illustrates a process for setting up the sender computer and the receiver computer for transmitting encrypted data packets. In block 2010 , the sender computer transmits a request to the KDC for a session identifier. In block 2020 , a clear and encrypted session identifier is sent from the KDC to the sender computer. In some embodiments, the KDC securely sends this session identifier to the sender computer via the PAL.
In block 2030 , the sender computer sends the encrypted session identifier to the receiver computer via an unsecured network such as the Internet. In block 2040 , the receiver computer transmits the encrypted session identifier to the KDC. In block 2050 , the KDC transmits a clear session identifier to the receiver computer. In Block 2060 , the sender computer transmits the session identifier and a request for pads and keys to the KDC. In block 2070 , the KDC transmits the pads and keys to the sender computer. In Block 2080 , the receiver computer transmits the session identifier and a request for pads and keys to the KDC. In block 2090 , the KDC transmits the pads and keys to the receiver computer. In block 2095 , the sender computer encrypts data within a packet according to the session identifier and sends the encrypted packet to the receiver computer over the unsecure network.
In some embodiments, the session identifier allows the sender computer to correctly encrypt the data packet and allows the receiver computer to correctly decrypt the data packet. In other embodiments, the session identifier also provides a convenient avenue to update policy restrictions and provide instructions to the sender computer and the receiver computer.
In some embodiments, the keys and IV are distributed to the sender computer and the receiver computer from the VDC through the PAL. In some instances, the keys and IV are periodically sent to the sender computer and the receiver computer. In other instances, the keys and IV are sent to the sender computer and the receiver computer on an as needed basis. In yet other instances, the keys and IV are sent to the sender computer and the receiver computer along with the session identifier.
The systems and methods for providing autonomous security deliver a secure and efficient mechanism for transmitting encrypted IP packets between sender and receiver computers. The systems and methods for providing autonomous security function within the size constraints of an unencrypted IP packet and neither introduce extra bytes into the encrypted IP packet nor increase the overall size of the encrypted IP packet by utilizing the slightly modified header ( 1002 ). In addition, the systems and methods for providing autonomous security encrypt and decrypt in such a manner as to minimize the burden on the host computer and to take full advantage the performance capabilities of modern microprocessor architectures.
The foregoing descriptions of specific embodiments of the invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise embodiments disclosed, and naturally many modifications and variations are possible in light of the above teaching. For example, even though specific embodiments utilize the Ipv4 standard, any routing protocol can be utilized with the invention.
The embodiments were chosen and described in order to explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents. | Systems and methods for providing autonomous security are configured to modify an original header associated with an original data packet wherein key information is added; encrypt original data associated with the original data packet in response to the key information; and form an encrypted data packet including the modified header and the encrypted data, wherein the encrypted data packet is a same size as the original data packet. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to tufting machine gauge parts, and more particularly to a modular hook assembly for staggered needle cut pile tufting machines.
In the production of tufted pile fabric each reciprocating needle cooperates with a loop or hook which seizes a loop of yarn from the needle and releases the loop to form loop pile fabric or holds the loop until it is cut by a knife acting in scissors-like fashion against the side of the hook to form cut pile fabric. The gauge of the pile fabric is determined by the spacing between adjacent gauge parts, i.e. the needles, hooks and knives, of the tufting machine. To produce fine gauge pile fabric, i.e. one tenth gauge and smaller, the spacing between adjacent gauge parts is 0.1 inch and smaller. As a consequence of the close spacing between the adjacent gauge part in fine gauge tufting machines, great difficulty has been experienced in providing hooks at the required spacing and maintaining the spacing. Moreover, in cut pile machines the transverse pressure applied to the individual hooks by the respective knives can give rise to deflection of the tips of the hooks. In view of the high accuracy required when the gauge parts are closely spaced it is highly desirable, if not mandatory, that this deflection be minimized to insure accurate and consistent seizing of the yarn hook from the cooperating needle. The conventional mounting of the hooks in corresponding slots in the hook bar and their securement by set screws creates difficulties in aligning closely spaced hooks and minimizing the deflections thereof. Furthermore, in the event of damage to a series of hooks or when such hooks are worn, the replacement of a new set is particularly demanding of time.
To overcome these problems it has been proposed to provide a hook module wherein the respective hook shanks are imbedded in a common body member in side-by-side disposition. Such constructions are illustrated in United Kingdom design registration Nos. 980,060 and 980,062. Such construction substantially eliminates the difficulties of aligning the hooks in the hook bar of the tufting machine since the hooks are aligned in a jig during the formation of the module and each body member may have an alignment surface for clamping of the module to a hook bar in the tufting machine.
Moreover, in fine gauge tufting machines it is known to locate the needles in staggered relationship in two rows and to mount cooperating hooks in a slotted hook bar, the hooks cooperating with the needles in one row having a longer bill than the hooks cooperating with the needles of the other row. For purposes of aligning the hooks in the hook bar, the throats of both the long billed set of hooks and the short bill set of hooks may be in alignment in the longitudinal direction of the hook bar, as illustrated in U.S. Pat. Nos. 4.003,321 and 3,913, 505. This, however, is unnecessary when hook modules are utilized. There does exist however the difficulty that in the event of damage to one hook in a module the entire module must be replaced, and similarly if knife pressure on one or the other sets of hooks is greater than on the other that set would have to be reground or replaced more frequently than the other set of hooks.
SUMMARY OF THE INVENTION
Consequently, it is a primary object of the present invention to provide a staggered hook module which improves the cost effectiveness of such modules by minimizing the extent to which components need be replaced when worn or damaged.
It is another object of the present invention to provide a staggered hook module for a staggered needle cut pile tufting machine wherein the long blade and short blade hooks are mounted in respective body parts adapted and arranged in such relative disposition that adjacent hooks are supported in a requisite disposition.
It is a further object of the present invention to provide a staggered hook module comprising respective body members for the long blade hooks and the short blade hooks each supporting a plurality of such hooks in side-by-side disposition thereon, the body members being adapted for mounting in such relative disposition that adjacent hooks are supported for cooperation with respective staggered needles in a tufting machine.
It is a still further object of the present invention to provide a staggered hook module comprising respective body members for the long blade hooks and the short blade hooks, each body member supporting a plurality of respective hooks, the body members being adapted and arranged to cooperate to locate the long blade hooks and the short blade hooks alternately in a requisite relationship.
In carrying out the invention there is provided a pair of body members each respectively supporting a series of hooks, one body member supporting long blade hooks and the other body member supporting short blade hooks. The body members have complementary reference surfaces adapted to co-operatively mate and means for securing the body members together, and when secured together a long blade hook is intermediate each short blade hook. The hooks may be molded into the respective body member to form standardized modules. When one or more of the long blade hooks, or the short blade hooks, are damaged, the body member carrying the damaged hooks only need be replaced. The modules, since the hooks can be assembled in a fixture, can have very accurate component precision. Thus, when the body members are secured together and mounted in a tufting machine, yarn seizure is precise and consistent. According to a preferred feature of the invention one of the body members has slots intermediate the hooks carried therein, and the hooks of the other body member are received in respective ones of the slots for added structural support of the latter hooks when the two body members are co-operatively mated.
BRIEF DESCRIPTION OF THE DRAWINGS
The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a diagrammatic side sectional elevation of a part of a tufting machine embodying a module constructed in accordance with the present invention;
FIG. 2 is a disassembled perspective view of the two body members comprising the assembled hook module respectively carrying the long and short billed hooks;
FIG. 3 is a top plan view of the assembled module;
FIG. 4 is a side elevational cross sectional view taken substantially along line 4--4 of FIG. 3;
FIG. 5 is a side elevational cross sectional view taken substantially along line 5--5 of FIG. 3;
FIG. 6 is a top plan view of the front hook supporting module;
FIG. 7 is an end elevational view of the rear of the rear end face of the module of FIG. 5; and
FIG. 8 is an end elevational view of the front face of the rear module.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and particularly to FIG. 1, the relevant portions of a tufting machine 10, are illustrated as including a needle bar 12 supported at the end of one or more push rods 14 driven axially reciprocably in conventional manner. Carried by the needle bar 12 arranged in rows disposed one behind the other and off set or staggered in the longitudinal direction of the needle bar is a plurality of needles 16,18 (only two of which are illustrated). The needles 16,18 may be arranged in modular units as disclosed in U.S. Pat. No. 4,138,956, assigned to the common assignee of the present invention. Thus, the needles 16 may be carried in a body member 20 while the needles 18 may be carried in a body member 22, the two body members having co-operating locating surfaces and being secured to the needle bar by a common screw 24. For a complete description of the needle modules reference may be had to the aforesaid U.S. Pat. No. 4,138,956.
Mounted in the bed of the tufting machine beneath the bed plate 26 is a plurality of front loopers or hooks 28 and a plurality of rear loopers or hooks 30, the hooks 28 co-operating with the needles 16, and the hooks 30 co-operating with the needles 18 to conventionally seize the loops of yarn presented by the respective needles. The hooks 28 and 30 are mounted in modular form, as hereinafter described, the hooks 28 being carried by a front body member 32 and the hooks 30 being carried by a rear body member 34, the two body members being clamped together and secured by screw means 36 to a hook bar 38. The hook bar may be oscillated conventionally to drive the hooks into co-operative relationship with the respective needle. The hooks 28,30 may also co-operate with respective knives 40 and 42 which may be carried by a common knife block 44 and oscillated in timed relationship with the oscillation of the hooks for co-acting with a face of the respective hooks in scissors-like manner for cutting the loops of yarn on the hooks to form cut pile.
Each hook 28 includes a substantially flat shank 46 having a stepped generally rectangular configuration, and a blade 48 extending forwardly from the shank in the plane thereof to define a throat 50 where the shank and blade join, the shank being further stepped at 52 rearwardly of the throat 50. Similarly the hook 30 includes a shank 54 and a blade 56 extending forwardly therefrom, the junction being stepped at 58 to define a throat, the shank having a further step 60 rearwardly of the throat 58. The blades 48 and 56 have at their leading free edges respective bills 62 and 64 which cooperate with the respective needles for seizing loops of yarn presented by the needles.
The hooks 28 are placed in a fixture with the throats 50 in substantial alignment with one another and with the bottom yarn engaging surfaces of the blades 48 in substantial planar alignment and the body member 32 is cast about the rear or mounting portion of the shanks. A through hole 66 is provided in each of the shanks 46 to receive liquid metal during the casting process, thereby to insure positive and permanent location of the hook within the body member 32. In a similar manner the hooks 30 are positioned in a fixture and the body member 34 cast about the mounting portion of the shanks 54, the liquid metal also being received within a hole 68 in the shank. The stepped portions 52,60 of the shanks aid in locating the hooks and provide a large surface for the metal of the body members to hug.
The body member 32 has a rear face 70 forming a substantially planar abutment surface against which a similar accurately formed planar surface 72 formed on the body member 34 is positioned when the body parts are assembled. The disposition of the surfaces relatively to the hooks being such that the bills of the hooks 28 are intermediate the bills of the hooks 30 and the bills are off set front to rear by the desired stagger of the tufting machine needle. The throats 50 and 58 may be aligned, or non-aligned as illustrated. One of the faces 70,72, for example, the face 72 may include one or more male formations 74 which may be in the form of a truncated conical protuberance while the other face 70 includes a like number of indentations or recesses 76 for receiving the protuberances. These male and female formations are provided in the mold so that they are accurately located on the respective faces of the body members; thus when the faces are in abutting relationship, the formations accurately align the body members one to the other in the plane of the surfaces. The body member 34 has a rear surface 78 rebated at 80 so as to form a step for accurate positioning the unit on a complementary surface of the hook bar 38, as illustrated. Each of the body members includes a substantially centrally disposed hole 82 through which the screw means 36 extends when the surfaces 70 and 72 are in abutment for securing and assembling the module to the hook bar 38.
The hooks 28 in the front body member 32 may be of conventional configuration while the hooks 30 of the rear body member 34 may be of an unconventional design to allow each hook 30 to be positioned intermediate adjacent hooks 28 of the front body member. However, in such a case the shanks of the hooks 30 would have an awkward configuration for the bottom yarn engaging surface of the blades and the bills to be properly disposed relatively to the blades and bills of the front module. To avoid such an unconventional design and to provide additional support for the elongated rear hooks 30, the invention proposes that the body members 32 be formed with slots 84 disposed intermediate the hooks 28 and of a depth substantially equal to the shank 54 between the throat 58 and the step 60. Thus, each hook 30 is received within a respective slot 84 when the body members 32 and 34 are assembled. The slot on one of the body member 32 may be open at that end for receiving the end hook of the member 34 and the slot is closed by the wall at the other end of the adjacent body member 32. With this construction the rear hooks 30 are not only positively secured within the body member 34, but are supported in the body member 32, thereby minimizing the amount of transverse deflection on these hooks and preventing excessive bending when engaged by their respective needles and knives.
Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. For example, the body members may be mounted one upon the other in which case the configuration of the hooks in one series would change accordingly. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims. | A staggered cut pile tufting machine has a modular hook assembly having long blade hooks and short blade hooks molded in separate body members. The body members have complementary reference surfaces adapted to cooperatively mate and be secured together. One of the body members includes slots between the hooks carried therein for receiving a portion of the hooks of the other body member when assembled. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to a contact device for making connection to an electronic circuit device and to methods of fabricating and using such a contact device, such as in the manufacture of semiconductor or other devices.
An important aspect of the manufacture of integrated circuit chips is the testing of the circuit embodied in the chip in order to verify that it operates according to specifications. Although the circuit could be tested after the chip has been packaged, the expense involved in dicing the wafer and packaging the individual chips makes it preferable to test the circuit as early as possible in the fabrication process, so that unnecessary efforts will not be expended on faulty devices. It is therefore desirable that the circuits be tested either immediately after wafer fabrication is completed, and before separation into dice, or after dicing, but before packaging. In either case, it is necessary to make electrical connection to the circuits' external connection points (usually bonding pads) in a non-destructive way, so as not to interfere with subsequent packaging and connection operations.
U.S. Pat. No. 5,221,895 discloses a probe for testing integrated circuits. The probe includes a stiff metal substrate made of beryllium copper alloy, for example. The substrate is generally triangular in form and has two edges that converge from a support area toward a generally rectangular tip area. There is a layer of polyimide over one main face of the substrate, and gold conductor runs are formed over the layer of polyimide. The conductor runs and the metal substrate form microstrip transmission lines. The conductor runs extend parallel to one another over the tip area and fan out toward the support area. A contact bump is deposited on the end of each conductor run that is on the tip area. The tip area of the substrate is slit between each two adjacent conductor runs whereby the tip area is divided into multiple separately flexible fingers that project in cantilever fashion from the major portion of the substrate.
The probe shown in U.S. Pat. No. 5,221,895, is designed to be used in a test station. Such a test station may include four probes having the configuration shown in U.S. Pat. No. 5,221,895, the probes being arranged in an approximately horizontal orientation with their contact bumps facing downwards, with the four rows of contact bumps along four edges of a rectangle. The DUT is generally rectangular and has connection pads along the edges of one face. The DUT is placed in a vacuum chuck with its connection pads upwards. The vacuum chuck drives the DUT upward into contact with the probe, and overdrives the DUT by a predetermined distance from first contact. According to current industry standards, such a test station is designed to produce a nominal contact force of 10 grams at each connection pad. Therefore, the amount of the overdrive is calculated to be such that if contact is made at all connection pads simultaneously, so that each contact bump is deflected by the same amount, the total contact force will be 10 grams force multiplied by the number of connection pads.
If the material of the probe substrate is a beryllium copper alloy and each flexible finger has a length of about 0.75 mm, a width of about 62 microns and a height of about 250 microns, and the probe is supported so that the mechanical ground is at the root of the fingers, the contact force produced at the tip of the finger is about 7.7 grams for each micrometer of deflection of the tip of the finger. Therefore, if the contact bumps at the tips of the fingers are coplanar and the connection pads of the DUT are coplanar, and the plane of the contact bumps is parallel to the plane of the connection pads, an overdrive of about 1.3 microns from first contact will result in the desired contact force of 10 grams at each connection pad. However, if one of the connection pads should be 1.3 microns farther from the plane of the contact bumps than the other connection pads, when the DUT is displaced by 1.3 microns from first contact, there will be no contact force between this connection pad and its contact bump, and all the contact force that is generated will be consumed by the other contacts. If one assumes that the contact force at a connection pad must be at least 50 percent of the nominal contact force in order for there to be a reliable connection, then the maximum variance from the nominal height that this design will accommodate is +/-0.7 microns. However, the height variations of contact bumps and connection pads produced by the standard processes currently employed in the semiconductor industry typically exceed 5 microns.
Furthermore, even if the contact bumps are coplanar and the connection pads are coplanar, tolerances in the probing apparatus make it impossible to ensure that the plane of the connection pads is parallel to the plane of the contact bumps, and, in order to accommodate these tolerances, it is necessary to displace the DUT by 75 microns in order to ensure contact at all connection pads. If the dimensions of the finger were changed to accommodate a displacement of 70-80 microns (75 microns +/-5 microns), the probe would become much less robust. If the probe were supported at a location further back from the root of the fingers, such that most of the deflection would be carried by the substrate rather than the fingers, the ability of the fingers to conform would be limited to 0.13 microns/gram deflection produced at the fingers themselves.
The connection pads of the DUT are not coplanar, nor are the connection bumps on the probe. Assuming that the nominal plane of the connection pads (the plane for which the sum of the squares of the distances of the pads from the plane is a minimum) is parallel with the nominal plane of the contact bumps, the variation in distance between the connection pad and the corresponding contact bump is up to 5 microns if both the DUT and the probe are of good quality.
At present, the connection points on an integrated circuit chip are at a pitch of at least 150 microns, but it is expected that it will be feasible for the pitch to be reduced to about 100 microns within a few years.
As the need arises to make connection at ever finer pitches, the stress in a probe of the kind shown in U.S. Pat. No. 5,221,895 increases. If the connection pads are at a spacing of 75 microns, this implies that the width of the fingers must be less than about 50 microns, and in order to keep the stress below the yield point, the height of the fingers must be at least 400 microns.
The necessary height of the fingers can be reduced by employing a metal of which the yield point is higher than that of beryllium copper. For example, if the substrate is made of stainless steel, having an elastic modulus of 207×10 9 N/M 2 , the maximum height of the fingers can be reduced to about 350 microns. However, it follows that the deflection is reduced below that necessary to comply with typical height variations found in the industry. Additionally, the resistivity of stainless steel is substantially higher than that of beryllium copper, and this limits the frequency of the signals that can be propagated by the microstrip transmission lines without unacceptable degradation. In general, prior techniques found limited application due to difficulties in achieving adequate deflection with the necessary force to achieve reliable connection, while withstanding the generated stresses.
In addition, although the microstrip transmission line has adequate characteristics for signals up to a frequency of 5 GHz, and it has been discovered that the so-called stripline configuration is desirable for higher frequencies.
SUMMARY OF THE INVENTION
In accordance with a first aspect of the present invention there is provided a method of making a multilayer composite structure for use in manufacture of a contact device for establishing electrical connection to a circuit device, said method comprising providing a substrate of a metal having a resistivity substantially greater than about 10 micro-ohm cm, adhering a first layer of metal having a resistivity less than about 3 micro-ohm cm to a main face of the substrate, the first layer having a main face that is remote from the substrate, adhering a second layer of dielectric material to the main face of the first layer, the second layer having a main face that is remote from the substrate, and adhering a third layer of metal to the main face of the second layer, the metal of the third layer having a resistivity less than about 3 micro-ohm cm.
In accordance with a second aspect of the present invention there is provided a method of making a contact device for use in establishing electrical connection to a circuit device, said method comprising providing a substrate of a metal having a resistivity substantially greater than about 10 micro-ohm cm, the substrate having a major portion and a tip portion projecting therefrom along an axis, adhering a first layer of metal having a resistivity less than about 3 micro-ohm cm to a main face of the substrate, the first layer having a main face that is remote from the substrate, adhering a second layer of dielectric material to the main face of the first layer, the second layer having a main face that is remote from the substrate, adhering a third layer of metal to the main face of the second layer, the metal of the third layer having a resistivity less than about 3 micro-ohm cm, selectively removing metal of the third layer to form discrete conductor runs extending over the tip portion parallel to said axis, while leaving portions of the second layer exposed between the conductor runs, whereby a multi-layer composite structure is formed, and slitting the tip portion of the composite structure parallel to said axis, whereby fingers are formed that project from the major portion of the composite structure in cantilever fashion and each of which supports at least one conductor run.
In accordance with a third aspect of the present invention there is provided a probe apparatus for use in testing an integrated circuit embodied in an integrated circuit chip, said probe apparatus comprising a support member having a generally planar datum surface, a generally planar elastic probe member having a proximal end and a distal end, at least one attachment member attaching the probe member at its proximal end to the support member with the probe member in contact with the datum surface, at least one adjustment member effective between the support member and a location on the probe member that is between the proximal and distal ends thereof for urging the distal end of the probe member away from the support member, whereby the probe member undergoes elastic deflection.
In accordance with a fourth aspect of the present invention there is provided a probe apparatus for use in testing an integrated circuit embodied in an integrated circuit chip, said probe apparatus comprising a support member having a bearing surface, a probe member having a proximal end and a distal end and comprising a stiff substrate having first and second opposite main faces and conductor runs extending over the first main face of the substrate from the distal end of the substrate to the proximal end thereof, the conductor runs of the probe member being distributed over a connection region of the first main face of the substrate in a first predetermined pattern, at least one attachment member attaching the probe member to the support member with the second main face of the probe member confronting the bearing surface of the support member, a circuit board comprising a substrate having a main face and conductor runs distributed over a connection region of said main face of the circuit board in a second predetermined pattern, a flexible circuit comprising a flexible substrate having a main face and first and second connection regions, and conductor runs extending between the first and second connection regions of the flexible substrate and distributed over the first connection region in a pattern corresponding to said first pattern and distributed over the second connection region in a pattern corresponding to said second pattern, a first attachment device attaching the flexible circuit to the support member with the first connection region of the flexible circuit confronting the connection region of the probe member and the conductor runs of the flexible circuit in electrically conductive connection with respective conductor runs of the probe member, and a second attachment device attaching the flexible circuit to the circuit board with the second connection region of the flexible circuit confronting the connection region of the circuit board and the conductor runs of the flexible circuit in electrically conductive connection with respective conductor runs of the circuit board.
In accordance with a fifth aspect of the present invention there is provided a method of making a multilayer composite structure for use in manufacture of a contact device for establishing electrical connection to a circuit device, said method comprising providing a substrate, adhering a first layer of dielectric material to a main face of the substrate, the first layer having a main face that is remote from the substrate, and adhering a second layer of metal to the main face of the first layer, the metal of the second layer having a resistivity less than about 3 micro-ohm cm.
In accordance with a sixth aspect of the present invention there is provided a method of making a contact device for use in establishing electrical connection to a circuit device, said method comprising providing a substrate having a major portion and a tip portion projecting therefrom along an axis, adhering a first layer of dielectric material to the main face of the substrate, the first layer having a main face that is remote from the substrate, adhering a second layer of metal to the main face of the first layer, the metal of the second layer having a resistivity less than about 3 micro-ohm cm, selectively removing metal of the second layer to form discrete conductor runs extending over the tip portion parallel to said axis, while leaving portions of the first layer exposed between the conductor runs, whereby a multilayer composite structure is formed, and slitting the tip portion of the composite structure parallel to said axis, whereby fingers are formed that project from the major portion of the composite structure in cantilever fashion and each of which supports at least one conductor run.
In accordance with a seventh aspect of the present invention there is provided a contact device having a plurality of nominally coplanar first contact elements for making electrical contact with corresponding nominally coplanar second contact elements of an electronic device by positioning the contact device and the electronic device so that the plane of the first contact elements is substantially parallel to the plane of the second contact elements and effecting relative displacement of the devices in a direction substantially perpendicular to the plane of the first contact elements and the plane of the second contact elements to generate a contact force of at least f at each pair of corresponding first and second contact elements, wherein it is necessary to effect relative displacement of the devices by a distance d in said direction from first touchdown to last touchdown, said contact device comprising a stiff substrate having a major portion with fingers projecting therefrom in cantilever fashion, each finger having a proximal end at which it is connected to the major portion of the substrate and an opposite distal end and there being at least one, and no more than two, contact elements on the distal end of each finger, a support member to which the substrate is attached in a manner such that on applying force in said direction to the distal ends of the fingers, deflection occurs both in the fingers and in the major portion of the substrate, and means for effecting relative movement of the devices in said direction, and wherein the substrate is dimensioned such that relative displacement of the devices in said direction by a distance d from first touchdown generates a reaction force at each contact element of about 0.1*f+/-0.1*f, and further relative displacement of the devices in said direction by a distance of about 75 micron or 5*d beyond last touchdown generates a reaction force at each contact element of about 0.9*f+/-0.1*f.
In accordance with an eight aspect of the present invention, there is provided a method for testing/manufacturing devices such as integrated circuits or displays (such as LCD panels), which may include the steps of carrying out a manufacturing process for the DUT, such as a planar-type integrated circuit manufacturing process, positioning the DUT on a positioning device, such as a vacuum chuck (the DUT may be in wafer or die form, in the case of integrated circuits, etc.), effecting alignment of a contact device in accordance with the present invention with the DUT to the extent required for proper placement, effecting relative movement of the DUT with respect to the contact device to establish initial contact thereto (as determined electrically or by a mechanical means), over-driving the relative movement to establish reliable electrical connection, wherein stresses are desirably shared between the extended fingers of the contact device and the substrate of the contact device, applying test signals to the DUT and determining whether the DUT is defective or otherwise within or outside acceptable specifications, recording whether the pass/fail condition of the DUT (which may include mechanical notation, such as inking the DUT if defective, etc., or by data recording), removing the DUT from the positioning device, and packaging and assembling the DUT if acceptable.
With the present invention, devices with connection points of fine pitch may be reliably tested and manufactured.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings in which:
FIGS. 1-5 illustrate various steps during fabrication of a contact device embodying the present invention, FIGS. 1 and 4 being plan views and FIGS. 2, 3 and 5 being sectional views;
FIG. 6 is a partial perspective view of a contact device embodying the invention;
FIG. 6A is a sectional view on the line VIA--VIA of FIG. 6;
FIG. 7 is a general view, partly in section, of a semiconductor tester;
FIG. 8 is a plan view of a circuit board and mounting plate that form part of the test head of the tester shown in FIG. 7;
FIG. 9 is an enlarged perspective view of the mounting plate and also illustrates back-up blocks that are attached to the mounting plate;
FIGS. 9A, 9B, and 9C are sectional views illustrating the manner in which the back-up blocks are attached to the mounting plate;
FIG. 10 is an enlarged view of a flexible circuit that is used to connect the circuit board to the contact device;
FIGS. 11A and 11B are sectional views illustrating the manner in which the contact device and the flexible circuit are positioned relative to the mounting block; and
FIGS. 12A and 12B are sectional views illustrating the manner in which the mounting plate and the flexible circuit are positioned relative to the circuit board.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a substrate 4 of elastic metal having an upper main face 6 and a lower main face. In a preferred embodiment of the invention, the substrate is stainless steel and is about 125 microns thick. The substrate is generally triangular in form, having two edges 8 that converge from a support area 10 toward a generally rectangular tip area 12. The substrate is substantially mirror-image symmetrical about a central axis 18.
Referring to FIG. 2, a thin film 14 of gold is deposited on the upper main face 6 of the substrate 4 by evaporation or sputtering. The gold film may be augmented by plating if desired. An insulating material such as polyimide is spun or sprayed onto the upper main face of the film 14 in the liquid phase and is then cured to form a layer 16 about 25 microns thick.
A layer 20 of gold is deposited over the upper main face 22 of the layer 16 by evaporation or sputtering. The layer 20 is patterned using conventional photolithographic techniques to form strips 26 that extend parallel to the central axis 18 over the tip area 12 of the probe and fan out from the tip area over the triangular part of the substrate 4 toward the support area 10 but which may be connected together at the support area. Each strip has a proximal end and a distal end relative to the support area 10. Additional metal is then deposited over the strips by plating. After the strips have been built up to the desired thickness, which may be about 12 microns, a layer 30 of photomask material (FIG. 5) is deposited over the upper surface of the structure shown in FIGS. 3 and 4 and holes 32 are formed in that layer over the distal end of each strip 26, as shown in portion (a) of FIG. 5. A hard contact metal, such as nickel, is deposited into these holes (FIG. 5, portion (b)) by plating, and the photomask material is then removed (FIG. 5, portion (c)). The connections between the strips are removed by etching. In this manner, separate conductor runs are formed over the layer 16, and each conductor run has a contact bump 34 over its distal end. The conductor runs are 50 microns wide and are at a spacing between centers of about 125 over the tip area.
Referring to FIG. 6, a cover layer 40 of polyimide is formed over the conductor runs 26, over a region of the substrate that is to the rear, i.e. toward the support area 10, of the rectangular tip area 12 and a layer 44 of gold is deposited over the layer 40 by evaporation or sputtering. The layer 44 may be augmented by plating. The result of the fabrication steps described above is a multilayer structure that comprises the substrate 4, the gold film 14, the polyimide layer 16, the gold conductor runs 26, the polyimide layer 40, and the gold layer 44.
The tip area of the multilayer structure is then slit, whereby the tip area is divided into multiple separately flexible fingers 48 that project in cantilever fashion from the major portion of the structure. A given finger of the substrate may carry the distal end portion of a single conductor run, or it may carry the distal end portions of two adjacent conductor runs. The slitting of the tip area may be performed by ablation using a ultraviolet laser. The poor thermal conductivity of stainless steel is a favorable factor with regard to the laser ablation process. The width of the kerf that is removed is about 17 microns, so that the width of a finger is either about 108 microns or about 233 microns. The length of each finger is about 1 mm.
The structure shown in FIG. 6 may be used as a contact device for making electrical connection to contact pads of an electrical circuit device, such as an integrated circuit chip or a flat panel display device. The nickel bumps 34 serve as probe elements for contacting the connection pads of the circuit device. When the contact device is in use, each nickel bump contacts a single connection pad of the circuit device. A bump 34a that is to contact a ground pad of the circuit device may be connected to the substrate by means of vias 46 formed in holes in the layer 16 before depositing the layer 20. Multiple vias 46 may be provided along the length of the conductor run 26 that ends at the bump 34a in order to ensure that the contact bump 34a is firmly grounded.
The configuration of the conductor runs and their spacing results in there being a stripline transmission line environment to the rear of the forward boundary of the layer 44, whereas there is a microstrip transmission line environment forward of the layer 44. Naturally, the slitting of the tip area results in degradation of the microstrip transmission line environment. In the case of the fingers being about 1 mm long, the microstrip transmission line environment extends to a point that is about 2 mm from the contact bumps. However the degradation is not so severe as to distort signals at frequencies below about 10 GHz to an unacceptable degree.
The structure shown in FIG. 6 may be used for probing a circuit device in a semiconductor tester, as will be described with reference to FIGS. 7-11.
Referring to FIG. 7, the tester comprises a prober 102 having a frame 102a that serves as a mechanical ground. A device positioner 104 having a vacuum chuck 106 is mounted within or as part of the prober 102. The prober includes stepping motors (not shown) that act on the device positioner for translating the vacuum chuck relative to the frame 102a in two perpendicular horizontal directions (X and Y) and vertically (Z), and for rotating the vacuum chuck about a vertical axis. The vacuum chuck holds a device under test, or DUT, 108. FIG. 7 illustrates the DUT 108 as a die that has previously been separated from other dice of the wafer in which it was fabricated, but it will be appreciated that, with appropriate modifications, the apparatus could be used for testing a semiconductor device at the wafer stage. As shown in FIG. 7, the DUT 108 has contact pads 112.
The tester also comprises a test head 116 that can be docked to the prober so that it is in a reliably reproducible position relative to the prober frame 102a. The test head 116 includes an essentially rigid circuit board 122 (FIG. 8) that comprises an insulating substrate and conductor runs 126 exposed at the lower main face of the substrate. Vias (not shown) extend through the substrate and terminate at contact pads 128 that are exposed at the upper main face of the substrate. The circuit board 122 is removably held in the test head by screws that pass through holes 130 in the circuit board. When the test head 116 is docked in the prober 102 and the circuit board 122 is installed in the test head, the circuit board 122 is disposed horizontally and the contact pads 128 engage pogo pins 132, shown schematically in FIG. 7, by which the contact pads of the circuit board are connected to stimulus and response instruments (not shown), for purposes of conducting appropriate tests on the DUT.
A mounting plate 136 is secured to the circuit board 122. The mounting plate is positioned relative to the circuit board by guide pins 134 that project downward from the mounting plate and enter corresponding holes in the circuit board. The manner in which the mounting plate is attached to the circuit board will be described below.
The mounting plate has a generally cylindrical exterior surface of which the central axis 138 is considered to be the axis of the plate. The plate 136 is disposed with its axis 138 vertical and defines a cross-shaped through opening (FIG. 9) that is mirror image symmetrical about X-Z and Y-Z planes that intersect at the axis 138. At the outer end of each limb of the cross, the plate 136 is formed with a notch 140 that extends only part way through the plate and is bounded in the vertically downward direction by a horizontal surface 142.
A backup block 146 having the general shape, when viewed in plan, of a trapezoid seated on a rectangular base is positioned with its rectangular base in one of the notches 140. Similar backup blocks 148 are mounted in the other notches. The following description of the backup block 146 and associated components applies equally to the backup blocks 148.
The rectangular base of the backup block 146 has a planar mounting surface 150 (FIG. 7) that can be seated against the horizontal surface 142 at the bottom of the notch 140. For assembling the backup block 146 to the mounting plate 136, the backup block is formed with a hole 152 extruding through its rectangular base, and the mounting plate is formed with a blind hole 156 that is parallel to the axis of the mounting plate and enters the plate 136 at the horizontal surface 142. A guide pin 160 is inserted through the hole 152 in the backup block and into the blind hole 156 in the mounting plate, and in this manner the backup block is positioned with a moderate degree of precision relative to the mounting plate.
The backup block 146 is then attached to the mounting plate 136 by a vertical locking screw 164 (FIG. 8, FIG. 9A) that passes through a clearance hole 168 in the backup block 146 and enters a threaded bore 172 in the mounting plate 136 and a horizontal locking screw 176 (FIG. 7) that passes through a clearance hole 180 in the mounting plate and enters a threaded bore 184 in the backup block. The backup block 146 is thereby attached to the mounting plate, and the guide pin 160 is then removed. The clearance holes 168 and 180 allow a small degree of horizontal and vertical movement of the backup block relative to the mounting plate.
Two horizontal screws 186, which are horizontally spaced and disposed one on each side of the screw 176, are inserted through threaded holes in the peripheral wall of the plate 136 and enter blind clearance holes in the backup block. Similarly, two vertical screws 190, which are horizontally spaced and disposed one on each side of the screw 164, are inserted through threaded holes in the backup block 146 and engage the surface 142 of the mounting plate 136. The screws 176 and 186 can be used to adjust the horizontal position of the backup block relative to the mounting plate 136. By selectively turning the screws 176 and 186, the backup block can be advanced or retracted linearly and/or rotated about a vertical axis. In similar fashion, using screws 164 and 190, the backup block can be raised or lowered relative to the mounting plate and/or tilted about a horizontal axis. When the backup block is in the desired position and orientation, the locking screws are tightened.
The apparatus shown in FIGS. 7-10 also comprises a contact device 194 associated with the backup block 146. The contact device 194 is generally triangular and has two edges that converge from a support area toward a generally rectangular tip area. The tip area of the contact device is divided into multiple fingers that extend parallel to an axis of symmetry of the contact device. The contact device includes conductor runs that extend from the support area to the tip area, and one run extends along each finger in the tip area. At its support area, the conductor runs of the contact device are exposed on the underside of the contact device. The contact device may be fabricated by the method that is described above with reference to FIGS. 1-6.
Inboard of the rectangular base, the trapezoidal portion of the backup block 146 extends downward toward the central axis 138. The contact device 194 is disposed below the inclined lower surface of the backup block 146 and is positioned relative to the backup block by guide pins 202 (e.g., FIGS. 11A and 11B) that project from the backup block and pass through alignment holes 204 in the contact device. The manner in which the contact device is attached to the backup block will be described below.
The apparatus also comprises a flexible circuit 208 having an inner edge region 208A and an outer edge region 208B (e.g., FIG. 10). The flexible circuit comprises a substrate of polyimide or similar insulating material, a ground plane (not shown) on the lower side of the substrate, and multiple discrete conductor runs 210 on the upper side of the substrate. Over the inner edge region 208A, the spacing of the conductor runs 210 corresponds to the spacing of the conductor runs across the support area of the contact device 194, and over the outer edge region 208B, the spacing of the conductor runs 210 corresponds to the spacing of the conductor runs 126 along the inner edge of the printed circuit board 122.
The flexible circuit is formed with inner and outer pairs of alignment holes 214A and 214B. The inner pair of alignment holes 214A are threaded by the guide pins 202, whereby the inner edge region 208A is positioned relative to the contact device 194. Similarly, the outer pair of alignment holes 214B are threaded by the guide pins 134, whereby the outer edge region 208B of the flexible circuit is positioned relative to the printed circuit board. The flexible circuit is also formed with two sets of mounting holes 218A and 218B.
The support area of the contact device 194, the inner edge region 208A of the flexible circuit, and a first length 222A of Shinetsu strip are clamped between the backup block and a clamping plate 226A by means of screws 230A. The outer edge region 208B of the flexible circuit 208, the inner region of the printed circuit board 122, and a second length 222B of Shinetsu strip are clamped between the mounting plate 136 and a second clamping plate 226B by means of screws 230B. The positions of the alignment holes 214A and 214B relative to the conductor runs of the flexible circuit are such that the conductor runs 210 at the inner edge region 208A of the flexible circuit are in registration with the conductor runs 26 in the support area of the contact device, and the conductor runs 210 in the outer edge region 208B of the flexible circuit are in registration with the conductor runs 126 along the inner edge of the printed circuit board. The Shinetsu strip, the thickness of which is exaggerated in FIG. 7, is characterized by anisotropic electrical conductivity when compressed perpendicular to its length: its conductivity is very good in directions perpendicular to its own plane and is very bad in directions parallel to its own plane and to its length. Thus, the Shinetsu strip 222A connects the conductor runs 26 of the probe member 194 to respective conductor runs 210 of the flexible circuit 208, and the Shinetsu strip 222B connects the conductor runs 210 of the flexible circuit 208 to respective conductor runs 126 of the printed circuit board 122.
Tightening of the clamping screws compresses the Shinetsu strips, which then establish a good electrically conductive connection between the conductor runs of the contact device and the conductor runs 126 of the printed circuit board 122, through the Shinetsu strips and respective conductor runs of the flexible circuit 208.
As described with reference to FIGS. 1-6, the tip area of the contact device 194 is divided into fingers, each of which has a contact run that terminates in a contact bump. Since the tip area is spaced from the support area, at which the contact device is clamped to the backup block, the tip area can be deflected away from the plane of the underside of the backup block. Vertical adjustment screws 234 are fitted in respective threaded holes in the backup block 146. By appropriate adjustment of the screws 234, the contact device can be preloaded to a condition in which the contact device 194 is deflected downwards relative to the backup block 146, and by further adjustment of the screws 234 the tip area can be forced downward, or permitted to rise, or tilted about the axis 18. It is important to note that the "mechanical ground" therefore extends to a location of the contact device that is beyond the support area but does not extend as far as the lip area. As described more fully below, proper positioning of mechanical ground can enable stress sharing between the fingers of the contact device and the contact device substrate, thereby enabling the contact device to withstand the stresses that result from applying force sufficient to ensure reliable contact between the DUT and the contact device, given the irregularities that can be expected in actual devices/conditions.
When all four backup blocks are properly installed in the mounting plate 136, the tip portions of the four contact devices extend along four edges of a square and are positioned for making electrically conductive contact to the contact pads of the device under test. By observing the DUT through the opening defined between the inner ends of the four backup blocks, the DUT can be positioned for contacting the contact bumps when the DUT is raised by the positioning device.
When the DUT is raised relative to the test head, the contact pads of the DUT engage the contact bumps of the contact device. After initial contact has been established (first touchdown), the DUT is raised an initial 10-15 microns, which is sufficient to absorb any expected error in coplanarity of the contact bumps and contact pads and achieve last touchdown (each contact bump is in contact with its respective contact pad). The DUT is then raised by a further 75 microns. The spring rate of the fingers and the spring rate of the base region of the substrate, between the fingers and the support area, are such that the contact force exerted at each contact pad is at least 10 grams. The initial deflection of 10-15 microns is sufficient to provide a contact force of about 2 grams at a single finger, whereas the further deflection of 75 microns provides a contact force of N*10 grams, where N is the number of fingers, or 10 grams per finger. By sharing the deflection between the fingers and the base region of the substrate, a high degree of compliance may be achieved, allowing contact with all the contact bumps, without sacrificing the contact force that is needed to achieve a reliable electrical contact between the contact bumps and the fingers.
The elastic nature of the metal of the substrate ensures that when the DUT is brought into contact with the contact bumps, and is slightly over driven, deflection of the fingers provides a desirable scrubbing action and also supplies sufficient contact force for providing a reliable pressure contact between the contact bump and the connection pad of the DUT.
The film 14 of gold may serve as the ground plane, and the substrate 4, although conductive, may not contribute to the electrical performance of the device, although this depends on the thickness and constituent material of the substrate. In alternative embodiments, for example, the substrate is of sufficient thickness so that it provides sufficient conductivity to serve as the ground plane, or may consist of beryllium copper, and thereby provide sufficient thickness to serve as the ground plane, with or without gold film 14.
It is should be particularly emphasized how the present invention achieves desirous stress load sharing between the fingers and the substrate. It has been determined that with available materials, to be of practical size and provide suitable compliance/deflection of the fingers (such as to accommodate deviations from coplanarity, etc.), stress loads induced in the fingers and the substrate should be balanced (i.e., maintained in an acceptable relative range, below the stress limit of the material). Proper positioning of a mechanical ground between the ends of the fingers and the back extremity of the support area can enable controlled balancing of the relative stress loads, while also ensuring an adequate deflection of the fingers to achieve adequate compliance. In preferred embodiments, the relative stress loads of the fingers and substrate are maintained/balanced in a ranges of about 0.7 to 1.3, 0.8 to 1.2 or 0.9 to 1.1. Other ranges may be utilized, provided that a desirable balance is maintained, while of meeting the conditions of adequate deflection/compliance in the fingers, while staying within the stress limits of the constant materials.
In combination with the stress load balancing, it also has been discovered that, with available materials, the length of the fingers, controlled by the length of the slit and overall physical geometry, etc., can be chosen to give the desired finger deflection/compliance, such as a desired deflection of greater than about 5 microns, 10 microns, 12, microns or 15 microns, in the case of, for example, 60-80 or 75 microns, etc., of overdrive, while maintaining stress balancing as described above, which can produce a probe element that produces reliable connection with the DUT while surviving the resulting stress loads, etc.
The present invention may be desirably applied to the testing and manufacture of devices such as integrated circuits or displays (such as LCD panels). Initially, a manufacturing process for the DUT 108 is conducted, such as a planar-type integrated circuit manufacturing process. For display devices, an appropriate LCD or other manufacturing process is conducted. After such manufacturing, the DUT 108 is positioned on a positioning device, such as vacuum chuck 106 of prober 102 (the DUT may be in wafer or die form, in the case of integrated circuits, etc.). The DUT 108 is aligned with contact device 194 to the extent required for proper placement. Thereafter, relative movement is effected of the DUT 108 with respect to the contact device 194 to establish initial contact therebetween (as determined electrically or by a known mechanical means). After initial contact, over-driving of the relative movement to a predetermined degree is conducted (such as described above) to establish reliable electrical connection, wherein stresses are desirably shared between the extended fingers of the contact device and the substrate of the contact device. Positioning of a mechanical ground as in the present invention is particularly desirous in this regard. Thereafter, test signals are applied to the DUT 108 and it is electrically determined whether the DUT is defective or otherwise within or outside acceptable specifications. The pass/fail condition of the DUT may be recorded (which may include mechanical notation, such as inking the DUT if defective, etc., or by data recording). Still thereafter, the DUT 108 may be removed from the positioning device. If the device is acceptable, known packaging and assembling of the DUT may be performed.
With the present invention, devices with connection points of fine pitch may be reliably tested and manufactured.
It will be appreciated that the invention is not restricted to the particular embodiment that has been described, and that variations may be made therein without departing from the scope of the invention as defined in the appended claims and equivalents thereof. For example, although the invention has been described with reference to the drawings in terms of strip line and microstrip transmission line environments, if the film 14 were omitted and every other conductor run 26 across the contact device were a ground conductor run, a combination of a microstrip and coplanar transmission line environment would be provided. If every other conductor run were not a ground run, a microstrip transmission line environment would be provided as far as the forward edge of the layer 44, and for some applications, it might be acceptable for the transmission line environment to terminate at this point, provided that it is quite close to the contact bumps. Application of the invention to a semiconductor tester has been described with reference to an implementation in which there is one contact bump on each finger of the contact device, and the use of individual fingers for each contact bump ensures maximum accommodation of non-coplanarity of the contact pads of the DUT. However, it might be advantageous to provide two contact bumps, each connected to its own conductor run, since torsion of the finger accommodates a difference in height of the respective contact pads, and the greater width of the finger provides substantially greater stiffness with respect to deflection. The invention is not limited to testing of devices prior to packaging and may he used for final testing of packaged devices, particularly a device that is packaged for surface mounting, since the terminals are then suitably positioned for engagement by the contact bumps. Further, numerical references, while giving unexpectedly desirable results in the preferred embodiments over prior art techniques, may be adjusted in other embodiments. | A contact device having a plurality of nominally coplanar first contact elements makes electrical contact with corresponding nominally coplanar second contact elements of an electronic device when the contact device and the electronic device are positioned so that the plane of the first contact elements is substantially parallel to the plane of the second contact elements and relative displacement of the devices is effected in a direction substantially perpendicular to the plane of the first contact elements and the plane of the second contact elements. The contact device comprises a stiff substrate having a major portion with fingers projecting therefrom in cantilever fashion, each finger having a proximal end at which it is connected to the major portion of the substrate and an opposite distal end and there being one or two contact elements on the distal end of each finger. A mechanical ground is positioned away from the fingers towards the proximal end, and deflection resulting from contact between the probe member and the electronic device is shared between the fingers and a portion of the substrate not including the fingers. Methods utilizing such a contact device also are disclosed. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority to U.S. Provisional Application No. 61/269,352 filed on Jun. 24, 2009, which application is incorporated herein by reference in its entirety for all purposes.
TECHNICAL FIELD
The present invention relates generally to musical instruments and, more particularly, to stringed musical instruments such as zithers and autoharps.
BACKGROUND OF THE INVENTION
For purposes of background, a “zither” is a specialized type of chorded or stringed musical instrument. More specifically, zithers include any one of several stringed musical instruments that consist of a flat, shallow resonator box (sets horizontally before the performer when in use) overlaid with a multiplicity (e.g., 20 to 40) of strings (also commonly referred to as “chords”). The strings nearest the performer when in use run above a fretted fingerboard against which they are stopped by the left hand to provide melody notes. The strings are generally plucked by a plectrum worn on the right thumb. At the same time, the right hand fingers pluck an accompaniment on the farther strings, which remain unstopped. The zither is capable of playing notes arranged in a series of octaves.
An “autoharp” is generally considered to be a specialized type of zither on which a simple harmony may be obtained by button-controlled dampers (operating in sets) that when depressed leave free the strings of the desired chord. U.S. Pat. No. 257,808 to Zimmermann discloses the original autoharp. More specifically, U.S. Pat. No. 257,808 teaches a musical instrument having a multiplicity of strings arranged in a number of octaves over a resonating box, wherein a series of chord bars are provided together with a series of dampening pads which engage selected strings when the chord bar is depressed. Thus, only certain of the strings are free to vibrate or give sound when strummed or picked. Further, the dampening is generally selected such that when a particular chord bar is depressed only those selected strings which constitute the notes in that chord are free to vibrate.
Manufactured and luthier-built autoharps generally have up to 21 spring-loaded or flexible levered chord bars rigidly fastened to the body of the autoharp, producing from one to five keys. Because the chord bars remain in a fixed position relative to the underlying strings, it difficult to play songs in keys the autoharp does not have. Accordingly, there is a need in the art for new and improved stringed musical instruments (including zithers and autoharps) that enable the playing of every key in the normal chromatic scale of 12 keys. In addition, there is a need in the art for stringed musical instrument retrofit kits that enable luthiers to modify existing stringed musical instruments (including zithers and autoharps) such that existing chord bars may be adjustably positionable relative to the underlying strings. The present invention fulfills these needs and provides for further related advantages.
SUMMARY OF THE INVENTION
In brief, the present invention in an embodiment is directed to a stringed musical instrument that comprises a body; a plurality of laterally spaced apart tensioned strings connected to the body, the tensioned strings being positioned above and across a top surface; and an adjustably positionable chord bar assembly connected to the body. In this embodiment, the chord bar assembly comprises a slidable chord bar rack operably connected to a plurality of chord bars, with the chord bar rack being interposed between the top surface of the body and the plurality of strings. The plurality of chord bars is positioned above chord bar rack and perpendicular relative to the plurality of tensioned strings. In this configuration, the chord bar assembly is adjustably positionable between at least a set up key position, a sharpened key position, and a flatted key position.
The inventive chord bar assembly may further comprise a pair of upwardly extending combs rigidly connected to either end of a sliding plate. The sliding plate is configured to be movable back and forth in a direction perpendicular to the plurality tensioned strings. Each upwardly extending comb has a plurality of laterally spaced apart pins, and each of the plurality of chord bars has pin receiving holes at each end. Each of the plurality of receiving pins is received into each respective pin receiving hole.
In another embodiment, the present invention is directed to an adjustably positionable chord bar rack assembly configured for attachment to a body of a stringed musical instrument. In this embodiment, the chord bar rack assembly is adjustably positionable between at least a set up key position, a sharpened key position, and a flatted key position when connected to the body of a stringed musical instrument. The chord bar rack assembly comprises: a pair of combs, with each comb having a plurality of laterally spaced apart and outwardly extending pins, the plurality of pins being configured to receive a plurality of corresponding pin receiving holes, with each of the plurality of corresponding pin receiving holes being positioned at an end of a chord bar of a plurality of chord bars; a sliding plate having a bass end and a treble end, the sliding plate being connected to the pair of combs at the bass and treble ends; a governor plate connected to the sliding plate at the bass end, the governor plate being configured for attachment to the body of the stringed musical instrument; a guide plate connected to the sliding plate at the treble end, the guide plate being configured for attachment to the body of the stringed musical instrument; and a governor body connected to the sliding plate at the bass end, the governor body being configured to selectively engage the governor plate to thereby prevent movement of the sliding plate relative to the positions of the governor and guide plates when attached to the body of the stringed musical instrument and to allow adjustable positioning between at least the set up key position, the sharpened key position, and the flatted key position.
These and other aspects of the present invention will become more readily apparent to those possessing ordinary skill in the art when reference is made to the following detailed description in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings are intended to be illustrative and symbolic representations of certain exemplary embodiments of the present invention and as such they are not necessarily drawn to scale. In addition, and for purposes of clarity, like reference numerals have been used to designate like features throughout the several views of the drawings.
FIG. 1 illustrates a side perspective view of a chorded zither having a conventional stationary chord bar rack of a first style in accordance with the prior art.
FIG. 2 illustrates a side perspective view of a chorded zither having a conventional stationary chord bar rack of a second style in accordance with the prior art, wherein the cover is shown in partial view so that the underlying chord bar components can be seen.
FIG. 3 a illustrates an exploded side perspective view of an adjustably positionable chord bar rack in accordance with an embodiment of the present invention.
FIG. 3 b illustrates an enlarged view of the governor body component of the adjustably positionable chord bar rack of FIG. 3 a.
FIG. 4 illustrates the adjustably positionable chord bar rack of FIG. 3 a , but where the adjustable chord bar rack is in the sharpened positioned in accordance with an embodiment of the present invention.
FIG. 5 illustrates the adjustably positionable chord bar rack of FIGS. 3 a and 4 , but where the adjustable chord bar rack is in the flattened position in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In order to aid in the understanding of the present invention, I first provide a short explanation of the two styles of “chord bar racks” commonly used in connection with prior art zithers and autoharps. Thus, and referring first to FIG. 1 (prior art), there is shown a first of two basic styles of known chord bar racks, which first style of chord bar rack is rigidly connected to the resonator box (body) of a common autoharp. Although there can be any number of chord bars connected to the autoharp body, I choose fifteen bars for purposes of illustration. As shown, two end racks 1 are securely fastened to the body 2 b of the autoharp 2 a by means of two wood screws 3 a at each end. The two end racks 1 are configured to hold a plurality individual chord bars 4 (wherein each chord bar is of the flexible levered variety the mechanics of which are not shown in detail). When an individual chord bar 4 is pressed, the felt 5 below mutes the string(s) 6 a it contacts. The open spaces 6 b allow that string 6 a to resonate to thereby produce a sound. All the open spaces 6 b create, in unison, a chord. Because the two end racks 1 are rigidly fixed to the body 2 b of the autoharp 2 a , only that one designated chord is available for play on that one chord bar 4 .
Referring next to FIG. 2 (prior art), there is shown a second of two basic styles of known chord bar racks. In this alternative configuration, a cover 7 partially hides some of the underlying mechanisms of the stationary chord bar rack. As shown, instead of two end racks 1 holding the individual chord bars 4 , two upwardly extending combs 8 hold the individual chord bars 4 (wherein the chord bars have pin receiving holes 10 b at each end and are of the spring-loaded variety the mechanics of which are not shown in detail) that slide over the pins 10 b of the combs 8 . The combs 8 have two holes 8 a to fasten it directly to the body 2 b of the autoharp 2 a by means of two wood screws 3 a at each end. Again, the chord bars 4 do not move relative to the position of the underlying strings 6 a , and are thus limited to the playing of only one chord.
In view of the foregoing, FIG. 3 a shows an exploded view of an embodiment of my invention. For purposes of convenience, I choose to expound on a 21 chord system (corresponding to a zither or autoharp having a plurality of strings) so that various details of my invention may be more readily appreciated by those of ordinary skill in the art. Thus, and in this regard, an important feature of my invention is to fasten the combs 8 and/or the end racks 1 (of a conventional zither or autoharp) to a movable sliding plate 11 , which plate 11 is configured to be adjustably positionable relative to the strings 6 a of the stringed musical instrument. The sliding plate 11 is fastened to a governor plate 12 at the bass end, and to a guide plate 13 at the treble end, both of which have formed tabs 14 that the sliding plate 11 is affixed under. As shown, the formed tabs 14 limit the distance the sliding plate 11 can travel in either direction. Attached to the sliding plate 11 is the governor body 15 (best seen in FIG. 3 b ), which contains an allen screw 16 , a spring 17 a , a ball-bearing 17 b , a threaded and counterbored hole from top to bottom 18 and two holes 19 for fastening to the sliding plate 11 . The governor body 15 is adjustably positionable over holes 20 on the governor plate 12 , thereby allowing the ball-bearing 17 b to snap into a selected hole 20 as the cover 7 (not shown) is pushed by hand in either direction.
Although only three holes 20 are needed to achieve all keys, any number could be implemented for more varied chord patterns or other configurations. As shown, both the governor plate 12 and the guide plate 13 have large, oval openings 21 to allow the necessary fastener 3 b holding the comb 8 and/or the end rack 1 to the sliding plate 11 to move freely. Two smaller holes 22 fasten the governor plate 12 and the guide plate 13 securely to the body 2 b of the autoharp 2 a . The center tab 23 a holds the governor body 15 securely to the sliding plate 11 . The two tabs 23 b at the bass end of the sliding plate 11 hold the bass end of the cover 7 (not shown) in place, while the two unattached brackets 24 hold the cover 7 (not shown) at the treble end in place. Four holes 25 on the sliding plate 11 are for holding the combs 8 in place.
FIG. 4 shows the entire chord bar rack assembly 26 together (which I call the “chromaslide”) and adjustably positioned to be in the sharpened position, whereas FIG. 5 shows the assembly 26 adjustably positioned to be in the flatted position. When the assembly 26 is in the middle position, it will be setting over the middle hole 20 on the governor plate 12 (i.e., ball-bearing 17 b snapped into the center hole 20 ), and all chord bars 4 will be in the original keys set up position. Thus, the chord bars 4 stay in the same relative positions no matter what key the autoharp 2 b is in.
The proper method for using my “chromaslide” is to have the adjustably positionable chord rack assembly 26 located in the middle position to play the keys it was set up for, for example, “A”, “D”, “G”, “C” and “F”. The top row (for explanation only) would contain the relative seventh chords to those major keys, while the bottom rows (again, for explanation only) would contain the minor chords relative to those major keys. When the cover 7 is pushed towards the bass side of the autoharp 2 b , all chords are moved down one half note. Now the major keys are “Ab”, “Db”, “Gb”, “B” and “E”, and all other chords will follow suit. If the cover 7 is pushed up to the treble side from the center position, all chords will be moved up one half note. Now, the major keys are “Bb”, “Eb”, “Ab”, “Db” and “Gb”. Again, all other chords in this position will follow the major chords. The keys and chords listed are for purposes of illustration only, as any arrangement could be used. Other examples of using this “chromaslide” would be pairing chords to create other chords, or adding many elaborate chords, sacrificing the number of keys, for the playing of more complicated pieces. The assembly 26 could be moved, for example, during the playing of a song, but must be done carefully, so the felts 5 are not stressed by the strings 6 a causing them to pull loose.
While the present invention has been described in the context of the embodiments illustrated and described herein, the invention may be embodied in other specific ways or in other specific forms without departing from its spirit or essential characteristics. Therefore, the described embodiments are to be considered in all respects as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing descriptions, and all changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. | An improved chorded zither is disclosed herein which may be characterized in that it comprises a novel adjustably positionable chord bar assembly (which assembly enables the playing of every key in the normal chromatic scale of 12 keys). In a preferred embodiment, the inventive chord bar assembly comprises a slidable chord bar rack operably connected to a plurality of chord bars, with the chord bar rack being interposed between the top surface of a body and a plurality of strings (associated with a stringed musical instrument). The plurality of chord bars is positioned above chord bar rack and perpendicular relative to the plurality of tensioned strings. The chord bar assembly is configured to be adjustably positionable between at least a set up key position, a sharpened key position, and a flatted key position. | 6 |
BACKGROUND OF THE INVENTION
The instant invention relates to a fluid heating system which includes at least one heat transfer module by which temperature of a fluid passing therethrough is effectively controlled. The system is selectively expandable to receive a plurality of such modules wherein heat transfer characteristic may be increased through employment of substantially the same or similar system components. The modules of the system having an interchangeable and replaceable construction and comprising long lengths of inexpensive, flexible tubing, such as nylon or plastic, wound in basket-weave fashion to provide, in aggregate, a large surface area for effective heat transfer. The apparatus also features a minimal quantity of heat transfer fluid to effect rapid heat transfer and optimum efficiency.
Heretofore heat transfer systems generally employed single or multiple coils usually wound in helical fashion. Such coils are constructed of copper or other metals and thus expensive in material and labor of fabrication. Also, other systems do not provide for interchangeable and replaceable heat transfer modules or expandable systems and employ larger volume of heat transfer fluid surrounding their coils.
SUMMARY OF THE INVENTION
The present invention obviates the above-mentioned and other shortcomings by providing a fluid heat transfer system employing stackable heat transfer modules thus allowing easy replacement or expansion of the system.
The apparatus has an elongated and sealable housing defining an inner wall surface encompassing a cylindrical interior space in which the heat transfer modules are placed. The housing is adapted to be axially expanded by the use of a collar or collars which may be inserted and affixed intermediate the top and bottom of the housing. Near the bottom of the housing an annular rib which protrudes into the inner space and serves to support the lowest heat transfer module in a spaced relation to the bottom of the housing to provide a space or region directly under the lowest module. In this region is received a heat producing medium such as electric heating elements. It is also contemplated that in the event cooling of fluid is desired that such a medium could be located within the interior space at the top of the housing.
Inlet and outlet manifolds are disposed at the upper portion of the housing to provide fluid flow communication from the outside of the housing to the heat transfer modules disposed in the interior space thereof.
The heat transfer modules comprise a base plate having center circular hole and a plurality of upstanding posts disposed in concentric radial relation thereon. Flexible tubings, of nylon or plastic composition, are spirally and helically wound in a basket-weave fashion about the posts. The base plate has a plurality of perforations adjacent the posts to provide for fluid circulation therethrough and about the tubings. The tubings are wound from the base plate to near the free end of the posts, but not beyond, to allow for stacking of the modules.
The housing includes a top end plate which includes a centrally disposed cylindrical post depending therefrom. The post serves to register and retain the modules in close spaced relation to the inner surface of the housing and also displace heat transfer fluid to minimize the volume thereof.
The features of the present invention which are believed to be novel are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the apparatus utilizing an expansion insert;
FIG. 2 is a vertical section taken through the housing of the apparatus showing heat transfer modules, with parts cut away, stacked therein;
FIG. 3 is a horizontal section taken substantially on line 3--3 of the FIG. 1;
FIG. 4 is an enlarged fragmentary horizontal section of one of the manifolds taken substantially on line 4--4 of the FIG. 1;
FIG. 5 is a horizontal section taken substantially on line 5--5 of the FIG. 1;
FIG. 6 is a side perspective view of a heat transfer module of the apparatus;
FIG. 7 is a plan view of the heat transfer module without tubing wound thereon for purposes of clarity; and
FIG. 8 is a vertical section taken substantially on line 8--8 of the FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the apparatus designated 10 comprises a housing generally designated 12. The housing 12 includes top and bottom hollow cylindrical members 14 and 15 respectively.
The top member 14 of the housing 12 has a cylindrical wall section 16 defining inner and outer surfaces 17 and 18 respectively. At both the top and lower end of said section 16 are disposed flat annular flanges 19 and 20 respectively; each radially extending from the wall section 16. Each flange includes a plurality of spaced apart holes 21 and 22 located in the top and lower flanges respectively; circumferentially disposed therealong as indicated in FIG. 3. Disposed near the top of the wall section 16 and opposite each other are rectangular apertures or slots 23 and 24 which provide communication through the wall section 16.
The bottom housing member 15 comprises a cylindrical wall section 25 having inner and outer surfaces 26 and 27 respectively. The lower end of section 25 terminates at a bottom wall 28. At the top end of the wall the section 15 is disposed a flat annular flange 29. The flange 29 extends outwardly from the outer surface 27 and includes a plurality of circumferentially disposed spaced apart holes 30. As shown in FIGS. 2 and 5, an annular rib or protuberance 31 extends inwardly from the inner surface 26. This rib is spaced upward from the bottom wall 28. Between the bottom wall 28 and the rib 31 are disposed means for maintaining heat transfer fluid temperatures which may comprise heating elements 32. These heating elements 32 pass through apertures (not shown) in the lower portion of wall section 25 and are connected thereto in such a manner to effect a seal thereat. An electric heating element such as the TGA chromalox type (Manufactures designation) with sealing accessories manufactured by Emerson Electric Co. may be used. It is also contemplated that heat absorbing element could also be used.
FIGS. 1 and 2 illustrate the apparatus 10 with expansion means comprising a hollow expansion collar 35. Such a collar or a plurality of such collars are employed to selectively increase the size of the housing 12 for purposes which will be further explained hereinafter. The collar 25 comprises a cylindrical wall section 36 having inner and outer surfaces 37 and 38 respectively. Flat flanges 39 and 40 are disposed at each end of the wall section 36. Each flange extends outwardly from the outer wall surface 38. Both flanges have a plurality of holes 41 and 42, respectively, disposed in spaced circumferential relation therealong.
It should be noted that the spacing, size and disposition of the holes in flanges 19 and 20 of member 14, flange 29 of member 15 and flanges 39 and 40 of the expansion collar 35 are the same wherein when such flanges are placed in mating relation for assembly of the housing the holes aligned in order that the housing 12 may be securely bolted together. FIGS. 1 and 2 only show bolts 43 at each side of the housing. However, it is contemplated that the flanges would be bolted together via a plurality of bolts as suggested by the holes in FIG. 3 showing a plan view of flange 19.
The housing 12 also includes a circular flat top cover plate 45 which has a plurality of holes 47 circumferentially disposed adjacent to edge. These holes are of such a size and location to align with the holes 21 of the flange 19 of the top member 14 wherein cover plate 45 is securely bolted to flange 19 by a plurality of bolts as explained above. Depending from the center of the cover 45 and affixed thereto is a tube 46 having a sealed bottom.
Turning attention to FIG. 4, a manifold 50 is shown. The manifold 50 comprises an encompassing side wall 51 and front and back walls 52 and 53 respectively, thereby defining a chamber 54. A outlet pipe 55 is disposed in the back wall 53 to effect fluid flow communication with the chamber 54. The front wall 52 includes a plurality of tubing connectors 56 each of which provide fluid flow communication with the chamber 54. The side wall 51 also includes an outwardly extending lip 57 disposed adjacent the front wall 52. As seen in FIGS. 1, 2 and 3, manifolds 50 are disposed on opposite sides of the outer surface 18 of wall section 16 of the top member 14 at a location wherein the tubing connectors 56 are located within slots 23 and 24 of wall section 16. The manifolds 50 are securely fastened to the wall section 16 at the lip 57 of the manifold via bolts 58.
It is pointed out at this time that gaskets or gasket materials well known to those skilled in the art are employed to effect a sealing at all junctures of parts during assembly of the housing to provide sealed space 60 within the housing.
As best seen in FIGS. 6, 7 and 8, heat transfer means comprising module 70 of the type employed in the apparatus is shown. The module 70 comprises a supporting structure in the form base plate 71 and a plurality of elongated members in the form of upstanding posts or rods 72 disposed and affixed in concentric and radial relation thereon. The base plate 71 has a plurality of aperture or holes 73 disposed adjacent the posts 72 to provide for fluid flow through the plate 71. The plate also has a center hole 74. Flexible tubing 75 is wound in basket-weave fashion about the posts 72 and in a spiral and helical manner relative to the plate 71 to form a porous bundle of tubing substantially in the shape of the space 60. However, the tubing 75 does not pass over the center hole 74. The tubing 75 is wound in the posts 72 from the plate 71 to near the top of the posts 72, but not beyond. The tubing 75 terminates in end portions 76 and 74 which are left long enough to attach to the tubing connectors 56 of the manifolds 50. It is contemplated that the tubing 74 would be of inexpensive materials such as nylon or other plastic materials having temperature characteristics commensurate with the anticipated operating parameters of the apparatus.
During assembly of the apparatus 10, the top and bottom members 14 and 15 of the housing 12 would be bolted and sealed together at their flanges. If additional heat transfer capacity is required, one or a plurality of said collars 35 would be installed by bolting the same between the top and bottom member 14 and 15. Upon assembly the inner surfaces of the top and bottom members and any flange that may be used substantially align to provide that the space 60 is defined as a substantially cylindrical in shape. Modules 70 are placed in the space 60 with the plate 71 of the lowest module resting on the annular rib 31 of the bottom member 14. It can be seen in FIG. 2 that this lowest module is space from the bottom wall 28 to provide a space therebetween for the heating elements 32. Other such modules 50 can then be vertically stacked one on top of another wherein the top of the rods or posts 72 of a lower module engage the base plate 71 of the next module thereabove to support the same. The base plate of each module 50 is circular in shape and has a diameter slightly smaller than the inner space 60 of a dimension to allow tubings from lower modules to pass between upper modules and the inner surfaces of the housing for connection to the tubing connectors 56 of the manifolds 50. The depending tube 46 is hollow and sealed and affixed to the center of the cover plate 45 by means such as welding or the like. The tube 46 is cylindrical in shape and dimensions to slide through the center hole 74 of base plate 71 of each module 70 in such a manner as to register and retain each module in equidistant spaced relation to the inner surfaces of the housing 12. The end portions 76 and 77 of the tubings 75 of each module 70 are connected to the manifolds 50 through use of the connectors 56 provided for that purpose. The end portions 76 of each module 70 would be connected to one of the manifolds 50 and the end portions 77 of each such same modules would be connected to the other manifold whereby fluid flow conduction would be effected from one manifold through each module and then to the other manifold.
On the top cover plate 45 is also mounted devices such as a pressure relief valve 80, a temperature and pressure gauge 81, and a pressure reducing valve 82, all of which operatively communicate with the inner space 60.
In operation the inner space 60 would be filled with a heat transfer fluid such as water. The heating elements 32 would be connected to an appropriate energy source and would include thermostatic controls (not shown) to regulate the heat transfer fluid in housing and thus control quantity of heat transferred by the modules. The fluid to be heated or cooled would be forced to flow, by means of a pump (not shown) or other equipment well known in the art, from one of the manifolds through the tubings of each heat transfer module used, and out through the other manifold. The fluid holes 73 in the base plate of each module 70 allow the heat transfer fluid in the housing to circulate about the tubings to effect efficient operation of the apparatus.
It can be seen that each of the modules 70 provide a very large heat transfer surface area through the use of large quantities of tubings wound and arranged in the manner heretofore described. Furthermore, the heat transfer capacities of the apparatus can be selectively increased to adapt to a plurality of uses merely by increasing the inner space of the housing 12 and adding thereto additional modules and tube connectors to the manifolds. Also, in the event that a module clogs or otherwise malfunction, the instant apparatus features that such a module could be easily and inexpensively replaced.
It will be appreciated that the embodiments of the invention have been chosen for the purposes of illustration and description herein is that preferred based upon requirements for achieving the objects of the invention and developing the utility thereof in a most desirable manner. It will be understood, that the particular structure and functional aspect emphasized herein are not intended to exclude but rather to suggest other such modifications and adaptions as fall within spirit and scope of the invention as hereinbefore described. | A fluid heat transfer apparatus having an expandable housing defining an enclosed interior space including fluid inlet and outlet manifolds communicating with said interior space and the exterior of said housing. The apparatus including heat transfer modules stackable in said interior space and each module comprising a flat supporting structure including upstanding elongated posts extending from one side thereof and lengths of flexible plastic tubing wound about the posts in basket-weave fashion with the ends of the tubing being connected to said inlet and outlet manifolds to provide conduction of fluid flow from said inlet to said outlet manifold. The housing being expandable to receive pluralities of said modules to selectively increase fluid heat transfer characteristic of said apparatus. The interior space being filled with a heat transfer fluid heated by a controlled heat producing medium such as electric heating elements. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional Application Ser. No. 61/054,459 filed May 19, 2008, entitled “Formation Fracturing Using Electromagnetic Radiation”.
BACKGROUND
[0002] When drilling a wellbore in the earth, a drilling fluid may be pumped down a drill string and through a drill bit attached to the end of the drill string. The drilling fluid may also flow through a bottom hole assembly (“BH2A”) located in the drill string above the bit. The BHA may house any number of tools or sensors for performing operations while the drill string is in the wellbore. The drilling fluid is generally used for lubrication and cooling of drill bit cutting surfaces while drilling, transportation of “cuttings” (pieces of formation dislodged by the cutting action of the teeth on a drill bit) to the surface, controlling formation pressure to prevent blowouts, maintaining well stability, suspending solids in the well, minimizing fluid loss into and stabilizing the formation through which the well is being drilled, fracturing the formation in the vicinity of the well, and displacing the fluid within the well with another fluid. When drilling is completed, the wellbore remains filled with the drilling fluid.
[0003] After drilling, casing is often placed in the wellbore to facilitate the production of oil and gas from the formation. The casing is a string of pipes that extends down the wellbore, through which the oil and gas will eventually be extracted.
[0004] The region between the casing and the wellbore itself is known as the casing annulus. To fill up the casing annulus and secure the casing in place, the casing is usually “cemented” in the wellbore. Before and even after casing is installed, the well may require wellbore treatment that is referred to as stimulation. Stimulation involves pumping stimulation fluids such as fracturing fluids, acid, cleaning chemicals, and/or proppant laden fluids into the formation to improve wellbore production. The stimulation fluids are pumped through the casing and then into the wellbore. If the casing is installed and more than one zone of interest of the formation is treated, tools may be run into the casing to isolate fluid flow at each zone.
[0005] In the case of hydraulic fracturing using fracturing fluids, the fluids are pumped at high pressure and rate into the reservoir interval to be treated, causing a vertical fracture to open. Proppant, such as grains of sand of a particular size, is mixed with the treatment fluid to keep the fracture open when the treatment is complete, thereby creating a plane of high-permeability sand through which fluids can flow.
[0006] Instead of stimulating the formation after installing casing, the well operator may choose to stimulate an uncased portion of a wellbore. To do so, the operator may run a liner extending from the surface into the uncased section of the wellbore with inflatable element packers to isolate the portions of the wellbore. Multiple packers allow the operator to isolate segments of the uncased portion of the wellbore so that each segment may be individually treated to concentrate and control fluid treatment along the wellbore. Generally, the packers are run for a wellbore treatment, but must be moved after each treatment if it is desired to isolate other segments of the well for treatment.
[0007] The tubing work string, which conveys the treatment fluid, may include a fracturing or jetting tool for delivering the treatment fluid to the cased or uncased borehole. Alternatively, the tubing string can include ports or openings for the fluid to pass into the wellbore and ultimately to the casing or the formation. Where more concentrated fluid treatment is desired in one position along the wellbore, a small number of larger ports may be used. Where it is desired to distribute treatment fluids over a greater area, a perforated tubing string may be used having a plurality of spaced apart perforations through its wall. The perforations can be distributed along the length of the tube or only at selected segments. The open area of each perforation can be pre-selected to control the volume of fluid passing from the tube during use.
[0008] While the introduction of stimulation fluids to the formation can increase formation fluid flow therein and production therefrom, such as by fracturing the formation to create additional fluid flow paths, further fluid flow enhancement will optimize production. Well stimulation deficiencies are overcome by the principles taught herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] For a more detailed description of the embodiments, reference will now be made to the following accompanying drawings:
[0010] FIG. 1 is a schematic, partial cross-section view of a fluid stimulation tool in an operating environment;
[0011] FIG. 2 is a cross-section view of a fluid pressurizing well stimulation assembly;
[0012] FIG. 3 is a cross-section of an apparatus for generating electromagnetic radiation in accordance with at least one of the embodiments;
[0013] FIG. 4 is a cross section at a perforation showing a schematic of an apparatus for generating electromagnetic radiation in accordance with another embodiment;
[0014] FIG. 5 is a cross-section of an apparatus for generating electromagnetic radiation in accordance with a further embodiment;
[0015] FIG. 6 is an example system for monitoring the position of magnetically permeable fluids in a formation; and
[0016] FIG. 7 is another example system for monitoring the position of magnetically permeable fluids in a formation.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0017] In the drawings and description that follows, like parts are marked throughout the specification and drawings with the same reference numerals. The drawing figures are not necessarily to scale. Certain features of the disclosure 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 disclosure 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.
[0018] In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ”. 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. Reference to up or down will be made for purposes of description with “up”, “upper”, “upwardly” or “upstream” meaning toward the surface of the well and with “down”, “lower”, “downwardly” or “downstream” meaning toward the terminal end of the well, regardless of the well bore orientation. In addition, in the discussion and claims that follow, it may be sometimes stated that certain components or elements are in fluid communication. By this it is meant that the components are constructed and interrelated such that a fluid could be communicated between them, as via a passageway, tube, or conduit. 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] FIG. 1 schematically depicts an exemplary operating environment for a fluid treatment or stimulation tool 100 . The tool 100 may be a pressurizing or hydrojetting tool. A drilling rig 110 is positioned on the earth's surface 105 and extends over and around a well bore 120 that penetrates a subterranean formation F for the purpose of recovering hydrocarbons. The well bore 120 may drilled into the subterranean formation F using conventional (or future) drilling techniques and may extend substantially vertically away from the surface 105 or may deviate at any angle from the surface 105 . In some instances, all or portions of the well bore 120 may be vertical, deviated, horizontal, and/or curved.
[0020] At least the upper portion of the well bore 120 may be lined with casing 125 that is cemented 127 into position against the formation F in a conventional manner. Alternatively, the operating environment for the fluid stimulation tool 100 includes an uncased well bore 120 . The drilling rig 110 includes a derrick 112 with a rig floor 114 through which a work string 118 , such as a cable, wireline, E-line, Z-line, jointed pipe, coiled tubing, or casing or liner string (should the well bore 120 be uncased), for example, extends downwardly from the drilling rig 110 into the well bore 120 . The work string 118 suspends a representative downhole fluid stimulation tool 100 to a predetermined depth within the well bore 120 to perform a specific operation, such as perforating the casing 125 , expanding a fluid path therethrough, or fracturing the formation F. The drilling rig 110 is conventional and therefore includes a motor driven winch and other associated equipment for extending the work string 118 into the well bore 120 to position the fluid stimulation tool 100 at the desired depth.
[0021] While the exemplary operating environment depicted in FIG. 1 refers to a stationary drilling rig 110 for lowering and setting the fluid stimulation tool 100 within a land-based well bore 120 , it is noted that mobile workover rigs, well servicing units, such as slick lines and e-lines, and the like, could also be used to lower the tool 100 into the well bore 120 . It should be understood that the fluid stimulation tool 100 may also be used in other operational environments, such as within an offshore well bore or a deviated or horizontal well bore. The exemplary tools and operating environment of FIG. 1 , and FIG. 2 below, can be used in conjunction with the various embodiments described herein.
[0022] Referring now to FIG. 2 , in another embodiment, the schematic fluid jetting tool 100 comprises an exemplary well completion assembly 200 . The well completion assembly 200 is disposed in the well bore 120 coupled to the surface 105 and extending down through the subterranean formation F. The completion assembly 200 includes a conduit 208 extending through at least a portion of the well bore 120 . The conduit 208 may or may not be cemented to the subterranean formation F. In some embodiments, the conduit 208 is a portion of a casing string coupled to the surface 105 by an upper casing string, represented schematically by work string 118 in FIG. 1 . Cement is flowed through an annulus 222 to attach the casing string to the well bore 120 . In some embodiments, the conduit 208 may be a liner that is coupled to a previous casing string. When uncemented, the conduit 208 may contain one or more permeable liners, or it may be a solid liner. As used herein, the term “permeable liner” includes, but is not limited to, screens, slots and preperforations. Those of ordinary skill in the art, with the benefit of this disclosure, will recognize whether the conduit 208 should be cemented or uncemented and whether conduit 208 should contain one or more permeable liners.
[0023] The conduit 208 includes one or more pressurized fluid apertures 210 . Fluid apertures 210 may be any size, for example, 0.75 inches in diameter. In some embodiments, the fluid apertures 210 are jet forming nozzles, wherein the diameter of the jet forming nozzles are reduced, for example, to 0.25 inches. The inclusion of jet forming nozzles 210 in the well completion assembly 200 adapts the assembly 200 for use in hydrojetting. In some embodiments, the fluid jet forming nozzles 210 may be longitudinally spaced along the conduit 208 such that when the conduit 208 is inserted into the well bore 120 , the fluid jet forming nozzles 210 will be adjacent to a local area of interest, e.g., zones 212 in the subterranean formation F. As used herein, the term “zone” simply refers to a portion of the formation and does not imply a particular geological strata or composition. Conduit 208 may have any number of fluid jet forming nozzles, configured in a variety of combinations along and around the conduit 208 .
[0024] Once the well bore 120 has been drilled and, if deemed necessary, cased, a fluid 214 may be pumped into the conduit 208 and through the fluid jet forming nozzles 210 to form fluid jets 216 . In one embodiment, the fluid 214 is pumped through the fluid jet forming nozzles 210 at a velocity sufficient for the fluid jets 216 to form perforation tunnels 218 . In one embodiment, after the perforation tunnels 218 are formed, the fluid 214 is pumped into the conduit 208 and through the fluid jet forming nozzles 210 at a pressure sufficient to form cracks or fractures 220 along the perforation tunnels 218 .
[0025] The composition of fluid 214 may be changed to enhance properties desirous for a given function, i.e., the composition of fluid 214 used during fracturing may be different than that used during perforating. In certain embodiments, an acidizing fluid may be injected into the formation F through the conduit 208 after the perforation tunnels 218 have been created, and shortly before (or during) the initiation of the cracks or fractures 220 . The acidizing fluid may etch the formation F along the cracks or fractures 220 , thereby widening them. In certain embodiments, the acidizing fluid may dissolve fines, which further may facilitate flow into the cracks or fractures 220 . In another embodiment, a proppant may be included in the fluid 214 being flowed into the cracks or fractures 220 , which proppant may prevent subsequent closure of the cracks or fractures 220 . The proppant may be fine or coarse. In yet another embodiment, the fluid 214 includes other erosive substances, such as sand, to form a slurry. Complete well treatment processes including a variety of fluids and fluid particulates may be understood with reference to Halliburton Energy Service's SURGIFRAC® and COBRAMAX®. The fluid component embodiments described above may be used in various combinations with each other and with the other embodiments disclosed herein.
[0026] Disclosed is a method and system for stimulating a formation using electromagnetic radiation. In at least some of the embodiments, in a formation that has been or is being stimulated or fractured, the flow of fluids is increased by heating the formation and the fluids via the coupling of electromagnetic radiation to materials that have been injected or “fracced” into the formation. In certain embodiments, an injectable or fracturing fluid is made magnetically permeable. The magnetically permeable fluid is injected into the formation, or in the case of fracturing operation, the fluid is injected with such pressure so as to fracture or split the formation. From the borehole, such as via the work string or the casing, electromagnetic radiation is directed to the magnetically permeable fluids. The magnetically permeable fluids are heated in response to the electromagnetic radiation. The produced heat also heats the surrounding formation and formation fluids. The heat reduces the viscosity of the formation fluids, thereby increasing the flow of the formation fluids. In at least some of the embodiments, a means is provided for monitoring the progression of stimulating or fraccing fluids into a formation.
[0027] In at least one embodiment, the fluidic material that is injected or fracced into the formation is magnetically permeable. In some embodiments, the fluidic material is made magnetically permeable by using a ferrofluid. In other embodiments, the fluidic material is made magnetically permeable by suspending magnetically permeable balls in the fluid. In certain embodiments, the fluidic material is made magnetically permeable by suspending magnetized balls in the fluid. In exemplary embodiments, the ball size is approximately 1 micron.
[0028] In at least one embodiment, a system is provided for fraccing magnetically permeable materials from the well bore into the formation, and to heat the formation and formation fluids by also sending from the well bore electromagnetic waves to the magnetically permeable materials. The reaction between the electromagnetic waves and the magnetically permeable materials produces heat that reduces viscosity and improves the fluid flow of formation fluids. In further embodiments, heating the fracced fluids and formation fluids causes reactions that can be used to locate the fracture.
[0029] In at least one embodiment, a system is provided for fraccing explosive balls into the formation. Application of heat in accordance with the principles herein causes the balls to explode to further increase the efficiency of the fraccing operation.
[0030] In at least one embodiment, a system is provided for fraccing chemicals into the formation. Application of heat in accordance with the principles herein causes the chemicals to release to deteriorate the formation and further increase the efficiency of the fraccing operation. For example, an acid may be released by heat into the formation to deteriorate the formation.
[0031] In at least one embodiment, a fluid is enhanced with a magnetically permeable material to form a magnetically permeable fluidic material. The magnetically permeable fluidic material is injected or fracced into a subterranean formation during stimulation or fracturing operations. In some embodiments, the magnetically permeable material is magnetized.
[0032] In some embodiments, the magnetically permeable material includes a ferrofluid. In other embodiments, the injectable fluid contains magnetically permeable objects or target particles. The objects or target particles may include magnetically permeable balls or magnetically permeable ellipsoids. The term “ball” or “balls” may refer to spheres, spheroids, ellipsoids, or any of these with a cavity. In some embodiments, the target objects are nanoparticles. In still further embodiments, the injectable fluid contains magnetized objects. In certain embodiments, the objects may be magnetized as they are being injected into the formation so as to avoid clumping. In some embodiments, the injectable magnetically permeable material comprises primarily the balls or magnetically permeable ellipsoids. In exemplary embodiments, the magnetically permeable objects or target particles comprise any ferromagnetic material with a Curie temperature above, or alternatively well above, the temperature to which the formation is to be heated for increased formation fluid flow.
[0033] Next, a low frequency electromagnetic wave generator disposed within the borehole, for example on a workstring or drillstring, radiates or emits energy toward the magnetically permeable target material. Referring to FIG. 3 , an apparatus 300 is coupled to a work string 318 and may be used to generate electromagnetic radiation directed into the formation F. In some embodiments, the apparatus 300 is disposed proximate the fluid treatment tools described herein. The apparatus 300 is disposed adjacent perforations 320 in a casing 325 . The apparatus 300 may include one or more electromagnets 314 and an electrical coil or solenoid 315 . In embodiments with a plurality of electromagnets, the electromagnets are driven so as to focus the time varying magnetic field onto the fracture in such a way as to launch surface waves. The apparatus 300 is powered and radiates electromagnetic waves which then couple with the magnetically permeable target material already disposed in the formation F, such as in the fluid 214 disposed in the perforation tunnels 218 in FIG. 2 . The electromagnetic energy is converted to heat energy in the magnetically permeable materials.
[0034] In some embodiments, heat is generated through hysteretic cycling the magnetically permeable materials. The electromagnetic waves are converted to heat energy as a result of cycling of the magnetic material around its permeability loop, wherein heat energy is created as the integral of the product of the electric field intensity and the magnetic flux density. In other embodiments, heat is generated through viscous drag of the magnetically permeable balls that are displaced by an oscillating magnetic field. At low frequencies, the oscillating magnetic field can induce flipping and spin of the magnetic particles in the magnetically permeable target material that emit heat into the formation via viscous drag.
[0035] Referring to FIG. 4 , a radial cross-section of a borehole including a casing 425 is shown. The casing includes a perforation 420 resulting from a stimulation or fracturing operation. An electromagnetic wave generating apparatus 400 , similar to the apparatus 300 , is disposed in the casing 420 adjacent the perforation 420 . The cross-sectional view shows an embodiment including two solenoids 415 , although other embodiments may include more solenoids. Included, but not shown, are bucking magnets above and below the solenoids 415 , similar to the permanent magnets 314 shown in FIG. 3 . The purpose of the bucking magnets is to polarize the casing to drive its AC permeability close to that of free space. Such a configuration of the casing due to the solenoids and the bucking magnets will further the desirable emission of electromagnetic waves from the wave generator apparatus 300 , 400 into the formation.
[0036] Still referring to FIG. 4 , the axis 418 along the borehole will be defined as the z-axis and will be positive when directed downward. Polar coordinates are used with the center of the borehole 418 as the radial reference and a line 430 from the center of the borehole 418 through the center of the perforation 420 as the zero-reference for the polar angle. The two solenoids 415 may be oriented along the z-axis, and may be represented by ideal dipole fields of certain frequencies and relative phases. In some embodiments, the relative phase between the dipoles may be a function of time. In some embodiments, the frequencies may be a function of time. In some embodiments, when sensing the depth of fracturing, the solenoids can be pulsed. In some embodiments, the dipoles need not be on opposite sides of the plane of initiation 422 of a fracture.
[0037] In some embodiments, the electromagnetic field can be put into the formation F by magnetically polarizing the casing into saturation with a permanent magnet or a DC electromagnet, in accordance with the embodiment described herein. Then, the oscillating the magnetic field is superimposed on the casing.
[0038] In other embodiments, and with reference to FIG. 5 , an apparatus 500 is conveyed by a work string 518 into an open, uncased borehole. The apparatus 500 includes a solenoid 515 or series of solenoids, and the permanent magnets are removed. The apparatus 500 and solenoid 515 are powered to direct electromagnetic waves toward the formation F and the magnetically permeable materials deposited therein, such as in fractures 520 . Thus, in some embodiments, the solenoid dipole fields can be disposed along the drill string or other work string 518 , or along the tool 500 axis.
[0039] Since a treatment fracture in the formation may be on the order of 1 mm wide at its inception, several meters high and tens to hundreds of meters long, the presence of the fracture can be conducive to propagation of surface electromagnetic waves. Even when the fraccing fluid is electrically insulating, the high relative permeability of the fluid created by the introduction of magnetically permeable materials can result in the speed of electromagnetic waves in the fluid being significantly less than the speed of electromagnetic waves in the surrounding formation. Such waves can be induced by placing an oscillating magnetic or electromagnetic dipole, as described herein, in an opening in the casing that has been provided to allow fraccing of the formation. The dipole axis is aligned with the long-axis of the opening in the casing. Alternatively, the openings are made directly in the uncased formation, as previously described, and the dipoles are disposed along the drill string, work string or tool axis.
[0040] In other embodiments, where the injectable fluids include high conductivity compared to the conductivity of the surrounding formation, such circumstances can be conducive to the launch of a surface wave.
[0041] By directing the magnetic field as described herein, the field can be made to skirt along the surface of the fracture. This is explained in terms of Maxwell's equations as follows:
[0000]
v
·
B
_
=
0
v
·
H
_
=
J
s
_
+
∂
∂
t
D
_
[0000] where is the magnetic flux density, is the magnetic field intensity, is a source current term, and is the displacement vector.
[0042] There will be no source terms in the region of interest, and the frequency are such that the time derivative of the displacement vector can be neglected. Therefore:
[0000] v− = 0
[0043] In words, the tangential component of is conserved across a boundary while the normal component of is conserved across the same boundary.
[0044] These boundary conditions imply that the larger the magnetic permeability of the fluid in the fracture can be made relative to the magnetic permeability of the formation, which is typically extremely close to the magnetic permeability of free space (4 p*10−7 H/m), the more the magnetic field will be aligned with the fracture plane itself.
[0045] At higher frequencies, where induction or propagation is considered, the resultant field is a surface wave. Energy propagated via a surface wave can interact directly with magnetic material along the fracture plane, deposited according to the principles described herein, causing it to heat up.
[0046] In some embodiments, when target objects are used as the magnetically permeable material, the objects may include a cavity into which a small amount of explosive charge is placed. The explosive charge is configured to detonate at a pre-defined temperature and pressure, and may be selected from any suitable material for downhole explosions. In further embodiments, acoustic waves emitted by such explosions will help promote the fraccing process and also provide acoustic emissions from which the propagation of the fraccing material can be monitored and the progress of the fracturing operation can otherwise be tracked.
[0047] In additional embodiments, the locations of the injected target objects or the fractures can be determined by the scattered return of magnetic or electromagnetic signals, and from a single wellbore. In one embodiment, a transmitter is powered to transmit a substantially constant frequency into the formation while monitoring for scattered electromagnetic signals at the same frequency using a separate antenna. The progression of fraccing is monitored by canceling a portion of the direct signal, and then tracking the change with time of the amplitude and phase of the received signal, where the phase is referenced to the transmitter. In a second embodiment, heating of the formation is periodically terminated and the electromagnetic wave signal for heating is replaced by an electromagnetic pulse. A receiver with source cancellation capabilities similar to those described with reference to the first embodiment receives echoes of the pulse. The times of the echoes, coupled with knowledge of the electrical properties of the formation and the electromagnetic properties of the stimulation fluid or the stimulation fluid with suspended magnetically permeable materials is used to determine the distance from which the echo was generated, and hence provide a lower limit to the depth of penetration of the fracturing process. In a third embodiment, a technique similar to nuclear magnetic resonance (NMR) echo measurements can also be used to generate a pulse and listen for a return. This is similar to the technique in the second embodiment above, but in addition to echoes, the exponential decay of the echoes is analyzed indicating, in those cases where balls are used as the magnetically permeable target objects, how much viscous drag is acting on the balls.
[0048] In some embodiments, monitoring the progression of the stimulation or fracturing process is achieved. In at least one embodiment shown in FIG. 6 , a monitoring system 600 is provided that can be embedded in the various embodiments described above. System 600 includes a reference that is provided from a signal that is injected into the formation from a wave form generator 602 and a transmitter 604 in accordance with the principles herein. In some embodiments, the signal is a sine wave at a fixed frequency and phase. The reference is provided as the reference signal to a lock-in amplifier 608 . A receiver 606 is also connected to the lock-in amplifier 608 . The lock-in amplifier 608 is coupled to a computer control 612 in some embodiments. The computer control 612 establishes the amplitude and phase of that component of the transmitted signal that interferes with the received signal. The output from the lock-in amplifier 608 is input into a differencing amplifier along with the output of the receiver 606 so as to subtract out the direct interference from the transmitter in the receiver. The output of the differencing amplifier is then connected to a separate lock-in amplifier 610 that is computer controlled. The output amplitude of the lock-in amplifier 610 is determined as a function of phase. Peaks in an amplitude/phase plot correspond to reflections from magnetic inhomogeneities in the fracturing fluid and thus trace the progression of the fracturing. The larger the phase, the further out the fraccing process has progressed.
[0049] In an alternative embodiment shown in FIG. 7 , a system 700 includes a waveform generator 702 connected to a transmitter 704 . In normal operation, the waveform generator 702 puts out a high power single frequency sine wave. However, when it is desired to determine how far the fraccing operation has penetrated the formation, the waveform generator 702 is switched by a switch 714 to a pulse generating mode. Under computer control 712 , a pulse is initiated, and upon termination of the pulse, a transmitting antenna 718 is disconnected from a power amplifier, snubbed, and a receiving antenna is switched by a switch 716 into a signal amplifier. In some embodiments, the receiving antenna is the transmitting antenna 718 . The computer 712 monitors the signal amplitude from the receiving antenna 718 and a receiver 706 for echoes of the transmitted pulse. In some embodiments, monitoring is executed by magnetic resonance signal processing.
[0050] 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 disclosure. 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. | A method of treating a subterranean formation includes injecting a magnetically permeable material into the formation and energizing the magnetically permeable material using electromagnetic radiation. The magnetically permeable material reacts to the electromagnetic radiation by producing heat. In some embodiments, a fracturing fluid is made magnetically permeable, injected into the formation to fracture the formation, and heated in response to electromagnetic radiation applied to the magnetically permeable material. In some embodiments, electromagnetically heated material is caused to explode. In some embodiments, the magnetically permeable material is tracked or monitored for fluid or fracture propagation. A system includes a fluid treatment tool ( 100, 200 ) disposed on a tubing string ( 118, 208, 318, 518 ) for injecting magnetically permeable material and an electromagnetic wave generator ( 300, 400, 500, 602, 702 ) disposed on the tubing string proximate the fluid treatment apparatus for applying electromagnetic radiation to the magnetically permeable material. | 4 |
GOVERNMENTAL RIGHTS
The U.S. Government has a license in this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as provided for in Contract No. SWR-94-RY-13 awarded by United States Air Force Research Laboratory through Synectics Corporation.
RELATED PATENT APPLICATION
This application claims the benefit of U.S. Provisional Application No. 60/091,007, filed Jun. 25, 1998 and entitled "Hand-Held Environmental Heat Stress Monitor".
TECHNICAL FIELD OF THE INVENTION
The present invention relates generally to the field of data acquisition systems, and particularly to a portable environmental data monitor that can be used to monitor environmental conditions affecting workers.
BACKGROUND OF THE INVENTION
In occupations or activities which occur under extreme environmental conditions, such as high heat and/or humidity, it is often necessary to monitor the environment to determine if working conditions are safe. The environmental parameters which are typically measured are dry bulb, wet bulb, and black globe temperature. From these three parameters, the wet bulb globe temperature (WBGT) index can be calculated. The WBGT index is an industry standard metric for assessing susceptibility to heat strain. There are a number of commercially available devices which calculate the WBGT index, and some devices suggest a maximum safe work time based on this result.
In the field of environmental monitoring it is desirable to have a portable measurement device so that measurements can easily be taken in different locations. Previous monitoring devices have sensors that are mounted to a tripod and attached to a separate display unit by a cable. This can limit their use to areas which can physically accommodate such equipment. Other devices use individual sensors which directly attach to the display unit, and are removed and placed in a protective case for storage.
SUMMARY OF THE INVENTION
One aspect of the invention is a portable stress monitor for monitoring conditions under which physiological activity is occurring. The conditions monitored may be environmental, such as ambient temperature and humidity, or physiological, such as heart rate or body temperature. A main housing has a front piece and a rear cover. A curved cradle at the surface of the main body holds a sensor module. The sensor module rests in the curved cradle, and has a generally cylindrical shape such that it is rotatable within the curved cradle from a sensor deployed position to a sensor storage position. One or more sensors are attached to the sensor module, each sensor mounted on a mast, such that the sensors extend outwardly from the main body when the sensor module is in the deployed position and rest in the main body when the sensor module is in the storage position. A main electronics circuit is contained within the main body, and is operable to process data acquired by the sensors. A sensor electronics circuit is contained within the sensor module, and is operable to perform sensor-related functions, such as signal conditioning and A/D conversion. A display is attached to the outer surface of the main body for providing read out information, and a keypad receives input from the user.
An advantage of the heat/stress monitor is that it is conveniently portable and provides protection for the sensors when the device is not in use. It does not require any assembly for use or storage. It is capable of determining work/rest cycles and water requirements, to prevent workers from having unhealthy reactions to environmental conditions. The device acquires data from various sensors, including wind speed, and this data is incorporated into a predictive model.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective front view of the stress monitor, with the sensor module in the "deployed" position.
FIG. 2 is a perspective rear view of the stress monitor of FIG. 1.
FIG. 3 is a perspective view of the sensor module of FIGS. 1 and 2.
FIG. 4 is a perspective front view of the assembled main body of FIGS. 1 and 2.
FIG. 5 is a block diagram of the main electronics contained within the main body.
FIG. 6 is a block diagram of the sensor electronics contained within the sensor module.
DETAILED DESCRIPTION OF THE INVENTION
Housing and Structure
FIGS. 1 and 2 are exploded front and rear views of an environmental data monitor 10 in accordance with the invention, respectively. In the example of this description, monitor 10 is adapted for use in monitoring environmental conditions associated with heat stress, and has sensors and programming appropriate for that application. However, monitor 10 could be easily adapted for monitoring other environmental conditions, such as cold, air quality, and noise. Appropriate sensors could be added or substituted for those described herein.
Structurally, monitor 10 is comprised of a main body 10a and a sensor module 10b. In FIGS. 1 and 2, sensor module 10b is in the "deployed" position, positioned for operation of its sensors. A hinged rear cover 22 of main body 10a is open, but could be closed to protect the sensors of sensor module 10b during use.
The main body 10a of monitor 10 has a front piece 11, a keypad 12, a CPU board 13, with a midpiece 14, a battery cover 21, a rear cover 22 with latch 22a, an endpiece 15, and a sensor module connector 16.
CPU board 13 is located between front piece 11 and midpiece 14. On its front side, CPU board 13 contains the graphics display and traces for keypad 12. Other electronic components are on the rear side. The electrical circuitry of CPU board 13 is explained below in connection with FIG. 5.
Midpiece 14 has a curved sensor bed 14c at its top end. As explained below, sensor bed 14c, such that sensor module 10b may rotate at least 180 degrees. FIG. 2 illustrates this rotation.
Sensor module connector 16 attaches to midpiece 14, such as by screws. The attachment is after its wiring harness 16a is threaded to CPU board 13. Sensor module connector 16 has alignment holes 16b, which prevent a rotating connector 32 on sensor module 10b from making contact with sensor module connector 16 until it is properly aligned.
A battery compartment 14a in midpiece 14 contains four AA-size batteries wired in series to provide a nominal six volt DC power source. A battery cover 21 is a friction fit rubber cover, which seals the battery compartment 14a when rear cover 22 is closed.
The `+` and `-` terminals of the batteries protrude through the battery compartment 14a and a wiring harness connects them to CPU board 13. An external connector 14b also attaches to CPU board 13 with a wiring harness. All wiring harnesses are of sufficient length to allow CPU board 13 to be removed from the midpiece 14 and manipulated for repair.
Once all wiring harnesses are attached to the CPU board 13, keypad 12 is placed into the front piece 11. Keypad 12 is made from conductive rubber and forms a weatherproof seal where it comes in contact with the midpiece 14. The front piece 11 attaches to the midpiece 14 by screws that enter through the rear of the midpiece 14.
Rear cover 22 and midpiece 14 have a hinge-type attachment 22a along their bottom edges. A sliding latch 22b is attached to the rear cover 22 by compression springs, which hold latch 22b in its latched position. The rear cover 22 is opened by operating the latch 22b. A compressible gasket may be attached to the perimeter of the rear cover 22 to serve as a seal and to allow the rear cover 22 to spring out from the midpiece 14 when unlatched.
Sensor module 10b is cylindrical in shape, with a rotating connector 32 at one end and a rotation knob 17 at the other. Connector 32 permits sensor module 10b to rotate within the sensor bed 14c of midpiece 14.
When monitor 10 is in the "storage" position (not shown), sensor module 10b is rotated approximately 180 degrees from the "deployed" position illustrated in FIGS. 1 and 2. This permits its sensors to be placed under rear cover 22, when cover 22 is hinged shut.
For assembly, sensor module 10b is slid into position on the main body 10a with the sensors in their deployed position and the rear cover 22 unlatched. Once the sensor module 10b is seated properly, endpiece 15 is positioned over the knob 17 and attached to the midpiece 14 with screws. For the storage position of monitor 10, the sensors can be rotated into the sensor cavities in the midpiece 14, and the rear cover 22 can be closed.
FIG. 3 illustrates sensor module 10b in further detail. A feature of the invention is that monitor 10 easily permits sensor modules 10b to be interchanged and used with the main body 10a. All signal processing and calibration information is stored in the sensor module 10b, with a digital control interface to the main body 10a.
Sensor module 10b is comprised of a cylindrical housing 31, having an upper half 31a and a lower half 31b. The two parts of housing 31 are screwed together, ultrasonically welded, glued, or otherwise attached.
The upper half 31a provides a platform for various sensors. In the embodiment of FIG. 3, sensor module 10b has a dry bulb sensor 33, relative humidity sensor 34, black globe sensor 35, and wind speed sensor 36. Thus, monitor 10 has three thermistors: dry bulb, black globe, and wind speed. Wet bulb globe temperature (WBGT) is obtained by measuring relative humidity with sensor 34 and the dry bulb temperature with sensor 33 and using a mathematical formula to determine wet bulb temperature. Alternatively, a dedicated wet bulb sensor could be used.
The dry bulb sensor 33, globe sensor 35, and wind speed sensor 36 are each located on a mast 33a, 35a, and 36a. These masts protrude perpendicular to the face of the cylindrical housing 31. A removable light-shadowing housing 34b covers the humidity sensor 34.
Sensor PCB (printed circuit board) 38 is contained within sensor housing 31, between upper half 31a and the lower half 31b. Sensor PCB 38 contains the sensor electronics 50, described below in connection with FIG. 6.
An atmospheric pressure sensor 37 is located inside sensor module 10b. In the embodiment of FIG. 3, pressure sensor 37 is mounted on the underside of sensor PCB 38.
At one end of sensor module 10b is a rotating connector 32, which has a groove on its edge to allow it to rotate within cylindrical housing 31. The upper half 31a and lower half 31b of housing 31 have mating ridges. An O-ring 32b is slipped onto the cylindrical housing 31.
When rotating connector 32 is plugged into fixed connector 16, there is a seated rotating connection between sensor module 10b and main body 10a. As a result of the rotating connector 32 and O-ring 32b, sensor module 10b is sealed from the effects of the environment. Alignment pins 32c provide strain relief for the connector pins and sockets when sensor module 10b is rotated.
Referring again to FIGS. 1 and 2, main body 10a has cavities into which the various sensors fit when sensor module 10b is rotated approximately 180 degrees into a "storage" position. The arrow is FIG. 2 illustrates the direction of rotation. The hinged rear cover 22 is closed to protect the sensors when they are stored. Cover 22 can also be re-closed after it is opened and the sensors are deployed into their "operate" position.
As stated above in connection with FIGS. 1 and 2, and as also illustrated in FIG. 4, main body 10a has an endpiece 15. The endpiece 15 fits over a rotation knob 17 on sensor module 10b. It attaches to main body 10a and holds sensor module 10b in place. Endpiece 15 may be removed to permit sensor module 10b to be removed, such as for replacement or repair.
Discrete wires 32d from the rotating connector 32 are attached to the sensor PCB 38. When the assembled sensor module 10b is attached to the main body 10a, rotating connector 32 is held in a fixed position with respect to the main body 10a by a mated connection. When the knob 17 is used to rotate the sensor module 10b, the upper half 31a, lower half 31b, and sensor PCB 38 rotate around the rotating connector 32.
Electronics Circuitry
FIGS. 5 and 6 are functional block diagrams of the electronics of the present invention. FIG. 5 illustrates the main electronics 50 contained within main body 10a. FIG. 6 illustrates the sensor electronics 60 contained within sensor module 10b. A serial digital interface 50a provides the electrical connection between main electronics 50 and sensor electronics 60.
Main electronics 50 has a central processing unit (CPU) 51a with a peripheral system device (PSD) 51b. The PSD 51b provides address decode logic, additional static RAM and digital I/O ports, and a bootloader routine for the flash memory 53. A static RAM 54 provides both scratchpad memory and nonvolatile storage for data logging applications. RAM 54 is backed up by a lithium battery 55. The lithium battery 55 also maintains a real time clock 56, which can be used for timestamping logged data. The graphics display 57 is addressed by the CPU 51a and uses a digital potentiometer 57a for contrast adjustment. The backlight control for the graphics display 57 is controlled by the PSD 51b. The keypad 52 is interfaced to digital I/O ports on the PSD 51b.
The system is powered by a DC power source, which may be either user-replaceable batteries placed in compartment 14a or an external power source.
An RS-232 converter 58 converts the TTL-level signals on the CPU board 10 to RS-232 signals for the external serial connector.
The main body 10a of monitor 10 functions as an intelligent user interface containing the graphics display, keypad, power supply CPU and associated digital electronics. The main body also contains an external port which can be used to supply external power and communicate with a personal computer through an RS-232 interface. Software can also be loaded into the device through this port and stored in flash memory.
The connection between main body 10a and sensor module 10b provides battery power, supply voltage, and a digital control interface. All sensing electronics and storage for calibration and sensor identification information is located on the sensor module 10b. This allows sensor module 10b to be calibrated independently of the main body 10a and to produce the same results when attached to any main body 10a.
The design of monitor 10 permits different types of sensor modules to be used with the main body, whereby the sensor module 10b can be queried by the main body 10a to determine the type of each sensor and its calibration information. The application software in the main body 10a can then configure itself to acquire and display the sensor data. Alternatively, a dedicated application for a given type of sensor module 10b can be loaded into the flash memory 53 through an external port.
Referring to FIG. 6, the sensor electronics 60 contains signal conditioning circuitry for the dry bulb sensor 33, the black globe sensor 35, the relative humidity sensor 34, the wind speed sensor 36, and the pressure sensor 37.
The analog voltages produced by the various sensors are digitized by the A/D converter 62. A D/A converter 63 is used to provide current to the wind speed sensor 36 and to heat it to a constant temperature above the dry bulb temperature. The amount of power required to heat the wind speed sensor 36 is related to the wind speed.
An EEPROM 64 stores all calibration information related to the sensors 33-37. The calibration information may include various calibration constants, unique to each sensor. In general, all circuitry and programming unique to any sensor is placed on sensor module 10b rather than in main body 10a so that sensor modules having the same, or different, sensors may be easily interchanged.
A/D converter 62, D/A converter 63, and EEPROM 64 all share the same serial control lines on the interface 50a, with the exception of their chip select signals. This minimizes the number of connections that need to be made between the CPU electronics 50 and the sensor electronics 60.
Voltage regulator 65 produces a stepped-up voltage for the sensor electronics 60. The battery voltage is delivered to the sensor electronics 60, where it is input to a battery monitor 66, whose output signal is converted to digital form by A/D converter 62, and delivered back to the CPU electronics 60. The location of battery monitor 66 in sensor electronics 60 is merely for convenience of using A/D converter 62, and in other embodiments, battery monitor 66 could be part of CPU electronics 50.
Data Processing
CPU 51a can be programmed to execute various environmental data processing algorithms. For example, when monitor 10 is used to heat stress monitoring, known heat strain models can be used. For example, a model based on the WBGT index may be used.
A feature of the invention is the incorporation of wind speed into heat strain models. As a result, the effect of evaporative cooling is considered in determining weather effects.
Measured parameter data acquired from sensor module 10b can be combined with user input parameter data acquired via keypad 12 or other means. Such parameters might include, clothing type, work type, or work rate.
As stated above, monitor 10 can be easily adapted for use with other or additional sensors. For example, one sensor might be an air quality sensor, such as one that measures oxygen content or one or more pollutants. Or, a sensor might measure noise. Other sensors might measure the user's physiological conditions, such as heart rate, blood pressure, or body temperature (skin or core). For physiological monitoring, sensors such as used by athletes could be used--for example, a heart rate monitor that attaches to the user's finger and provides input to the A/D converter 62 of sensor module 10b or directly to the processor 51 of the main body 10a.
Other Embodiments
Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternative embodiments, will be apparent to persons skilled in the art. It is, therefore, contemplated that the appended claims will cover all modifications that fall within the true scope of the invention. | A hand-held monitor (10) for monitoring environmental or physiological conditions affecting the user. The monitor (10) has a main housing (10a) and a sensor module (10b). The sensor module (10b) has a plurality of sensors (33-36) extending from it. The sensor module (10b) is generally cylindrical in shape and rests in a curved cradle (14c) of the main housing (10a). This permits the sensor module (10b) to rotate between a position in which the sensors are deployed and extend outwardly from the main housing (10a), and a position in which the sensors rest in the main housing (10a). The main housing (10a) contains processor-based electronics circuitry (50) for processing the data acquired by the sensors. The sensor module (10b) contains sensor electronics circuitry (60), including all circuitry unique to the sensors, and is easily detachable from the main housing (10a). This permits sensor modules having the same or different sensors to be easily interchanged. | 6 |
BACKGROUND OF THE INVENTION
The present subject matter relates generally to interlocking siding. More specifically, the present invention relates to an interlocking siding design that provides an external profile though which there are no perforations exposed after installation.
Siding provides an exterior barrier for walls and surfaces in order to protect the under layers from the effects of weather and moisture. Siding can also contribute to the aesthetic value of a house or structure, by adding a tasteful color or texture to the surface. Aesthetic value also can affect the property value of a structure or building, so the appearance of the siding is important. Siding is usually affixed to the outside of a building in panels in an overlapping assembly. Since the siding is traditionally applied in segments, it allows for the expansion and contraction of the building materials that is caused by various temperatures and humidity. Siding can be composed of many different materials including but not limited to wood, vinyl, metal, cement, or plastic.
Certain kinds of siding can be very labor intensive to manufacture and install. Some siding is made of expensive materials, which increases the total cost of the installation and purchase of the siding. Installing siding can be labor intensive because it must be installed in such a way that seals the outside layer from the elements. Also, siding is only typically installed during moderate weather, thus limiting the possibility of installation in some regions with harsh winters.
During installation, constant attention must be given to the distance of overlap of the siding segments, and the placement, to make sure the segments are appropriately spaced. The placement of the siding is important to create a uniform pattern on the outer surface thus giving the attractive aesthetic appearance in addition to the functional barrier.
Accordingly, a need exists for an interlocking siding product and method as described and claimed herein.
BRIEF SUMMARY OF THE INVENTION
In order to meet the ever growing need to provide an interlocking siding that is easy to assemble, install and provides an effective barrier and is aesthetically appealing, the present subject matter discloses a siding with a unique structure. The siding panel includes an indicia for a fastener placement combined with a unique mating potion geometry. The top edge of the siding has a front face for facing outside towards the elements and a rear face for facing the internal structure. The panel includes a top front edge that extends above the top rear edge. The lower edge of the panel includes three sections adapted for mating to the top edge of an adjacent panel. The front face of the lower edge extends the lowest, the middle section is recessed, and the rear section falls between the lowest extension and the recessed portion. A barrier may be formed using identical panels, making installation easy and maintenance free.
When two or more panels are mated together, they form a barrier to moisture and other elements. In addition to forming a barrier and keeping out moisture, the mating mechanism facilitates a mistake-free assembly. When mated, the front face of the lower edge of an upper panel extends far enough down the front face of the lower panel to cover the indicia for fastener placement located on the front face of the lower panel. Therefore when assembled, all of the fasteners used to secure the panels to the internal structure will be hidden, thus providing an effective barrier that is visually pleasing. No evidence of the fasteners is left to be seen at an outward view, they will all be hidden underneath the overlapping structure of the siding.
The front face of the panel may include a fastener notch. The notch allows the fastener head to sit inside the body of the siding panel rather than protrude beyond the front face. Also, the notch provides indicia for fastener placement such that an installer may be assured the fasteners are properly located to be covered by the adjacent overlapping panel, thus making it easier to assemble and mistake proof.
In some embodiments the body of the interlocking siding may be made of recycled or waste materials. Recycled or waste materials may be cost effective and may also reduce placement in landfills, thus helping the environment. For example, the panels may be formed from a single or multilayer extrusion process. In a multilayer extrusion, the one or more inner layers may include recycled or waste products, while the outer layer may be from another material entirely.
In some embodiments the body and rear face of the interlocking siding panels may incorporate various patterns and cut outs to decrease the amount of material needed to create the siding. This decreased amount of material will keep the overall cost of materials down thus making the siding more affordable. Decreasing the amount of material will also lessen the weight of the siding and made the product more flexible, which will also make the installation easier.
The method of installation is simple and easy. The first piece to fit at the base of the structure may be a starter strip. The starter strip has a flat bottom and a two tier top face for mating with the bottom edge of the adjacent panel. After the starter strip is fixed where indicated, the installer may fit the first piece of panel siding onto the starter strip, the bottom edge of the panel overlapping and interlocking the top edge of the starter strip. Once the first panel is secured to the starter strip, it may be fastened into the structure where indicated. All subsequent siding panels will fit accordingly in a uniform pattern, using this same method without the need for measuring or use of a spacer to assure consistency, saving time and money. Since all of the siding panels are identical, it will be easy to stack the panels together without needing to differentiate between the panels. The starting strip and unvarying design of siding will allow for a mistake proof installation that can be accomplished by a non-expert.
In one example, an interlocking panel system includes: a first panel including: a front face including a fastener notch; a rear face; a top edge, wherein the top edge includes a top front edge that extends above a top rear edge; and a lower edge, wherein the lower edge includes a front edge that extends below a bottom middle edge and a bottom rear edge, further wherein the bottom rear edge extends below the bottom middle edge; and a second panel including: a front face including a fastener notch; a rear face; a top edge, wherein the top edge includes a top front edge that extends above a top rear edge; and a lower edge, wherein the lower edge includes a front edge that extends below a bottom middle edge and a bottom rear edge, further wherein the bottom rear edge extends below the bottom middle edge; wherein, when the lower edge of the first panel is placed onto the top edge of the second panel, the bottom front edge of the first panel covers the fastener notch of the second panel.
The fastener notch may be V shaped, U shaped, or other. In some embodiments, when the lower edge of the first panel is placed onto the top edge of the second panel, the bottom rear edge of the first panel abuts the top rear edge of the second panel. Similarly, in some embodiments, when the lower edge of the first panel is placed onto the top edge of the second panel, the bottom middle edge of the first panel abuts the top front edge of the second panel. In some versions, the rear face of the first panel includes a plurality of notches.
In some examples, the interlocking panel system includes a starter strip, wherein the starter strip includes a front face including a fastener notch, a rear face, a top edge wherein the top edge includes a top front edge that extends above a top rear edge, and a base edge including a drip channel, wherein when the lower edge of the second panel is placed onto the top edge of the starter strip, the bottom front edge of the second panel covers the fastener notch of the starter strip. In such an embodiment, when the lower edge of the second panel is placed onto the top edge of the starter strip, the bottom rear edge of the second panel abuts the top rear edge of the starter strip and, when the lower edge of the second panel is placed onto the top edge of the starter strip, the bottom middle edge of the second panel abuts the top front edge of the starter strip.
In some versions of the interlocking panel system, the first panel is a multilayer construction wherein an inner layer is made from waste material.
An advantage of the siding is that it is interlocking.
Another advantage of the siding is it is easy to install
A further advantage of the siding is that it provides a superior barrier surface.
Yet another advantage of the siding is there are no exposed fasteners.
Yet another advantage of the siding is all panels are the same size and consistent color.
Another advantage of the siding is maintenance free and can be installed in any climate condition.
Additional objects, advantages and novel features of the examples will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following description and the accompanying drawings or may be learned by production or operation of the examples. The objects and advantages of the concepts may be realized and attained by means of the methodologies, instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements.
FIG. 1 is a side view of an interlocking panel.
FIG. 2 is a side view of an alternative design for an interlocking panel.
FIG. 3 is a side view of another alternative design for an interlocking panel.
FIG. 4 is a side view of another alternative design for an interlocking panel.
FIG. 5 is a side view of another alternative design for an interlocking panel.
FIG. 6 is a perspective view of a body structure and the finish surface of an interlocking panel with multi-lamination.
FIG. 7 is a side view of a starter strip.
FIG. 8 is a side view of an alternative design of a starter strip.
FIG. 9 is a side view of an arrangement of interlocking panels beginning with the starter strip.
FIG. 10 is a flow chart depicting a method of installing interlocking panels and starter strip.
FIG. 11 a illustrates an example of V shaped fastener notch that may be used in the interlocking panel shown in FIG. 1 .
FIG. 11 b illustrates an example of U shaped fastener notch that may be used in the interlocking panel shown in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates an example of an interlocking panel 10 . As shown in FIG. 1 , the interlocking panel includes a body 12 with a front face 14 and a rear face 16 . The front face 14 is the exterior of the panel 10 , which faces the elements, and the rear face 16 will be the interior of the panel 10 that faces the wall of the house, stud, sheathing, or other structure. The interlocking panel 10 includes a top edge 18 and a lower edge 20 . The top edge 18 includes a top front edge 17 that extends above a top rear edge 19 . The configuration of the top edge 18 allows it to connect to the lower edge 20 when the interlocking panels 10 are stacked adjacently. The lower edge 20 includes a bottom front edge 21 extending below a recessed bottom middle edge 23 and bottom rear edge 25 , which falls between the bottom front edge 21 and the bottom middle edge 23 . Accordingly, the top edge 18 connects by interlocking to the lower edge 20 when stacked adjacently.
As shown in FIG. 1 , the interlocking panel 10 includes a fastener notch 22 . The fastener notch 22 provides placement indicia to indicate where the fasteners should be placed. When the lower edge 20 is placed on top of a corresponding top edge 18 of another plank, the front face 14 of the lower edge 20 will cover the fastener notch 22 , thus covering any evidence of an opening through the panel 10 and preserving the integrity of the barrier. The fastener notch 22 may be routed in a “V” or “U” so the screw head sits slightly recessed when installed, thereby allowing the next siding panel 10 to fit together easily without catching on the screw head. In FIG. 1 , the front face of the lower edge 20 extends down a considerable amount, but it is contemplated that this distance may be more or less as long as it still covers the fastener notch 22 of the next panel. Examples of fastener notches 22 are shown in FIG. 11 a and FIG. 11 b . However, other fastener notch 22 configurations may be used.
The interlocking panel 10 in FIG. 1 can be made out of many different materials such as wood, plastic, cement, or vinyl. It is suggested that the panels be composed of a waste material, or recycled material, to contribute to conservation and keep costs down. However, it is contemplated that in other embodiments, the interlocking panel 10 can be made of any material that is capable of providing a barrier from the elements.
FIG. 2 is an alternative design, very similar to FIG. 1 where the front face 14 includes a two-tiered profile for aesthetic value. The front face 14 includes a ridge 27 giving the panel 10 additional texture. In FIG. 2 there is one ridge 27 on the front face 14 , but it is contemplated that in other embodiments, there may be any variation of ridges 27 .
FIG. 3 is another design of an interlocking panel. This variation includes a number of notches 29 on the rear face 16 to conserve the amount of material used to form the panel 10 . Also, FIG. 3 contains an outside layer 24 that may be composed of a more expensive, protective, and aesthetically pleasing material, because the outside layer 24 is a thin high quality layer. Then the rest of the body 12 can be composed of a more cost efficient material.
As shown in FIG. 3 , the top edge 18 and lower edge 20 are shaped differently than in the example shown in FIG. 1 . In FIG. 1 the top edge 18 and lower edge 20 include squared corners to rest against each other, whereas in FIG. 3 the top edge 18 and lower edge 20 include an interlocking shape. Accordingly, the top edge 18 connects by interlocking to the lower edge 20 when stacked adjacently.
FIG. 4 is yet another variation of an interlocking panel 10 that is very similar to FIG. 3 . The difference between FIG. 4 and FIG. 3 is the top edge 18 and lower edge 20 profiles.
FIG. 5 is another variation of an interlocking panel 10 in which there are several cut outs 31 in the body 12 , thus saving on materials, and providing an alternative design. In FIG. 5 there are two cut outs in a generally oval shape, but the cut outs may be in any shape, and can be in various numbers.
FIG. 6 shows further how in the inner portion of the panel 10 may be composed of a different material than the outer portion. As discussed previously, the inner material may be composed of a waste material, recycled material, or any material that is more economical. The multilayer panel 10 in FIG. 6 may be formed using a multilayer extrusion process.
FIG. 7 shows the starter strip 30 that may be used as the base upon which adjacent panels 10 may be stacked. The starter strip 30 contains a body 32 with a front face 34 and a rear face 36 , similar to the panel 10 . The starter strip 30 is smaller than the panels, and is sturdy enough to stabilize the first panel, so the others may follow. The starter strip 30 also contains a top edge 38 and a base edge 40 . The top edge 38 will connect to the lower edge 20 or one of the first siding panels to connect to the starter strip 30 . The base edge 40 will be placed at the base of the house or structure. The base edge 40 also provides a drip channel 42 to prevent water from returning to the inner structure. The top edge 38 will be shaped to correspond with the design of the panels 10 .
FIG. 8 also shows a starter strip 30 that is very similar to FIG. 7 . The base edge 40 in FIG. 8 is shaped slightly different than the base edge 40 in FIG. 7 , in that the drip channel 42 is in a different position. It is understood that the drip channel 42 in the base edge 40 may be in any location along the base edge 40 , left, right or center.
As further shown in FIGS. 7 and 8 , the front face 34 may take on any of numerous profiles. Accordingly, it is contemplated that the starter strip 30 may be any shape, as long as it is adapted to integrate with the siding panels 10 .
FIG. 9 demonstrates how the panels 10 would fit together to form the siding, starting with the starter strip 30 at the bottom. The starter strip 30 would sit at the base of the structure, and the panels 10 would stack on top of the starter strip 30 .
FIG. 10 depicts the method 110 of assembling the siding panels. The first step 120 is mounting the starter strip at the base of the structure. While the presently preferred method of mounting the starter strip at the base of the structure is by screwing the starter strip to the structure, in alternative embodiments, the starter strip may be mounted by nailing, gluing or otherwise securing the starter strip to the structure. The second step 130 is aligning the first siding panel with the starter strip and locking them in place. The starter strip and the siding panel have the corresponding notches that are meant to be locked in place and provide an effective moisture barrier. It is obvious when the starter strip and the panel are locked in place because they will lock or snap in place and fit together easily. The next step 140 is screwing the first siding panel to the structure. It is apparent to place the screws in the screw fastener notches that are indicated on the siding panels. Again, in alternate embodiments, the siding panels may be secured via other means. Once the siding panel is screwed to the structure, it is secure. The last step 150 is aligning and mounting the subsequent siding panels. The subsequent siding panels are secured just as the first siding panel was secured to the siding strip. They snap or lock into place and then are screwed to the wall or stud. In instances in which the panels do not span the width of a structure, the seams of the panels should be staggered (not aligned) to help to prevent water penetration through the siding to the substructure and butt joints (for example, 45% angle butt joints) may be provided along the seams, whereby the siding panels may be glued, caulked or otherwise adhered or sealed.
It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. | An interlocking panel system including: a pair of panels, each including: a front face including a fastener notch; a rear face; a top edge, wherein the top edge includes a top front edge that extends above a top rear edge; and a lower edge, wherein the lower edge includes a front edge that extends below a bottom middle edge and a bottom rear edge, further wherein the bottom rear edge extends below the bottom middle edge; wherein, when the lower edge of the first panel is placed onto the top edge of the second panel, the bottom front edge of the first panel covers the fastener notch of the second panel. | 4 |
BACKGROUND
The present invention relates to wiring in semiconductor structures and, more particularly, relates to dual-metal self-aligned wires and vias.
Current practice in back end of the wiring processing is to use self-aligned schemes, where metal troughs are defined in an interlayer dielectric layer or in a hard mask, and vias are printed and etched in such a way that only the union of the metal trough and the via shape form vias down to the previous metal wiring level. Reliable printing of small vias, however, is a major issue, so current practice is to design a bar shape to increase areal pattern printability, and where this bar crosses the union with the metal trough is the resulting via. However, if this bar overlaps onto an adjacent metal trough, then that union will result in an undesirable via and possibly short that adjacent line to underlying wires.
BRIEF SUMMARY
The various advantages and purposes of the exemplary embodiments as described above and hereafter are achieved by providing, according to a first aspect of the exemplary embodiments, a method of forming a semiconductor structure including: forming first conductive spacers on a semiconductor substrate; forming second conductive spacers with respect to the first conductive spacers, at least one of the second conductive spacers adjacent to and in contact with each of the first conductive spacers to form combined conductive spacers; recessing the second conductive spacers with respect to the first conductive spacers so that the first conductive spacers extend beyond the second conductive spacers; depositing an interlayer dielectric (ILD) to cover the first and second spacers except for an exposed edge of the first conductive spacers; patterning the exposed edges of the first conductive spacers to recess the edges of the first conductive spacers in predetermined locations to form recesses with respect to the ILD and unrecessed edges with respect to the ILD; and filling the recesses with an insulating material to leave the unrecessed edges of the first conductive spacers as vias to subsequent wiring features.
According to a second aspect of the exemplary embodiments, there is provided a method of forming a semiconductor structure including: forming mandrels on a semiconductor substrate; depositing a first conductive layer on the mandrels so as to cover the mandrels; depositing a second conductive layer over the first conductive layer; removing a portion of the second conductive layer and a portion of the first conductive layer to form first conductive spacers comprising the first conductive layer and second conductive spacers comprising the second conductive layer, at least one of the second conductive spacers adjacent to and in contact with each of the first conductive spacers to form combined conductive spacers; depositing an interlayer dielectric (ILD) to cover the first and second spacers except for exposed edges of the first conductive spacers; patterning the exposed edges of the combined conductive spacers to recess the edges of the combined conductive spacers in predetermined locations to form recesses with respect to the ILD and unrecessed edges with respect to the ILD; and filling the recesses with an insulating material to leave the unrecessed edges of the first conductive spacers as vias to subsequent wiring features.
According to a third aspect of the exemplary embodiments, there is provided a semiconductor structure including: a semiconductor substrate; a wiring layer on the semiconductor substrate, the wiring layer including: a plurality of fin-like structures and having a height (H), width (W) and length (L) such that L>H>W, each of the fin-like structures comprising a first layer of a first metal and a second layer of a second metal wherein the first metal is different from the second metal; and an interlayer dielectric (ILD) covering the plurality of fin-like structures except for exposed edges of the plurality of fin-like structures at predetermined locations as vias to subsequent wiring features.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
The features of the exemplary embodiments believed to be novel and the elements characteristic of the exemplary embodiments are set forth with particularity in the appended claims. The Figures are for illustration purposes only and are not drawn to scale. The exemplary embodiments, both as to organization and method of operation, may best be understood by reference to the detailed description which follows taken in conjunction with the accompanying drawings in which:
FIGS. 1A to 9A and 1 B to 9 B illustrate a first method of practicing the exemplary embodiments.
FIGS. 10A to 16A and 10 B to 16 B illustrate a second method of practicing the exemplary embodiments.
FIGS. 17A to 24A and 17 B to 24 B illustrate a third method of practicing the exemplary embodiments.
DETAILED DESCRIPTION
The problem with prior art wiring schemes is the difficulty in forming small-pitch metal wiring and necessary interlevel vias. The present inventors propose making wiring levels using two dissimilar metals, where the metals are formed in such a way that one metal is formed adjacent to one or two layers of the other metal, and only that one metal layer is used as a “stud-up” via to the next level. That one metal (via) is self-aligned to the metal line in the width direction, and forms only a portion of the total line width. The mask employed to define the position of that via can thus overlap the other-metal portion of adjacent lines without resulting in parasitic vias.
Referring to the Figures in more detail, and particularly referring to FIGS. 1A to 9A and 1 B to 9 B, there is illustrated a first method for practicing the exemplary embodiments. In the Figures, the “A” Figures illustrate cross-sectional views taken in the direction of arrows A-A shown in FIG. 1B , and the “B” Figures illustrate plan views.
FIGS. 1A and 1B illustrate a semiconductor structure 10 including a semiconductor substrate 12 having a plurality of mandrels 14 situated thereon. While only two mandrels 14 are shown, it should be understood that there will be many more such mandrels as these mandrels will form the basis for forming wiring lines. The mandrels 14 may be formed by depositing a layer of a sacrificial material such as silicon dioxide or carbon-doped oxide and then defining the mandrels 14 by a conventional photoresist process and reactive ion etching (RIE) such as by use of fluorine-containing plasmas, such as CF 4 , CHF 3 , and C 4 F 6 . After the mandrels 14 are defined, the photoresist may be stripped. An advantage of the exemplary embodiments is that the mandrels 14 may be conventionally defined since the pitch of the mandrels 14 is about twice the pitch of the wiring to be subsequently defined. The mandrels 14 may have a nominal width of 50-200 nm and height of 60-200 nm.
Semiconductor substrate 12 may be a bulk semiconductor or semiconductor on insulator substrate that has proceeded through front end of the line processing including forming transistors and vias and contacts with respect to these transistors. Semiconductor substrate 12 may also have one or more metal wiring levels (i.e., middle of the line or back end of the line wiring levels) before processing by the exemplary embodiments. Contacts or vias connecting to conductive structures within semiconductor substrate 12 intersect the top surface of semiconductor substrate 12 . These contacts or vias may make contact with the wiring layer to be built on semiconductor substrate 12 as described hereafter.
Referring now to FIGS. 2A and 2B , a first metal layer 16 is deposited, preferably conformally deposited, over the mandrels 14 and the semiconductor substrate 12 . The first metal layer 16 may be conventionally deposited by a process such as chemical vapor deposition. The thickness of the first metal layer 16 may be approximately one half to one quarter the desired final wire width, such as between 10 and 40 nm for current technologies. It is preferred that the first metal in first metal layer 16 is tungsten.
The semiconductor structure 10 may undergo a RIE process, indicated by arrows 18 in FIG. 2A , to remove horizontal portions of first metal layer 16 to expose mandrels 14 but leave spacers of first metal on the sidewalls of mandrels 14 . The RIE process may be a process employing chlorine. The mandrels 14 may then be etched to remove them. If the mandrels 14 are silicon dioxide, they may be etched by hydrofluoric acid (HF) or buffered HF. If the mandrels 14 are carbon-doped oxide, the mandrels 14 may be etched by a RIE process such as fluorine plasmas or by chemical oxide removal as based on a mixture of ammonia and vapor-HF. The resulting structure is shown in FIGS. 3A and 3B where the spacers of first metal wiring layer 16 form fin-like structures 20 which have a height “H”, a width “W” and a length “L” usually such that L>H>W. That is, the fin-like structures 20 are tall and thin and have a length that is usually larger than the height of the fin-like structures 20 . The fin-like structures 20 may hereafter be referred to as spacers 20 .
Referring now to FIGS. 4A and 4B , a second metal layer 22 is deposited, preferably conformally deposited, over the spacers 20 and the semiconductor substrate 12 . The thickness of the second metal layer 22 may be approximately one eighth to one third of the desired final wire width, such as between 5 and 35 nm for current technologies, and in any event may be selected so as to not fill the spaces 24 between spacers 20 except where connections between adjacent lines is desired such as at location 26 shown in FIG. 4B . It should be understood that the spaces 24 between spacers 20 has been exaggerated for clarity in describing the exemplary embodiments. It is preferred that the second metal in the second metal layer 22 is aluminum.
The semiconductor structure 10 may then undergo a RIE process, indicated by arrows 28 in FIG. 4A , to remove horizontal portions of second metal layer 22 to expose spacers 20 but leave spacers 30 of second metal on the sidewalls of spacers 20 . The RIE process used may be BCl 3 removal of Al 2 O 3 followed by low-power chlorine plasma. In this RIE process, indicated by arrows 28 in FIG. 4A , the second metal layer 22 is also recessed to lower the height of second metal layer 22 . The resulting structure is shown in FIGS. 5A and 5B in which spacers 20 are “sandwiched” between shorter spacers 30 . Spacers 20 extend beyond shorter spacers 30 . Shorter spacers 30 are adjacent to and in physical contact with first spacers 20 . Shorter spacers 30 are also on either side of first spacers 20 to form the “sandwich”. Connection at location 26 between the second metal layer 22 (now second spacers 30 ) is preferably maintained.
The shorter spacers 30 provide an important advantage in that they form a wider line for greater conductivity and will be covered by an insulating material in a subsequent step. Interlayer wiring is conducted by the thinner first spacers 20 . Narrow first spacers 20 form refractory via material self-aligned to the more-conductive second spacers 30 , easing alignment of subsequent wire levels to vias from this level.
The first metal in spacers 20 and the second metal in spacers 30 should be selected such that they may be selectively etched by RIE or another process with respect to one another. Tungsten as the first metal and aluminum as the second metal meet this objective in that the aluminum spacers 30 may be etched with a chlorine-based RIE without adversely affecting the tungsten spacers 20 .
The combination of first spacers 20 and second spacers 30 will form wiring lines in the finished structure. It may be desirable to selectively remove portions of first spacers 20 and second spacers 30 to form these wiring lines. After applying a suitable photoresist and patterning, the unwanted portions of first spacers 20 and second spacers 30 may be selectively removed at 40 to result in the structure shown in FIGS. 6A and 6B . In one etching process, a two-step etching process may be employed wherein the first spacers 20 (if tungsten) may be etched by the fluorine-based RIE process described above while the second spacers 30 (if aluminum) may be etched by the chlorine-based RIE process described above. The order of etching of the first spacers 20 and second spacers 30 may be reversed.
Referring now to FIGS. 7A and 7B , an interlayer dielectric (ILD) layer 32 is applied and planarized to reveal the top edges of first spacers 20 . Sufficient ILD layer 32 must be maintained to avoid exposing second spacers 30 . As shown in FIGS. 7A and 7B , only the top edges of first spacers 20 are exposed. ILD layer 32 may consist of Carbon-doped oxide (CDO). ILD layer 32 may also consist of a combination of CDO preceeded by deposition of a thin barrier material to better isolate the first spacers 20 and second spacers 30 from the bulk of ILD layer 32 .
Then, vias are defined using photoresist applied to ILD layer 32 which is patterned using available lithography and etched using RIE to pull down (recess) the first conductive spacers 20 except where it is desired for the first conductive spacers 20 to form vias to the next metal wiring level. The RIE process utilized may be the fluorine-based process described above for etching the first spacers 20 . FIGS. 8A and 8B illustrate where first spacers 20 have been recessed 34 to leave only portions 36 of first spacers 20 which form the vias to the next wiring level. The first spacers 20 must be recessed sufficiently so that when the recesses 34 are filled with an insulating material, the first spacers 20 , except for portions 36 , will be insulated from the next wiring level.
FIGS. 9A and 9B illustrate the deposition and planarization of insulating material 38 to fill the recesses 34 shown in FIGS. 8A and 8B . The insulating material 38 must be planarized sufficiently so that portions 36 of first spacers 20 are exposed. The insulating material 38 may be any insulating material that is capable of filling the recesses 34 . Such insulating materials 38 may be silicon dioxide, carbon-doped oxide, polyimides, or polynorbornenes.
Further processing may then continue to form a second wiring level (not shown) according to processing illustrated in FIGS. 1A to 9A and 1 B to 9 B or by conventional processing.
Referring now to FIGS. 10A to 16A and 10 B to 16 B, there is illustrated a second method for practicing the exemplary embodiments. In the Figures, the “A” Figures illustrate cross-sectional views taken in the direction of arrows A-A shown in FIG. 10B , and the “B” Figures illustrate plan views.
The second method begins with the same semiconductor structure 100 including a semiconductor substrate 112 having a plurality of mandrels 114 situated thereon as previously illustrated and described with respect to FIGS. 1A and 1B .
Referring now to FIGS. 11A and 11B , a first metal layer 116 is deposited, preferably conformally deposited, over the mandrels 114 and the semiconductor substrate 12 . The thickness of the first metal layer 16 is approximately one half to one third the desired final wire width, such as between 10 and 40 nanometers. It is preferred that the first metal in first metal layer 116 is tungsten. Then, a second metal layer 122 is deposited, preferably conformally deposited, over the first metal layer 116 . The thickness of the second metal layer 122 is approximately one half to two thirds of the desired final wire width, such as between 15 to 40 nanometers and in any event may be selected so as to not fill the spaces 124 between mandrels 114 except where connection between adjacent lines is desired such as at location 126 shown in FIG. 11B . It should be understood that the spaces 124 between mandrels 114 has been exaggerated for clarity in describing the exemplary embodiments. It is preferred that the second metal in the second metal layer 122 is aluminum.
The semiconductor structure 100 undergoes a RIE process, indicated by arrows 128 in FIG. 11A , to remove horizontal portions of second metal layer 122 and first metal layer 116 to expose mandrels 114 . The RIE process may include a two-step RIE process in which a chlorine-based RIE (described above) may be utilized to etch the second metal layer 122 to form spacers 132 of second metal on sidewalls of first metal 116 , and a fluorine-based RIE (described above) may be utilized to etch the first metal layer 116 to form spacers 130 of first metal on sidewalls of mandrels 114 . The second metal layer 122 may be etched to recess the spacers 132 below the top of the first metal layer 116 . The mandrels 114 may then be etched by HF, buffered HF or RIE, as described in the first exemplary embodiment, to remove them. The resulting structure is shown in FIGS. 12A and 12B where the remnants of first metal wiring layer 116 form fin-like structures 130 which have a height “H”, a width “W” and a length “L” usually such that L>H>W. That is, the fin-like structures 130 are tall and thin and have a length that is usually larger than the height of the fin-like structures 130 . The fin-like structures 130 will hereafter be referred to as first spacers 130 . Adjacent to and in physical contact with the first spacers 130 are second spacers 132 which are the remnants of second metal layer 122 .
In an alternative embodiment, the mandrels 114 may remain in place and need not be etched away if they are made of appropriate insulators, such as carbon-doped oxides or SiO 2 .
It is noted that in the semiconductor structure 100 illustrated in FIGS. 12A and 12B , the second spacers 132 are only on one side of the first spacers 130 . An advantage of the second exemplary method is that fewer processing steps may be required and second spacers 132 provide physical support to first spacers 130 after removal of the mandrels 114 . Connection at location 126 between the second metal layer 122 (now second spacers 132 ) is preferably maintained.
The combination of first spacers 130 and second spacers 132 may form wiring lines in the finished structure. It may be desirable to selectively remove portions of first spacers 130 and second spacers 132 to form these wiring lines. After applying a suitable photoresist and patterning, the unwanted first spacers 130 and second spacers 132 may be selectively removed at 142 by etching to result in the structure shown in FIGS. 13A and 13B . In one etching process, a two-step etching process may be employed wherein the second spacers 132 (if aluminum) may be etched by the chlorine-based RIE process described above and the first spacers 130 (if tungsten) may be etched by the fluorine-based RIE process described above.
Referring now to FIGS. 14A and 14B , an interlayer dielectric (ILD) layer 134 is applied and planarized to reveal the top edges of first spacers 130 . Sufficient ILD layer 134 must be maintained to avoid exposing second spacers 132 . As shown in FIGS. 14A and 14B , only the top edges of first spacers 130 are exposed.
Then, ILD layer 134 is masked with a photoresist and the first spacers 130 are etched using a fluorine-based RIE as previously described to pull down (recess) the first spacers 130 except where it is desired for the first spacers 130 to connect as vias to the next metal wiring level. FIGS. 15A and 15B illustrate where first spacers 130 have been recessed 136 to leave only portions 138 of first spacers 130 which will contact as vias to the next metal wiring level. The first spacers 130 must be recessed sufficiently so that when the recesses 136 are filled with an insulating material, the first spacers 130 , except for portions 138 , will be insulated from the next wiring level.
FIGS. 16A and 16B illustrate the deposition and planarization of insulating material 140 to fill the recesses 136 shown in FIGS. 15A and 15B . The insulating material 140 must be planarized sufficiently so that portions 138 of first spacers 130 are exposed. The insulating material may be, for example, silicon dioxide, carbon-doped oxide or SiLK.
Further processing may then continue to form a second wiring level (not shown) according to processing illustrated in FIGS. 1A to 9A and 1 B to 9 B, FIGS. 10A to 16A and 10 B to 16 B, or by conventional processing.
Referring now to FIGS. 17A to 24A and 17 B to 24 B, there is illustrated a third method for practicing the exemplary embodiments. In the Figures, the “A” Figures illustrate cross-sectional views taken in the direction of arrows A-A shown in FIG. 17B , and the “B” Figures illustrate plan views.
The third method begins with the same semiconductor structure including a semiconductor substrate 12 having a plurality of first spacers 20 situated thereon as previously illustrated and described with respect to FIGS. 1A to 3A and 1 B to 3 B. In the third exemplary embodiment, it is desired to place a thin layer of material, in this case another layer of first metal, between the second metal layer to be deposited and substrate 12 .
Referring now to FIGS. 18A and 18B , a second layer of first metal 216 is deposited, preferably conformally, over first spacers 20 . The thickness of second layer of first metal 216 is desired to be between 3 and 6 nm, although other thicknesses sufficient to prevent interaction between second metal layer 222 (deposited hereafter) and substrate 12 can be employed.
Thereafter, as shown in FIGS. 19A and 19B , second metal layer 222 is deposited, preferably conformally, over second layer of first metal 216 . As discussed with respect to the first exemplary embodiment, the first metal in first spacers 20 and second layer of first metal 216 may be tungsten while the second metal in second metal layer 222 may be aluminum. The semiconductor structure 200 then undergoes a multiple step RIE process 228 which includes first employing a chlorine-based RIE to remove horizontal portions of second metal layer 222 and recess second metal layer 222 to form second spacers 30 . In a next step, a fluorine-based RIE is employed to remove horizontal portions of second layer of first metal 216 . The result is shown in FIGS. 20A and 20B . It is noted that a portion 217 of second layer of first metal layer 216 is situated underneath second spacer 30 to isolate second spacer 30 from physical contact with substrate 12 .
Further processing of semiconductor structure 200 may continue as described with respect to the first exemplary embodiment.
That is, wiring lines that are formed by the combination of first spacers 20 and second spacers 30 may be selectively removed as illustrated in FIGS. 21A and 21B and as described above.
Then, an interlayer dielectric (ILD) layer 32 is applied and planarized to reveal the top edges of first spacers 20 and second layer of first metal 216 as shown in FIGS. 22A and 22B . Only the top edges of first spacers 20 are exposed.
Then, as shown in FIGS. 23A and 23B , recesses 34 are formed in ILD layer 32 to leave only portions 36 of first spacers 20 and second layer of first metal 216 which constitute the vias to the next metal wiring level.
FIGS. 24A and 24B illustrate the deposition and planarization of insulating material 38 to fill the recesses 34 shown in FIGS. 23A and 23B .
Further processing may then continue to form a second wiring level (not shown) according to processing illustrated in FIGS. 1A to 9A and 1 B to 9 B, FIGS. 10A to 16A and 10 B to 16 B, FIGS. 17A to 24A and 17 B to 24 B, or by conventional processing.
It will be apparent to those skilled in the art having regard to this disclosure that other modifications of the exemplary embodiments beyond those embodiments specifically described here may be made without departing from the spirit of the invention. Accordingly, such modifications are considered within the scope of the invention as limited solely by the appended claims. | Method of forming a semiconductor structure which includes forming first conductive spacers on a semiconductor substrate; forming second conductive spacers with respect to the first conductive spacers, at least one of the second conductive spacers adjacent to and in contact with each of the first conductive spacers to form combined conductive spacers; recessing the second conductive spacers with respect to the first conductive spacers so that the first conductive spacers extend beyond the second conductive spacers; depositing an ILD to cover the first and second spacers except for an exposed edge of the first conductive spacers; patterning the exposed edges of the first conductive spacers to recess the edges of the first conductive spacers in predetermined locations to form recesses with respect to the ILD; and filling the recesses with an insulating material to leave unrecessed edges of the first conductive spacers as vias to subsequent wiring features. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S. patent application Ser. No. 13/743,062, entitled “ROTATED CHANNEL SEMICONDUCTOR FIELD EFFECT TRANSISTOR,” issued as U.S. Pat. No. 8,927,984 on Jan. 6, 2015, which claims benefit of the earlier filing date of U.S. Provisional Patent Application No. 61/587,448, entitled “HIGH INTEGRATION ROTATED CHANNEL SEMICONDUCTOR FIELD EFFECT TRANSISTOR,” filed on Jan. 17, 2012. U.S. Pat. No. 8,927,984 and U.S. Provisional Patent Application No. 61/587,448 are hereby incorporated by reference herein in their entirety. All patents, patent applications and publications cited herein are hereby incorporated by reference in their entirety in order to more fully describe the state of the art as known to those skilled therein as of the date of the invention described herein.
FIELD OF DISCLOSURE
[0002] The disclosed apparatus and method relate generally to junction and metal oxide/insulator field effect transistors and methods of making the same, and more specifically to metal insulator field effect transistors comprising of group-III nitride materials and/or zinc oxide based semiconductor field effect transistors.
BACKGROUND
[0003] Lateral metal oxide semiconductor field effect transistors are a unique class of three terminal transistor devices which include source, drain and gate electrode terminals wherein the electric fields sustained between the source and drain is distributed laterally. In silicon-based semiconductor materials, a variant of LMOSFETs known as laterally diffused metal oxide semiconductor field effect transistors (LDMOSFETs) are typically manufactured—the advantages of which include cost-efficacy, and performance advantages around a low defect interface between silicon and silicon dioxide and/or other “high—K” dielectric materials such as hafnium oxide which are materials suspended between the semiconductor and the gate electrode and employed to achieve the transistor field effect. However, silicon based LDMOSFETs have fundamental limits centered on the low critical field of the material defined as the electric field beyond which the material breaks down and losses its semiconductor properties—a direct consequence of the relatively low energy band gap of the material of 1.14 eV; its low switching frequency of below 100 kHz; its high on-resistance of above 200 mΩ-cm −2 ; and its low operating temperatures of about 150° C.
[0004] Furthermore, the utility of hybrid hetero-structures comprising of AlInGaN based materials deposited directly onto silicon substrates have costs and performance benefits. The cost benefits arising from the economies of scale stemming from the availability of large surface area silicon substrates—which is historically the most affordable semiconductor substrates as well as well the fully amortized cost of silicon processing equipment. The performance benefits arising from the availability of a two dimensional electron gas (2DEG) at the interfaces of AlInGaN layers semiconductor layers leading to performance benefits such as ultra-low impedances or On-Resistances. However, the defectivity pertinent to these hybrid materials i.e. above 10 6 cm −2 dislocation densities has been posited as a preeminent factor in lower field and voltage rating as well as a contributor to the deleterious density of surface states in AlInGaN/GaN based hybrid materials on silicon based transistors. Moreover, the utility of lower energy gap substrate materials such as silicon can lead to pre-mature breakdown even for AlInGaN/GaN MOSFETs as depletions regions in the off-state may extend into the lower critical field silicon substrate.
[0005] Nonetheless, these hybrid materials on silicon have enabled a generation of devices including AlGaN based High Electron Mobility Transistors (HEMTs) and “normally-on” field effect transistors utilizing Schottky gates. Whereas significant effort has been invested in the commercialization of AlGaN based LMO(I)SFETs, the realization of devices which have critical field ratings at about the theoretical field strength of AlInGaN based devices and voltage ratings exceeding breakdown voltages of 800V remains technically challenging and elusive.
[0006] A process which enables the placement of high quality AlInGaN based materials i.e with dislocation densities below about 10 7 cm −2 on substrate materials with comparable energy band gap and critical breakdown field strength in conjunction with large surface areas of at least about 50 mm diameter and which relocates the current conducting channel away from orthogonally propagating line and or area defects such as in devices in which the current conducting channel is rotated to occur in the plane of a sidewall of the semiconductor would effectively allow the realization of AlInGaN based transistors which can function at approximately the theoretical critical field anticipated for AlInGaN based materials, at a voltage rating between 800V to 15,000V as well as by pass the deleterious surface state effects of line defects terminating at the nominal planar lateral surface of the semiconductor; and at a levelized cost structure approximately similar to silicon based devices.
[0007] Whereas the advent of silicon carbide (SiC) based devices has extended the functionality of power MO(I)SFETs to higher electric fields and thus higher operating voltages of up to 10kV—essentially due to the higher band gap of the material of 3.0 eV; vertical MOSFET architecture; higher switching frequencies; and higher operating temperatures of about 230° C.; SiC based power transistors are still very expensive and with levelized cost of 50 to 100 times those of their silicon counterparts thus limiting their market adoption; the on-Resistances of SiC based transistors at operating temperatures of interests i.e. above 100° C. are markedly higher i.e about 10-100 times those anticipated for AlInGaN based power transistors as a result of the absence of the high channel mobility in AlInGaN based devices due to the sustained two dimensional electron gas (2DEG) typically formed at the interfaces of AlGaInN semiconductor layers.
SUMMARY
[0008] In one aspect, a transistor device comprises a substrate comprising a non-polar or semipolar Al 2 O 3 or a ZnO or a Group III-Nitride-based material, and a structure disposed on a first side of the substrate, the structure comprising a plurality of semiconductor layers and the semiconductor layers comprising of a plurality of Al x Ga 1-x N and/or Al y In z Ga 1-y-z N and/or Zn x Mg 1-x O materials for value range 0≦x<1, 0≦y<0.5, 0≦z<0.5. The device further comprises of an intentional current-conducting sidewall channel upon which electrode materials are deposited to consist of electrode terminals allowing or inhibiting current flow from a first electrode through the action of a second electrode to a third electrode along the said intentional current-channel sidewall.
[0009] In one aspect, a transistor device comprises a substrate comprising a Al 2 O 3 or a ZnO or a Group III-Nitride-based material, which is n-type, and a structure disposed on a first side of the substrate, the structure comprising a plurality of semiconductor layers and the semiconductor layers comprising of a plurality of Al x Ga 1-x N and/or Al y In z Ga 1-y-z N and/or Zn x Mg 1-x O materials comprising of n-type or p-type species and wherein the n-type or p-type species maybe introduced by one or a plurality of doping techniques including ion-implantation, gas-phase incorporation, solution incorporation and diffusion. The device may further comprises of an intentional current-conducting sidewall channel which maybe formed by wet or solution etching techniques and or by dry etching techniques including reactive ion etching and or inductively coupled plasma reactive ion etching and or selective area deposition. The device may further comprises of at least one dielectric or insulating medium sustained on surface of intentional current-conducting sidewall channel and with metal and or conducting semiconductor material electrodes which may comprise of n-type or p-type species supported on the first of substrate.
[0010] In one aspect, a transistor device comprises a substrate comprising a non-polar or semipolar Al 2 O 3 or a ZnO or a Group III-Nitride-based material, and a structure disposed on a first side of the substrate, the structure comprising a plurality of semiconductor layers and the semiconductor layers comprising of a plurality of Al x Ga 1-x N and/or Al y In z Ga 1-y-z N and/or Zn x Mg 1-x O materials for value range 0≦x<1, 0≦y<0.5, 0≦z<0.5. The device further comprises of an intentional current-conducting sidewall channel upon which at least one additional layer of Al x Ga 1-x N and/or Al y In z Ga 1-y-z N and/or Zn x Mg 1-x O materials for value range 0≦x<1, 0≦y<0.5, 0≦z<0.5 is sustained on surface of the said intentional current-conducting sidewall channel upon which electrode materials are deposited to consist of electrode terminals which may inhibit current flow from a first electrode through the action of a second electrode to a third electrode along the said intentional current-conducting sidewall channel as a depletion-mode device shown in FIG. 1 .
[0011] In one aspect, a transistor device comprises a substrate comprising a non-polar or semipolar Al 2 O 3 or a ZnO or a Group III-Nitride-based material, and a structure disposed on a first side of the substrate, the structure comprising a plurality of semiconductor layers and the semiconductor layers comprising of a plurality of Al x Ga 1-x N and/or Al y In z Ga 1-y-z N and/or Zn x Mg 1-x O materials for value range 0≦x<1, 0≦y<0.5, 0≦z<0.5. The device further comprises of an intentional current-conducting sidewall channel upon which at least one additional layer of Al x Ga 1-x N and/or Al y In z Ga 1-y-z N and/or Zn x Mg 1-x O materials for value range 0≦x<1, 0≦y<0.5, 0≦z<0.5 maybe sustained in conjunction with at least one dielectric layer on surface of the said intentional current-conducting sidewall channel upon which electrode materials are deposited to consist of electrode terminals which may allow current flow from a first electrode through the action of a second electrode to a third electrode along the said intentional current-conducting sidewall channel as an enhancement-mode device shown in FIG. 2 .
[0012] In one aspect, an array of transistor devices comprising a first type of transistor device comprising of common non-polar or semi-polar Al 2 O 3 or a ZnO or a Group III-Nitride-based substrate, and a structure disposed on a first side of the substrate, the structure comprising a plurality of semiconductor layers and the semiconductor layers comprising of a plurality of Al x Ga 1-x N and/or Al y In z Ga 1-y-z N and/or Zn x Mg 1-x O materials for value range 0≦x<1, 0≦y<0.5, 0≦z<0.5. The first type devices further comprises of an intentional current-conducting sidewall channel upon which at least one additional layer of Al x Ga 1-x N and/or Al y In z Ga 1-y-z N and/or Zn x Mg 1-x O materials for value range 0≦x<1, 0≦y<0.5, 0≦z<0.5 in conjunction with at least one dielectric layer are sustained on surface of the said intentional current-conducting sidewall channel upon which electrode materials are further deposited to consist of electrode terminals allowing or inhibiting current flow from a first electrode through the action of a second electrode to a third electrode along the said intentional current-conducting sidewall channel are linked with a second type of transistor device on the same common substrate, and a structure disposed on a first side of the substrate, the structure comprising a plurality of semiconductor layers and the semiconductor layers comprising of a plurality of Al x Ga 1-x N and/or Al y In z Ga 1-y-z N and/or Zn x Mg 1-x O materials for value range 0≦x<1, 0≦y<0.5, 0≦z<0.5. The second type devices further comprises of an intentional current-conducting sidewall channel upon which at least one additional layer of Al x Ga 1-x N and/or Al y In z Ga 1-y-z N and/or Zn x Mg 1-x O materials for value range 0≦x<1, 0≦y<0.5, 0≦z<0.5 is sustained on surface of the said intentional current-conducting sidewall channel upon which electrode materials are further deposited to consist of electrode terminals allowing or inhibiting current flow from a first electrode through the action of a second electrode to a third electrode along the said intentional current-conducting sidewall channel and wherein first and second type transistors as well as the posterior extremities maybe separated by a passivating field dielectric and or through an heavy atom implantation region as shown in FIG. 3 . The array of transistors may be further fabricated to comprise only of the either types of device such as only an array of enhancement- or depletion-mode devices as shown in FIGS. 4 and 5 respectively and upon which a multiplicity of a combination of arrays of devices maybe further integrated and separated by an isolation layer as shown in FIG. 6 .
[0013] In one aspect, an array of transistor devices comprising of common non-polar or semi-polar Al 2 O 3 or a ZnO or a Group III-Nitride-based substrate, and a structure disposed on a first side of the substrate, the structure further comprising of multiplicity of mesas, and the mesas comprising of a multiplicity of intentional current-conducting sidewalls, the mesas comprising a plurality of semiconductor layers and the semiconductor layers comprising of a plurality of Al x Ga 1-x N and/or Al y In z Ga 1-y-z N and/or Zn x Mg 1-x O materials for value range 0≦x<1, 0≦y<0.5, 0≦z<0.5. The mesas maybe further engineered to comprise of depletion-mode devices in the similitude of FIG. 1 to form an array as shown in FIG. 8 and wherein the array of devices maybe separated by an isolation layer comprising of a dielectric medium as shown in FIG. 8 a or an heavy atom implant region; or the mesas maybe further engineered to comprise of enhancement-mode devices in the similitude of FIG. 2 to form an array and wherein the array of devices maybe separated by an isolation layer comprising of a dielectric medium or heavy atom implant in the similitude of FIGS. 8 and 8 a ; or the mesas maybe further engineered to comprise of an array of depletion- and enhancement-mode devices and wherein the array of devices maybe separated by an isolation layer comprising of a dielectric medium or heavy atom implant in the similitude of FIGS. 8 and 8 a.
[0014] In one aspect, an array of transistor devices comprising of common non-polar or semi-polar Al 2 O 3 or a ZnO or a Group III-Nitride-based substrate, and a structure disposed on a first side of the substrate, the structure further comprising of a terrace of several intentional current-conducting sidewalls, the terraces comprising a plurality of semiconductor layers and the semiconductor layers comprising of a plurality of Al x Ga 1-x N and/or Al y In z Ga 1-y-z N and/or Zn x Mg 1-x O materials for value range 0≦x<1, 0≦y<0.5, 0≦z<0.5. The terraces maybe further engineered to comprise of depletion-mode devices in the similitude of FIG. 1 to form an array as shown in FIG. 9 and wherein the array of devices maybe separated by an isolation layer comprising of a dielectric medium or heavy atom implant as shown in FIG. 9 a ; or the terraces maybe further engineered to comprise of enhancement-mode devices in the similitude of FIG. 2 to form an array and wherein the array of devices maybe separated by an isolation layer comprising of a dielectric medium or heavy atom implant in the similitude of FIGS. 9 and 9 a ; or the terraces maybe further engineered to comprise of an array of depletion- and enhancement-mode devices and wherein the array of devices maybe separated by an isolation layer comprising of a dielectric medium or heavy atom implant in the similitude of FIGS. 9 and 9 a.
[0015] Other aspects, embodiments and features of the disclosed apparatus and method will become apparent from the following detailed description when considered in conjunction with the accompanying drawings. The accompanying figures are schematic and are not intended to be drawn to scale. In the figures, each identical, or substantially similar component that is illustrated in various figures is represented by a single numeral or notation. For purposes of clarity, not every component is labeled in every figure. Nor is every component of each embodiment of the disclosed apparatus and method shown where illustration is not necessary to allow those of ordinary skill in the art to understand the disclosed apparatus and method. All patent applications and patents incorporated herein by reference are incorporated by reference in their entirety. In case of conflict, the present specification, including definitions, will control.
[0016] Some embodiments describe a semiconductor device. The semiconductor device can include a substrate, a buffering layer disposed above the substrate, and a channel layer having a first portion and a second portion, wherein the first portion has a first thickness and the second portion has a second thickness, and wherein a wall adjoining the first portion and the second portion includes a sidewall channel. The semiconductor device can also include a plurality of electrodes configured to be in electrical communication with the sidewall channel, wherein the plurality of electrodes is configured to receive voltages to provide a controlled current flow through the semiconductor device.
[0017] In any of the embodiments described herein, the channel layer can include one or more of Zn x Mg 1-x O, Al x Ga 1-x N, and Al y In z Ga 1-y-z N, wherein 0≦x≦1, 0≦y≦0.5, 0≦z≦0.5.
[0018] In any of the embodiments described herein, the substrate can include a non-polar or semi-polar semiconductor material.
[0019] In any of the embodiments described herein, the non-polar material or semi-polar semiconductor material includes Al 2 O 3 , ZnO, or a Group-III Nitride.
[0020] In any of the embodiments described herein, the sidewall channel is configured to accommodate a two dimensional electron gas formed by a piezo polarization of the channel layer.
[0021] In any of the embodiments described herein, the sidewall channel is substantially perpendicular to the first portion and the second portion of the channel layer.
[0022] In any of the embodiments described herein, wherein the sidewall channel is configured to substantially avoid crystalline defects of the channel layer.
[0023] In any of the embodiments described herein, wherein the crystalline defects of the channel layer include threading dislocations, and misfit and prismatic dislocations.
[0024] In any of the embodiments described herein, the semiconductor device can further include an alloy layer disposed between the channel layer and the plurality of electrodes, wherein the alloy layer is configured to provide control of the sidewall channel's sheet carrier density.
[0025] In any of the embodiments described herein, the alloy layer includes a plurality of sub-layers, each sub-layer having a dissimilar concentration of aluminum from other sub-layers.
[0026] In any of the embodiments described herein, the alloy layer includes a plurality of sub-layers, each sub-layer having a dissimilar concentration of indium from other sub-layers.
[0027] In any of the embodiments described herein, the alloy layer includes Zn x Mg 1-x O, Al x Ga 1-x N, or Al y In z Ga 1-z N, wherein 0≦x≦1, 0≦y≦0.5, 0≦z≦0.5.
[0028] In any of the embodiments described herein, the buffering layer includes Zn x Mg 1-x O, wherein 0≦x<1, 0≦y<0.5, 0≦z<0.5.
[0029] In any of the embodiments described herein, the semiconductor device can further include an insulating layer disposed between the channel layer and one of the plurality of electrodes.
[0030] In any of the embodiments described herein, the channel layer includes a third portion having a third thickness, wherein a second wall adjoining the second portion and the third portion includes a second sidewall channel.
[0031] In any of the embodiments described herein, the first thickness and the third thickness are substantially identical.
[0032] In any of the embodiments described herein, the first thickness and the third thickness are different.
[0033] Some embodiments describe a method for fabricating a semiconductor device. The method can include providing a substrate including a non-polar or semi-polar semiconducting material, providing a buffering layer above the substrate, wherein the buffering layer includes Al x In y Ga 1-x-y N, where 0≦x<0.5, 0≦y<0.5, and providing a channel layer above the buffering layer. The method can further include controlling a thickness of a first portion of the channel layer, thereby creating a sidewall channel that adjoins the first portion and the rest of the channel layer, and providing a plurality of electrodes above the channel layer.
[0034] In any of the embodiments described herein, controlling the thickness of the first portion of the channel layer includes etching the first portion of the channel layer, thereby reducing the thickness of the first portion of the channel layer.
[0035] In any of the embodiments described herein, etching the first portion of the channel layer includes performing inductively coupled plasma reactive ion etching on the first portion of the channel layer.
[0036] In any of the embodiments described herein, controlling the thickness of the first portion of the channel layer includes selectively depositing a semiconductor material on the first portion of the channel layer, wherein the semiconductor material includes a material of the channel layer.
[0037] In any of the embodiments described herein, providing the buffering layer includes performing physical vapor deposition or chemical vapor deposition.
[0038] In any of the embodiments described herein, the method can further include providing an insulating layer above the channel layer before providing the plurality of electrodes.
[0039] In any of the embodiments described herein, the method can further include doping the alloy layer with a plurality of donor dopants.
[0040] Some embodiments describe an integrated device. The integrated device can include a substrate, a buffering layer disposed above the substrate, and a plurality of depletion mode devices. One of the plurality of electrodes in one of the plurality of depletion mode devices is configured to be in electrical communication with one of the plurality of electrodes in another depletion mode device.
[0041] In any of the embodiments described herein, the integrated device can further include at least one enhancement mode device, wherein one of the plurality of electrodes in one of the at least one enhancement mode device is configured to be in electrical communication with one of the plurality of electrodes in one of the plurality of depletion mode devices.
[0042] In any of the embodiments described herein, the integrated device further includes a spacer disposed between one of the plurality of depletion mode devices and one of the at least one enhancement mode device, wherein the spacer includes an insulating material to electrically isolate the channel layer of the one of depletion mode devices and the channel layer of one of the at least one enhancement mode device.
[0043] In any of the embodiments described herein, the electrodes of one of the plurality of depletion mode devices includes a first gate electrode, a first source electrode, and a first drain electrode, wherein the electrodes of one of the at least one enhancement mode device includes a second gate electrode, a second source electrode, and a second drain electrode, and wherein the first source electrode is coupled to a power supply, the first gate electrode and the first drain electrode are coupled to the second drain electrode, and the second source electrode is coupled to a ground potential.
[0044] In any of the embodiments described herein, the channel layer of the depletion mode devices and the channel layer of the enhancement mode devices include one or more of Zn x Mg 1-x O, Al x Ga 1-x N, and Al y In z Ga 1-y-z N, wherein 0≦x≦1, 0≦y≦0.5, 0≦z≦0.5.
[0045] In any of the embodiments described herein, the channel layer of one of the plurality of the depletion mode device and the channel layer of one of the at least one enhancement mode device comprise a single semiconducting layer.
[0046] In any of the embodiments described herein, the substrate includes a non-polar or semi-polar semiconductor material.
[0047] In any of the embodiments described herein, the non-polar material or semi-polar semiconductor material includes Al 2 O 3 , ZnO, or a Group-III Nitride.
[0048] In any of the embodiments described herein, the buffering layer includes Zn x Mg 1-x O, wherein 0≦x<1, 0≦y<0.5, 0≦z<0.5.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] FIG. 1 is a cross-sectional view of a Rotated Channel field effect semiconductor transistor device including one or more semiconductor, and electrode layers and operating in depletion-mode according to one embodiment;
[0050] FIG. 2 is a cross-sectional view of a Rotated Channel Metal Oxide/Insulator Semiconductor Transistor device including one or more semiconductor, a dielectric, and electrode layers and operating in enhancement mode according to one embodiment;
[0051] FIG. 3 is a cross-sectional view of a Rotated Channel Metal Oxide/Insulator semiconductor transistor device in enhancement mode monolithically linked with a Rotated Channel Field Effect Semiconductor Transistor in depletion mode on a common substrate and separated by a dielectric layer according to one embodiment;
[0052] FIG. 4 is a cross-sectional view of more than one Rotated Channel Metal Oxide/Insulator Semiconductor Transistor devices in enhancement-mode monolithically linked on a common substrate and separated by a dielectric layer according to one embodiment;
[0053] FIG. 5 is a cross-sectional view of more than one Rotated Channel Metal Oxide/Insulator Semiconductor Transistor devices in depletion mode monolithically linked on a common substrate and separated by a dielectric layer and an implant isolation region according to one embodiment;
[0054] FIG. 6 is a cross-sectional view of a plurality of Rotated Channel Metal Oxide/Insulator Semiconductor Transistor devices shown for a combinations of enhancement-mode monolithically linked on a common substrate and separated by a dielectric layer and or an implant isolation region so as to form a circuit such as an inverter circuit or other complimentary circuits according to one embodiment and can representatively depict a combinations of depletion-mode monolithically linked on a common substrate and separated by a dielectric layer and or an implant isolation region so as to form a circuit such as an inverter circuit or other complimentary circuits according to another embodiment;
[0055] FIG. 7 is a topological representation of an example inverter circuit from through the monolithic integration and combination of transistor devices described according to one embodiment;
[0056] FIG. 8 is a cross-sectional view of a plurality of Rotated Channel Metal Oxide/Insulator Semiconductor Transistor devices comprising of device active mesas shown for a combination of depletion-mode devices monolithically linked on a common substrate and maybe further connected so as to form a circuit such as an inverter circuit or other complimentary circuits according to one embodiment and can representatively depict a similar combination of enhancement-mode devices monolithically linked on a common substrate and separated by a dielectric layer and or an implant isolation region so as to form a circuit such as an inverter circuit or other complimentary circuits according to another embodiment;
[0057] FIG. 8 a is a cross-sectional view of a plurality of Rotated Channel Metal Oxide/Insulator Semiconductor Transistor devices comprising of device active mesas shown for a combination of depletion-mode monolithically linked on a common substrate and separated by a dielectric layer and or an implant isolation region and maybe further connected so as to form a circuit such as an inverter circuit or other complimentary circuits according to one embodiment and can representatively depict a similar combination of enhancement-mode devices monolithically linked on a common substrate and separated by a dielectric layer and or an implant isolation region so as to form a circuit such as an inverter circuit or other complimentary circuits according to another embodiment;
[0058] FIG. 9 is a cross-sectional view of “Terraced” Rotated Channel Metal Oxide/Insulator Semiconductor Transistor devices shown for a plurality of depletion mode devices monolithically linked on a common substrate and maybe further connected so as to form a circuit such as an inverter circuit or other complimentary circuits according to one embodiment and can representatively depict a similar combination of enhancement-mode devices monolithically linked on a common substrate and separated by a dielectric layer and or an implant isolation region so as to form a circuit such as an inverter circuit or other complimentary circuits according to another embodiment;
[0059] FIG. 9 a is a cross-sectional view of a plurality of “Terraced” Rotated Channel Metal Oxide/Insulator Semiconductor Transistor devices shown for a plurality of depletion-mode monolithically linked on a common substrate and separated by a dielectric layer and or an implant isolation region and maybe further connected so as to form a circuit such as an inverter circuit or other complimentary circuits according to one embodiment and can representatively depict a similar combination of enhancement-mode devices monolithically linked on a common substrate and separated by a dielectric layer and or an implant isolation region so as to form a circuit such as an inverter circuit or other complimentary circuits according to another embodiment;
DETAILED DESCRIPTION
[0060] Disclosed apparatus and method are for illustrative purposes only and is not intended to be limiting. In fact, those of ordinary skill in the art can appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made.
[0061] Before explaining at least one embodiment in detail, it is to be understood that the disclosed apparatus and method are not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The disclosed apparatus and method are capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. Numerous embodiments are described in this patent application, and are presented for illustrative purposes only. The described embodiments are not intended to be limiting in any sense. The disclosed apparatus and method are widely applicable to numerous embodiments, as is readily apparent from the disclosure herein. Those skilled in the art will recognize that the disclosed apparatus and method can be practiced with various modifications and alterations. Although particular features of the disclosed apparatus and method can be described with reference to one or more particular embodiments or figures, it should be understood that such features are not limited to usage in the one or more particular embodiments or figures with reference to which they are described.
[0062] As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, can readily be utilized as a basis for the designing of other structures, methods and systems. It is important, therefore, that the disclosed apparatus and method be regarded as including equivalent constructions to those described herein insofar as they do not depart from the spirit and scope of the disclosed apparatus and method.
[0063] For example, the specific sequence of the described process can be altered so that certain processes are conducted in parallel or independent, with other processes, to the extent that the processes are not dependent upon each other. Thus, the specific order of steps described herein is not to be considered implying a specific sequence of steps to perform the process. Other alterations or modifications of the above processes are also contemplated. For example, further insubstantial approximations of the process and/or algorithms are also considered within the scope of the processes described herein.
[0064] In addition, features illustrated or described as part of one embodiment can be used on other embodiments to yield a still further embodiment. Additionally, certain features can be interchanged with similar devices or features not mentioned yet which perform the same or similar functions. It is therefore intended that such modifications and variations are included within the totality of the disclosed apparatus and method. Rotated Channel MO(I)SFET power devices and methods provided herein can alleviate some, if not many or all of the deficiencies of current power transistors including the deleterious effects of line defects. Line defects include threading dislocations orthogonally penetrating the current conduction plane, and misfit and prismatic dislocations. Rotating the current conducting channel to be parallel to traversing threading dislocations as in the intentional sidewall channel and as opposed to the conventional lateral sense dramatically reduces the density of intersecting or interpenetrating threading dislocations and enables high performance at increasing electric fields as well as concomitantly preserving the beneficial 2DEG in the crystalline plane of the current conducting channel and is further contrasted from conventional fin-FETs based on cubic or zinc blende materials such as silicon and or In x Ga 1-x As and or Al x In 1-x As and or Al x Ga 1-x As and or In x Ga 1-x P which are not piezoelectric materials and do not sustain a spontaneous and piezoelectric polarization effects and thus do not sustain the 2DEG on intentionally formed sidewalls.
[0065] Furthermore, the Rotated Channel MO(I)SFET increases the power density realized by device unit per unit area as there are at least two “device active” i.e. current conducting, intentional sidewalls per every lateral surface of device and thus in principle increasing the power density by at least a factor of two. For RCMOSFETs fashioned in the mesa and or terrace configuration, the integration density can be further multiplied by the number of mesas and or terraces engineered into the structure leading to a very convenient technique of drastically increasing integration density through fabrication methods. The structure of the RCMOSFET further allows the convenient fabrication and monolithic integration of other circuit components such as capacitors and more importantly inductors through the relative ease and access to a high dielectric constant substrate and epitaxial layers integrated with high dielectric constant materials as in the case of a capacitor; ready-integration of dilute magnetic nitrides and or ferromagnetic thin films such as for example Mn x Ga 1-x N and or NiFe and or CoFe which maybe employed for planar spiral inductors. Device structures provided include one or more epitaxial layers, including one or more undoped, n-type, and or p-type doped epilayers, a dielectric layer, and or one or more electrodes. In some embodiments, the epilayers can have thicknesses ranging between about 1 μm to about 300 μm, and preferably between about 1 μm and about 15 μm.
[0066] Some transistor devices provided herein include monocrystalline layers (i.e., single crystal layers), and transistor devices provided include one or more monocrystalline epilayers. As described further herein, epilayers are realized by deposition of the layers.
[0067] In some devices described herein, Al 2 O 3 and or AlGaInN and or ZnO-based materials can be employed to form part or the entire semiconductor portion of transistor, for example the semiconductor layers through which electrical charges are conducted. Furthermore, in some instances a non-polar or semi-polar ZnO or r-plane Al 2 O 3 or a non-polar or semi-polar Group-III Nitride substrate can be used to provide a substrate on which semiconductor layers of the transistor can be deposited. The Group-III Nitride can include GaN and MN. Due to potentially low lattice mismatch between for example, the non-polar or semi-polar ZnO or GaN substrate and the epitaxial layers, such a substrate can enable at the onset, the growth of low defect density monocrystalline epitaxial layers including ZnO-based epitaxial layers, and or Al x Ga 1-x N and or Al y In z Ga 1-y-z N where 0≦x≦1, 0≦y≦0.5, 0≦z≦0.5 which can fundamentally enable efficient device performance as there are fewer line defects intersecting and or shorting the plane or path of current conduction. The ZnO or GaN or Al 2 O 3 substrates can be optically transparent and, if desired, doped so as to be electrically conductive and may vary in crystal orientation to include the following orientations (10±10) m-plane non-polar materials or (11±20) a-plane non-polar materials; or (10−1±1), (20−2±1), (10−1±2), (11−2±1), (11−2±2) semipolar materials. For instances such ZnO substrate or r-plane Al 2 O 3 can provide a low-cost and large surface area (greater than about one-inch diameter) substrates for ZnO-based, Al x Ga 1-x N and Al y In z Ga 1-y-z N materials and can facilitate the production of cost effective and efficient power transistor devices.
[0068] FIGS. 1-6 and 8 - 9 a are cross-sectional views of a Rotated Channel Semiconductor Field Effect Transistor device including one or more semiconductor layers and a substrate. In some embodiments, the substrate is ZnO based material, labeled 10 in figure, upon which a buffering layer, layer 20 , comprising of semiconductor layers of ZnO based materials including but not limited to Zn x Mg 1-x O and/or Zn x Co 1-x O; and or Al x Ga 1-x N and/or Al y In z Ga 1-z N based materials with 0≦x≦1, 0≦y≦0.5, 0≦z≦0.5 is deposited directly onto the substrate layer 10 . In some embodiments buffering layer, layer 20 , can be accomplished by variety of processing techniques including physical vapor deposition techniques including but not limited to pulsed laser deposition (PLD), molecular beam epitaxy (MBE), magnetron and or direct current sputtering, and or thermal or electron beam evaporation. In some embodiments buffering layer, layer 20 can be achieved by physical vapor deposition techniques between 25° C. and 1100° C. In some embodiments buffering layer, layer 20 , can be accomplished by variety of processing techniques including chemical vapor deposition techniques including but not limited to metalorganic chemical vapor deposition (MOCVD), plasma enhanced chemical vapor deposition (PECVD), metalorganic molecular beam epitaxy (MOMBE), hydride and/or halogen vapor phase epitaxy (HVPE). In some embodiments buffering layer, layer 20 can be achieved by above chemical vapor deposition techniques between 100° C. and 1100° C. In some embodiments buffering layer, layer 20 , can be accomplished by variety of processing techniques including solution phase techniques including but not limited to liquid phase epitaxy (LPE), Flux growth, and Ammonothermal crystallization. In some embodiments buffering layer, layer 20 can be achieved by above solution phase techniques between 50° C. and 1100° C.
[0069] In some embodiments, a channel layer 30 comprising of Zn x Mg 1-x O and/or Al x Ga 1-x N and/or Al y In z Ga 1-z N based materials with 0≦x≦1, 0≦y≦0.5, 0≦z≦0.5 where the layer 30 can vary in thickness from about 0.5 μm to about 300 μm and preferably between 0.5 μm and 15 μm is deposited. In some embodiments semiconductor layer, layer 30 , maybe undoped or of N − or P − net carrier concentration not exceeding 10 18 cm −3 . In some embodiments, the channel layer 30 can be accomplished by variety of processing techniques including physical vapor deposition techniques including but not limited to pulsed laser deposition (PLD), molecular beam epitaxy (MBE), magnetron and or direct current sputtering, and or thermal or electron beam evaporation. In some embodiments, the channel layer 30 can be achieved by physical vapor deposition techniques between 25° C. and 1100° C. In some embodiments, the channel layer 30 can be accomplished by variety of processing techniques including chemical vapor deposition techniques including but not limited to metalorganic chemical vapor deposition (MOCVD), plasma enhanced chemical vapor deposition (PECVD), metalorganic molecular beam epitaxy (MOMBE), hydride and or halogen vapor phase epitaxy (HYPE). In some embodiments, the channel layer 30 can be achieved by above chemical vapor deposition techniques between 100° C. and 1100° C. In some embodiments, the channel layer 30 can be accomplished by variety of processing techniques including solution phase techniques including but not limited to liquid phase epitaxy (LPE), Flux growth, Ammonothermal crystallization. In some embodiments semiconductor layer, layer 30 can be achieved by above solution phase techniques between 50° C. and 1100° C.
[0070] In some embodiments, the channel layer 30 includes an intentional current-conducting sidewall 35 . The intentional current conducting sidewall 35 can be formed by etching the channel layer 30 . The intentional current-conducting sidewall layer 35 can be accomplished by a variety of techniques including wet etching and or reactive ion etching and or inductively coupled plasma reactive ion etching and or selective area deposition to enable a profile of sufficient sidewall dimension as to form a current conducting channel for example of side wall height between about 0.5 μm and 400 μm and preferably between about 0.5 μm and 15 μm and sidewall thickness from about 0.05 μm to about 15,000 μm. In some embodiments multiple sidewalls can be achieved to form a terrace thus the terraced RCMOSFET and even further achieving ultrahigh device integration per unit area.
[0071] In some embodiments an alloy layer comprising of a Zn x Mg 1-x O and/or Al x Ga 1-x N and/or Al y In z Ga 1-z N based materials with 0≦x≦1, 0≦y≦0.5, 0≦z≦0.5, layers 40 are deposited directly on the intentional current-conducting sidewall layer 35 and of thickness varying between about 0.001 μm to about 50 μm and preferably between about 0.005 μm and about 0.05 μm and with Al or In fraction preferably between 0.1 and 0.3 achieved with similar processes and temperatures as the adjacent semiconductor layer, layer 30 . In some embodiments the alloy layer 40 may possess multiple sub-layers of dissimilar concentration of Al in Al x Ga 1-x N and/or Al y In z Ga 1-y-z N based materials and/or Mg in ZnMgO alloys. In some embodiments layers 40 may possess sub-layers of dissimilar concentration of In in Al x Ga 1-x N and/or Al y In z Ga 1-y-z N based materials and/or Mg in ZnMgO alloys. Where the concentration of Al in Al x Ga 1-x N and/or Al y In z Ga 1-y-z N and or In in Al x Ga 1-x N and/or Al y In z Ga 1-y-z N based materials and/or Mg in ZnMgO alloys can be used to control the sheet carrier density of the 2DEG formed on the intentional current-conducting sidewall and of thickness varying between about 0.001 μm to about 50 μm and preferably between about 0.005 μm and about 0.05 μm. In some embodiments the alloy layer 40 may possess sub-layers of different N − and/or P − dopant concentration within the range of 10 15 cm −3 to 10 18 cm −3 . In some embodiments, N − and/or P − dopants maybe introduced into layer 30 and 40 by techniques including gas phase incorporation and/or ion implantation and/or solution incorporation.
[0072] In some embodiments layers 30 and 40 , maybe implanted with elements from group VIII of the periodic table thus forming an isolation layer, layer 55 . In some embodiments such as for example in FIG. 2 , an additional dielectric layer, layer 50 , is deposited on top of and adjacent to layer 40 . In some embodiments layer 50 is an insulating layer, of a dielectric material of composition A x B 1-x O y and or A x B 1-x N y where A maybe selected from a group comprising of Al, Ga, La, Hf, Sc and B may be selected from a group consisting of Si, Zr, Zn, Ga and Sr and where 0≦x≦1 and whereupon the dielectric layer, layer 50 , allows for the field effect to bear upon the 2DEG sustained along the intentional current-conducting layer 35 and at the interface of layers 30 and 40 and whereupon layer 50 maybe of thickness varying between about 0.001 μm to about 50 μm and preferably between about 0.005 μm and about 0.05 μm. In some embodiments, an electrode materials comprising of metals and or poly-silicon, and or indium tin oxide, and or zinc gallium oxide, and/or zinc indium oxide, and or zinc aluminum oxide, layer 60 , maybe deposited directly onto layer 40 or maybe deposited directly onto layer 50 and known as the source electrodes. In some embodiments additional electrode, layer 70 , maybe deposited directly on semiconductor layer 40 or layer 50 and known as the gate electrode. In some embodiments, additional electrodes, layer 80 , can be deposited maybe deposited directly on semiconductor layers 40 or maybe deposited directly onto layer 50 and known as the drain electrode. In some embodiments, a passivating layer, comprising of an oxide, and or nitride, and or oxynitride and or a halogenated polymer, layer 90 , is deposited around the semiconductor materials and or electrodes.
[0073] In some embodiments, layer 10 can be doped n-type. In some embodiments, layer 10 may comprise of n-type impurities between 10 14 cm −3 and 10 21 cm −3 . In some embodiments, layer 10 may possess n-type resistivity from 10 6 Ω-cm to 10 −3 Ω-cm.
[0074] In some embodiments, layer 10 can be doped p-type. In some embodiments, layer 10 may comprise of p-type impurities between 10 14 cm −3 to 10 21 cm −3 . In some embodiments, layer 10 may possess p-type resistivity from 10 6 Ω-cm to 10 −3 Ω-cm.
[0075] In some embodiments, layer 20 may be undoped or doped n-type between 10 14 cm −3 to 10 21 cm −3 and may possess resistivity from 10 5 Ω-cm to 10 −4 Ω-cm.
[0076] In some embodiments, layer 20 may be undoped or doped p-type with p-type dopants between 10 14 cm −3 to 10 21 cm −3 and may possess resistivity from 10 5 Ω-cm to 10 −3 Ω-cm.
[0077] In some embodiments, layer 30 can be undoped or intrinsic or may be doped n-type with donor dopant concentration between 10 14 cm −3 and 10 21 cm −3 or may be p-type doped with acceptor concentration between 10 14 cm −3 to 10 21 cm −3 . In some embodiments, layer 30 may possess n-type or p-type resistivity from 10 6 Ω-cm to 10 −3 Ω-cm.
[0078] In some embodiments, layer 40 maybe undoped or n-type doped and with resistivity from 10 6 Ω-cm to 10 −4 Ω-cm. In some embodiments, layer 40 and layer 50 may possess p-type resistivity from 10 6 Ω-cm to 10 −3 Ω-cm.
[0079] In some embodiments, drain and source electrodes, layers 60 and 80 may be selected from a group comprising of metals or metal stacks including Al, Pt, Au, Si, Ti, W, Cu, Ti/Au, Ti/Al, Ti/Al/Au, Ti/Al/Pt/Au, Cr/Au, Cr/Al, Cr/Al/Au, Al/Au, Al, Al/Pt, In, Ru and or a group comprising of metals or metal stacks including Cr, and/or NiO and/or polysilicon and/or Ni/Al/Au, Ni/Ti/Au, Pt/Au, Pt, Au, Ag or any combination of the foregoing to form electrical contact to the underlying semiconductor layers.
[0080] In some embodiments, layer 70 , the gate electrode may be selected from a group comprising of metals or metal stacks including Ti/Au, Ti/Al, Ti/Al/Au, Ti/Al/Pt/Au, Cr/Au, Cr/Al, Cr/Al/Au, Al/Au, Al, Al/Pt, In, Ru and or a group comprising of metals or metal stacks including Cr, and/or polysilicon NiO and or Ni/Al/Au, Ni/Ti/Au, Pt/Au, Pt, Au, Ag or any combination of the foregoing to form electrical contact to the underlying semiconductor layers.
[0081] In some embodiment such as in FIG. 3 , a plurality of RC-MO(I)SFET linked together may be a combination of enhancement and depletion mode devices wherein the enhancement mode devices requires an increasingly positive bias to allow current flow across the current conducting sidewall channel and the depletion mode device requires an increasing negative bias to inhibit current flow across the current conducting sidewall channel and wherein the two device regions are separated by a field insulator such as a field dielectric of for example, silicon oxide.
[0082] In some embodiment such as in FIG. 4 , a plurality of RC-MO(I)SFET linked together may be a combination of enhancement mode devices wherein the enhancement mode devices requires an increasingly positive bias to allow current flow across the current conducting sidewall channel and wherein the two device regions are separated by a field insulator such as a field dielectric of for example, silicon oxide.
[0083] In some embodiment such as in FIG. 5 , a plurality of RC-MO(I)SFET linked together may be a combination of depletion mode devices wherein the depletion mode devices requires an increasingly negative bias to inhibit current flow across the current conducting sidewall channel and wherein the two device regions are separated by a field insulator such as a field dielectric of for example, silicon oxide.
[0084] In some embodiment such as in FIG. 6 , a plurality of RC-MO(I)SFET linked together may be a combination of enhancement and depletion mode devices wherein the enhancement mode devices requires an increasingly positive bias to allow current flow across the current conducting sidewall channel and the depletion mode device requires an increasing negative bias to inhibit current flow across the current conducting sidewall channel and wherein the multiple device regions are separated by a field insulator such as a field dielectric of for example, silicon oxide and or a region implanted with heavy elements such as from group VIII of the periodic table of elements as to form circuits, such an inverter, or other logic and/or complimentary circuits as shown, for example, in the cross-section of FIG. 6 and circuit topology of FIG. 7 wherein 301 labels the high voltage potential and source of the depletion mode device, typically set to a potential of 0 to 100 V, 305 labels the low voltage potential and source of the enhancement mode device, typically set to a potential of 0 to-100 V, 306 labels the digital input node and gate of the enhancement mode device, 303 labels the digital output node, drain of the enhancement mode device, and drain of the depletion mode device, 307 labels the gate of the depletion mode device, 302 labels the depletion mode device, 304 labels the enhancement mode device, where the depletion mode device and enhancement mode device are formed on the same substrate.
[0085] As used herein, when a structure (e.g., layer, region) is referred to as being “on”, “over” “overlying” or “supported by” another structure, it can be directly on the structure, or an intervening structure (e.g., layer, region) also can be present. A structure that is “directly on” or “in contact with” another structure means that no intervening structure is present. A structure that is “directly under” another structure means that no intervening structure is present.
[0086] The terms “including”, “having,” “comprising” and variations thereof mean “including but not limited to”, unless expressly specified otherwise.
[0087] The term “consisting of” and variations thereof mean “including and limited to”, unless expressly specified otherwise.
[0088] The enumerated listing of items does not imply that any or all of the items are mutually exclusive. The enumerated listing of items does not imply that any or all of the items are collectively exhaustive of anything, unless expressly specified otherwise. The enumerated listing of items does not imply that the items are ordered in any manner according to the order in which they are enumerated.
[0089] The terms “a”, “an” and “the” mean “one or more”, unless expressly specified otherwise.
[0090] Headings of sections provided in this patent application and the title of this patent application are for convenience only, and are not to be taken as limiting the disclosure in any way.
[0091] Having thus described several aspects of at least one embodiment, 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 disclosed apparatus and method. Accordingly, the foregoing description and drawings are by way of example only. | A transistor device, such as a rotated channel metal oxide/insulator field effect transistor (RC-MO(I)SFET), includes a substrate including a non-polar or semi-polar wide band gap substrate material such as an Al 2 O 3 or a ZnO or a Group-III Nitride-based material, and a first structure disposed on a first side of the substrate comprising of AlInGaN-based and/or ZnMgO based semiconducting materials. The first structure further includes an intentional current-conducting sidewall channel or facet whereupon additional semiconductor layers, dielectric layers and electrode layers are disposed and upon which the field effect of the dielectric and electrode layers occurs thus allowing for a high density monolithic integration of a multiplicity of discrete devices on a common substrate thereby enabling a higher power density than in conventional lateral power MOSFET devices. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of PCT/EP2009/060778 filed Aug. 20, 2009 and claims priority to U.S. Provisional Application No. 61/190,864, filed Sep. 3, 2008 and German Patent Application No. 10 2008 041 788.2, filed Sep. 3, 2008, the entire disclosures of which are herein incorporated by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a sandwich panel with a core structure, in particular with a honeycomb-shaped core structure and plane-parallel cover layers applied on both sides of said core structure to form a floor surface in a fuselage airframe of an aircraft. The fuselage airframes of passenger aircraft are usually provided with at least one floor frame which is used, inter alia, for creating a walkable floor surface. The floor frame consists of a plurality of crossbars which are arranged in parallel behind one another and transversely to the direction of flight and are connected to annular formers of the fuselage airframe structure. In the longitudinal direction of the fuselage airframe, seat rail profiled parts which are used for attaching the passenger seats, inter alia, and also increase the rigidity of the floor frame are arranged on the crossbars in a mutually parallel spacing. Usually inserted between the seat rail profiled parts is a plurality of floor panels which are generally formed by sandwich panels approximately 1 cm thick. The floor panels have a generally honeycomb-shaped core structure which is overlaid on both sides by cover layers. The core structure of the floor panels is generally formed by Nomex® paper, while the cover layers are produced with a fibre-reinforced plastics material such as, for example, a glass fibre-reinforced phenol resin or a carbon fibre-reinforced epoxy resin.
[0003] In order to meet passengers' increasing requirements in terms of comfort, modern aircraft are fitted with a plurality of sanitary facilities and wetrooms as well as galley blocks which are arranged, distributed through the passenger cabin. In the regions of the sanitary and galley facilities, heavy loads are applied which have to be absorbed by the floor panels, that is to say, the underlying floor frame, and transferred into the fuselage airframe structure. The galley and sanitary modules are usually connected to the floor frame by so-called “hard points” which allow the load to be transferred at selected points from the module into the underlying structure and additionally allow a tolerance compensation via the connection.
[0004] According to the prior art, the galley, wetroom and sanitary modules are attached to supports which run under the floor panels and between two crossbars in the longitudinal direction of the aircraft. The “hard points” of the modules can be directly screwed, for example, into these supports.
[0005] However, where there is this type of attachment, changing the spatial position of the modules is only possible by making extensive modifications to the floor frame. Thus, it is only possible to make changes specifically desired by the clients at a considerably increased constructive effort because the floor frame has to be adapted to the altered cabin layout.
SUMMARY OF THE INVENTION
[0006] It is therefore the object of the invention to provide a sandwich panel onto which a sanitary, wetroom and/or galley module can be directly attached and the geometric dimensions of which, including the overall height, do not differ from the known standard floor panels.
[0007] This object is achieved by a sandwich panel which has the features of claim 1 .
[0008] Due to the fact that the core structure has at least one recess at least in certain regions, into which a reinforcing structure is integrated, it is possible for galley, wetroom or sanitary modules of a great weight to be directly attached to a sandwich panel configured according to the invention, without further supporting measures. The insertion of additional supports into the floor frame is unnecessary. Compared to the floor panels used as standard, there is no local thickening or elevation (bead).
[0009] Thus, the layout of the passenger cabin of the aircraft, in particular the spatial positioning of the sanitary and galley modules on the floor frame can be varied in a simple and rapid manner. Extensive constructive adaptations of the floor frame to the altered position of the modules are no longer necessary, since the sandwich panel according to the invention can be positioned in a locally variable and universal manner in all regions along the floor frame. The sandwich panel can therefore be positioned substantially freely in the direction of flight, i.e. parallel to the longitudinal axis (x-axis) of the aircraft.
[0010] The at least one reinforcing structure integrated locally into the core structure reinforces the core structure of the sandwich panel in particular such that forces which act vertically and parallel to the upper side of the panel can be absorbed.
[0011] A development of the sandwich panel provides that the at least one reinforcing structure is formed with at least one core.
[0012] In known sandwich panels, the main function of the core structure is to keep the cover layers in a fixed spacing from one another, while the actual load transfer takes place by means of the cover layers. As a result of directly integrating the reinforcing structure into the core structure, the sandwich panel according to the invention can also directly absorb compressive forces which act vertically to the panel surface.
[0013] A further development of the sandwich panel allows for the core to be provided at least in certain regions with at least one strip which is formed using a prepreg material, the reinforcing fibres of which each have a uniform running direction of in particular ±45°. This measure improves the mechanical strength of the core, in particular the ability thereof to transfer shearing forces.
[0014] The prepreg materials used are preferably narrow strips which have an arrangement of reinforcing fibres with, in each case, a uniform fibre run direction. A plurality of these prepreg strips which have alternating fibre orientations of +45° and −45° are wound round the core to achieve a high loading capacity mainly in the thrust direction. The prepreg material consists of reinforcing fibres which have been previously impregnated with a curable plastics material such as, for example, an epoxy resin, a polyester resin or a phenol resin. Reinforcing fibres include in particular carbon fibres, glass fibres and Aramid® fibres. The prepreg material is generally held ready on large rollers and can be easily drawn off therefrom, so that the core-wrapping operation can be automated and integrated into continuous production processes which are already available for sandwich panels.
[0015] A further development of the invention allows for at least one reinforcing structure to be provided at least in certain regions with at least one two-dimensional blank, said at least one blank being formed by a prepreg material, the reinforcing fibres of which have a running direction of 0° and/or 90°.
[0016] This configuration means that the covered core can also be loaded by tensile forces. In principle, the core can be covered by any desired sequence of prepreg materials with running directions in each case of ±45, 0° and 90° according to the requirements of the increased loading conditions provided for the sandwich panel (floor panel), as long as the shape of the core allows the preimpregnated reinforcing fibre layers to be draped without folds and laid without any gaps. The blanks of the prepreg material with a fibre orientation of 0° or 90° can generally be laid on the core only in the direction of a longitudinal or transverse axis of the core due to the greater width, to avoid a distorted drape. Alternatively, the blanks can be positioned at least in certain regions on an upper side and/or a lower side of the core, leaving free the encircling edges.
[0017] A further configuration provides that the at least one reinforcing structure can be introduced in an interlocking manner at least in certain regions into the recess inside the core structure, and forms a material bond with the recess.
[0018] This produces an effective transfer of force between the reinforcing structure and the surrounding sandwich panel. Due to the fact that the core is enwrapped by a prepreg material which has not yet cured, it does not necessarily have to be bonded into the recess. Alternatively however, the reinforcing structure can be bonded additionally with the core structure by a suitable adhesive. To further increase the strength, a filling compound formed using a curable plastics material can be introduced into a peripheral region of the core structure, i.e. into the closed-cell honeycomb which surrounds the reinforcing structure. The height of the reinforcing structure corresponds as exactly as possible to the height of the core structure of the rest of the sandwich panel, so that ideally, the reinforcing structure is embedded in the surrounding core structure of the sandwich panel in an almost complete interlocking fit and material bond, and thickenings (elevation due to bead formation) are avoided.
[0019] According to a further advantageous configuration of the sandwich panel, the at least one core is formed with a core structure, in particular with a honeycomb-shaped core structure, and/or with a rigid foam.
[0020] The use of a honeycomb-shaped core structure which is also used for the rest of the sandwich panel allows a simplified production process, since fewer starting materials have to be held in readiness. In a particularly advantageous manner, the core can be formed with the portion which has been cut out of the core structure, but in this case the external dimensions of the portion have to be reduced by an amount corresponding to a material thickness of the reinforcing layers which are to be laid later on. In this respect, the superficial shape of the core approximately corresponds to a superficial shape of the recess inside the core structure of the sandwich panel.
[0021] A further advantageous development of the sandwich panel provides that the reinforcing structure is formed by a combination of at least two reinforcing structures. This configuration means that reinforcing structures with a complex superficial shape can be formed by combining at least two reinforcing structures with a simpler basic shape. The cores of these reinforcing structures with a simpler shape, taken separately, can be covered or enwrapped by the necessary reinforcing layers in a running direction which is optimised in terms of force flow. Furthermore, dividing a complex reinforcing structure into a plurality of reinforcing structures with a simpler shape makes it easier to drape the prepreg strips over the core without any folds.
[0022] By combining, for example a cuboid core with a core which has a cuboid shape, but with inclined or bevelled trapezoidal side faces (so-called “obelisk”), it is possible in a particularly advantageous manner to construct a reinforcing structure for which the occurrence of notch stress is avoided as far as possible in the later sandwich panel. In general, the recess will have a rectangular shape.
[0023] A further advantageous configuration allows for the at least one reinforcing structure to be provided with at least one stopper, in particular a cylindrical stopper. Inside the reinforcing structure, this measure provides an integration region for a “hard point”, for example an insert, a bilateral screw-clamping piece or the like, thereby enabling a component, for example a galley module, to be directly mechanically attached to the sandwich panel. The stoppers are generally prefabricated. In the case of cylindrical stoppers, they are formed by a plurality of superimposed circular portions of a fibre-reinforced prepreg material which has not fully cured at the time of processing. After the reinforcing structure has been embedded or bonded into the core structure which is initially at least still open, and after applying the upper cover layer, the entire arrangement including the stoppers is cured all at the same moment by the application of pressure and/or temperature. The cylindrical stoppers have diameters of between 10 mm and 200 mm so that corresponding recesses or holes can be provided in the reinforcing structure. The stoppers are then covered with the prepreg strips with the reinforcing fibre layers at ±45° and the web-shaped, generally rectangular blanks with the reinforcing fibre layers at 0° or 90°.
[0024] Furthermore, the object according to the invention is achieved by a method in accordance with claim 9 for the production of a sandwich panel with a core structure, in particular with a honeycomb-shaped core structure which is provided on both sides with plane-parallel cover layers, in particular a sandwich panel according to claims 1 to 8 , the method comprising the following steps:
introducing at least one recess into the core structure, introducing at least one recess into the at least one core, inserting a stopper into the recess in the core, winding round the core with strips formed using a fibre-reinforced prepreg material to form at least one reinforcing structure, introducing the reinforcing structure at least in certain regions in an interlocking manner into the at least one recess while creating a material bond, applying the cover layers to both sides of the core structure, curing the at least one reinforcing structure and the cover layers by applying pressure and/or temperature, introducing a hole into the at least one stopper at the end of the curing process, into which hole an attachment element can be introduced to attach a further component to the sandwich panel.
[0033] Due to the fact that the at least one reinforcing structure is introduced into a recess made previously in the core structure before the cover layers are applied on both sides of the core structure, i.e. said reinforcing structure is introduced into the sandwich panel which is still open, it is possible to integrate the at least one reinforcing structure into the sandwich panel. If required, the reinforcing structure can be bonded into the recess. Due to the flush embedding, it is no longer necessary to change the standard overall height of the sandwich panel or to locally thicken the sandwich panel to increase the load-bearing ability.
[0034] According to the method, in step a) first of all a recess is made in the core structure, the depth of which extends over the entire height of the core structure to achieve a flush termination of the reinforcing structure. The recess can have almost any desired geometric shape, but is usually in the shape of a cuboid with vertical and/or at least two opposing, bevelled or inclined edges. In the next step b), a plurality of reinforcing layers consisting of a strip-shaped prepreg material is laid onto the core. In this respect, preferably at least two different prepreg strips in each case with a different fibre orientation of +45° or −45° are wound alternately onto the core.
[0035] The (supporting) core itself is formed for example from a rigid foam material. Alternatively, the core can also be produced from the same material which is used to form the core structure of the sandwich panel itself, i.e. for example, with a honeycomb-shaped Nomex® paper. In addition, an upper side and/or a lower side of the core can be covered with further reinforcing fibre layers in which the reinforcing fibres preferably have a running direction of 0° or 90°. The angle values in respect of the running direction of the reinforcing fibres in the prepreg strips relate in each case to an angle which exists between a longitudinal axis of the prepreg strip or their parallel outer edges and the respectively considered longitudinal axis of the reinforcing fibres. The lay or deposition angle at which the prepreg strips are laid on the core is to be distinguished therefrom. This angle which is determined between the longitudinal axis of the strip and a component edge is not constant and can vary depending on the lay site.
[0036] Thereafter, the core prepared thus is embedded in the recess in the core structure of the sandwich panel to achieve an interlocking and material bonding integration of the reinforcing structure.
[0037] The regions, adjoining the core, of the surrounding core structure of the sandwich panel can be provided with a curable filling compound to improve the transfer of forces from the reinforcing structure into the core structure. The filling compound is preferably formed using a curable plastics material, for example, an epoxy resin, polyester resin or phenol resin which is optionally fibre-reinforced or stabilised in another way. In step c), the cover layers are applied to both sides of the core structure. The cover layers are generally joined to the core structure by a suitable adhesive. In the final step d), the entire arrangement is cured. Up until the end of step d), the reinforcing structure, the two cover layers and the optional filling compound are in an uncured, i.e. still ductile state.
[0038] Further advantageous embodiments of the method are set out in the further claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] In the drawings:
[0040] FIG. 1 is a plan view of a first, cuboid reinforcing structure with a core, onto parts of which reinforcing fibre layers have been applied,
[0041] FIG. 2 is a side view of the reinforcing structure according to FIG. 1 with a second reinforcing structure arranged vertically offset underneath, with an approximately trapezoidal cross-sectional shape,
[0042] FIG. 3 is a plan view of a partial portion of a sandwich panel still open at the top, with the embedded reinforcing structure according to FIG. 2 , and
[0043] FIG. 4 is a cross-sectional view through a cylindrical stopper with an attachment element (hard point) which can be accommodated therein.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0044] In the drawings, the same constructive elements have the same reference numerals in each case.
[0045] FIG. 1 is a plan view of a first reinforcing structure which is provided to be embedded into a core structure of the sandwich panel according to the invention. A first cuboid reinforcing structure 1 comprises, inter alia, a core 2 which is formed with a plurality of honeycomb-shaped cells (so-called “honeycomb”) and around which a plurality of strips 3 to 6 is wound. The core 2 has a cuboid shape, the side faces being inwardly inclined all round (bevelled at an angle of 45°). The strips 3 to 6 are formed from a curable, fibre-reinforced prepreg material, the reinforcing fibres of which having different running directions. The strips 3 and 4 are formed by reinforcing fibres which have a running direction of −45°, while the strips 5 , 6 wound on top have a fibre running direction of +45°. The strips 3 to 6 are covered or enwrapped by a web-shaped blank 7 which is likewise formed from a prepreg material. Unlike the strips 3 to 6 , the reinforcing fibres in the blank 7 have a running direction of 0° and/or 90°.
[0046] Furthermore, a cylindrical stopper 8 with a diameter of 90 mm is introduced into a central region of the core 2 . The cylindrical stopper 8 is formed by a plurality of circular cutouts, layered one on top of another and consisting of a fibre-reinforced prepreg material. A height of the stopper 8 approximately corresponds to a height of the core 2 , to avoid a bead formation (i.e. thickening) of the sandwich panel. Inserted into the lateral peripheral portions of the reinforcing structure 1 are in each case three likewise cylindrical stoppers with a smaller diameter of approximately 19 mm, but with the same height as stopper 8 , of which only the two upper, opposing stoppers 9 , 10 have been provided with a reference numeral. The stopper 8 is used for the later integration of an attachment element (cf. in particular FIG. 4 ), particularly of a hard point, an insert, a screw-clamping piece or the like, thereby enabling, for example, a component to be attached by screwing to the sandwich panel according to the invention, while at the same time producing a tolerance compensation.
[0047] FIG. 2 is a side view of the cuboid reinforcing structure 1 according to FIG. 1 with a second reinforcing structure shown underneath in a vertically offset position and with a trapezoidal cross-sectional shape.
[0048] This results in a more complex shape of the (entire) reinforcing structure, on which nevertheless the reinforcing fibre layers of the prepreg material to be laid can be draped ideally without any folds.
[0049] The strips 3 to 6 are guided around the outer edges of the core 2 and surround it on all sides. The same applies to the blanks 7 .
[0050] The second reinforcing structure 11 is formed with a cuboid core 12 . Corresponding to the first reinforcing structure 1 , the core 12 is covered or enwrapped all round by a plurality of strips 13 to 16 and blanks 17 of a prepreg material with a fibre orientation of ±45° and 0° and/or 90°. The stopper 8 penetrates the two reinforcing structures which are shown vertically offset to one another merely to provide a better illustration.
[0051] Both reinforcing structures 1 , 11 are combined into one reinforcing structure 18 and integrated into a correspondingly configured recess (cf. FIG. 3 ) in a core structure of a sandwich panel to be produced.
[0052] The reinforcing structure 11 , as shown in FIG. 2 , is generally positioned underneath the reinforcing structure 1 in the recess of the core structure of the sandwich panel, so that the cuboid, first reinforcing structure 1 rests on one side against the upper cover layer of the sandwich panel, while the second reinforcing structure 11 with the trapezoidal cross-sectional shape rests against the lower cover layer with its shorter lower side and rests against the cuboid reinforcing structure 1 with its longer upper side.
[0053] The two reinforcing structures 1 , 11 form an (entire) reinforcing structure 18 , the second trapezoidal reinforcing structure 11 minimising notch stresses in the later sandwich panel. Furthermore, the prepreg materials can be draped or laid more easily around the separated reinforcing structures.
[0054] FIG. 3 shows a plan view of a detail of a sandwich panel which is still open at the top and has an embedded reinforcing structure.
[0055] A sandwich panel 19 with a core structure 20 is already provided on the lower side with a cover layer 21 but upwardly has not yet been closed by an upper cover layer. The complex reinforcing structure 18 formed by combining the first and second reinforcing structures 1 , 11 is inserted into a recess 22 . Since both reinforcing structures 1 , 11 are enwrapped by adhesively acting, initially not yet cured prepreg materials, an additional adhesive bonding is not generally required. The recess 22 is configured such that it exactly fits the superficial shape of the reinforcing structure 18 , to achieve an interlocking and material-locking (adhesive) integration, free from possible gaps or cavities which would reduce the mechanical loading capacity of the finished sandwich panel. In this respect, it is very important that the height of the reinforcing structure 18 to be integrated corresponds as exactly as possible to the height of the core structure 20 used, in order to avoid undesirable thickenings or local elevations of the sandwich panel 19 . As a result, there is an “interlocking” bonding between the reinforcing structure 18 and the core 2 surrounding said reinforcing structure 18 along the edges.
[0056] Furthermore, the illustration of FIG. 3 shows the upper blank 7 formed by a web-shaped prepreg material which is constructed with reinforcing materials with a fibre orientation of 0°—and/or 90°. In a region 23 in which the core structure 20 adjoins the reinforcing structure 18 , a suitable filling compound 24 is introduced at least into certain regions of the core structure 20 or into the honeycombs thereof. The filling compound is preferably formed by a curable plastics material which is provided, if appropriate, with a reinforcement to mechanically strengthen the material. Furthermore, the stopper 8 is indicated by a dashed line, since it is completely covered by the blank 7 .
[0057] FIG. 4 is a cross-sectional view through the sandwich panel with cover layers applied to both sides in the region of the large-area, central stopper (cf. FIG. 3 ).
[0058] The sandwich panel 19 is provided with the cover layers 21 , 25 . The reinforcing structure 18 with the stopper 8 inserted therein is located between the cover layers 21 , 25 . A stepped hole 26 used for integrating or attaching an attachment means 27 is introduced into the stopper 8 . The attachment means 27 comprises two sleeves 28 , 29 which are to be connected together. The sleeves 28 , 29 can be connected together, for example, by a combined screw-clamping connection. The sleeve 28 on the left-hand side has a tapped hole 30 into which a screw bolt (not shown) can be screwed to connect a further component, for example, a galley module.
[0059] As a result of the reinforcing structure 18 which is integrated according to the invention into the core structure 20 , the sandwich panel 19 has a high load bearing ability while its outer geometric dimensions remain unchanged compared to the standard dimensions of the sandwich panels usually used as floor panels.
[0060] To carry out the method according to the invention, in a first step a), at least one recess 22 is made in the core structure 20 of the sandwich panel 19 to be formed. The recess 22 is to be made as precisely as possible to ensure an integration, which is ideally interlocking and material-locking, of the at least one reinforcing structure 1 , 11 , 18 . The recess 22 can be made using, for example, a CNC-controlled milling machine. In principle, it is possible to use the worked cutout to form the recess 22 as a core for the later reinforcing structure 1 , 11 , 18 .
[0061] Recesses or holes for receiving stoppers can then be made in the prepared cores 2 , 12 . The stoppers are formed using a plurality of superimposed cutout layers of a prepreg material which is initially still soft and the stoppers have, for example, a cylindrical shape with a diameter of between 10 mm and 200 mm.
[0062] In a further step b), a plurality of strips 3 to 6 , 13 to 16 which are each formed using a fibre-reinforced prepreg material, are wound onto a core 2 , 12 . These cores 2 , 12 can be formed using, for example, a rigid foam or a core structure material which corresponds to the material used to provide the core structure 20 of the sandwich panel 19 . In the laying process, strips with a fibre orientation of +45° and strips with a fibre orientation of −45° are alternately laid down around the core 2 , 12 in a plurality of windings. Finally, blanks 7 of a prepreg material with a fibre orientation of 0°—and/or 90°—are laid on the core 2 , 12 . The core 2 , 12 is ideally completely surrounded by the prepreg material. Thereafter, the prepared reinforcing structure 1 , 11 , 18 is introduced into the recess 22 . Regions of the core structure 20 adjoining the reinforcing structure 1 , 11 , 18 , i.e. the associated honeycombs can optionally be filled with a filling compound consisting of a curable plastics material to improve the connection. For example, a strip of the core structure 20 which surrounds the embedded reinforcing structure 1 , 11 , 18 and has a width of up to 2.0 cm is filled as completely as possible with a curable filling compound. The reinforcing structure 1 , 11 , 18 can optionally also be adhesively bonded therein.
[0063] In the following step c), the cover layers 21 , 25 are applied to both sides of the core structure 20 . In the final step d), the entire structure is cured by applying pressure and/or temperature in suitable devices, for example, a furnace or an autoclave. In principle, it is possible to provide one side of the core structure 20 with a cover layer 21 , 25 before the recess 22 is made in the core structure 20 .
[0064] After the curing procedure in step d), holes or stepped holes are made in the stoppers to receive attachment elements for connecting further components to the sandwich panel. Possible examples of attachment elements include inserts or clamping-screw sleeves which can be fastened in the holes in cured stoppers.
LIST OF REFERENCE NUMERALS
[0000]
1 (first) reinforcing structure
2 core (honeycomb cells)
3 strip (prepreg material, fibre orientation of −45°)
4 strip (prepreg material, fibre orientation of −45°)
5 strip (prepreg material, fibre orientation of +45°)
6 strip (prepreg material, fibre orientation of +45°)
7 blank (prepreg material, fibre orientation of 0°/90°)
8 stopper (large)
9 stopper (small)
10 stopper (small)
11 (second) reinforcing structure
12 core (honeycomb cells)
13 strip (prepreg material, fibre orientation of −45°)
14 strip (prepreg material, fibre orientation of −45°)
15 strip (prepreg material, fibre orientation of +45°)
16 strip (prepreg material, fibre orientation of +45°)
17 blank (prepreg material, fibre orientation of 0°/90°)
18 reinforcing structure (combined)
19 sandwich panel (floor panel)
20 core structure
21 (first) cover layer
22 recess
23 region
24 filling compound
25 (second) cover layer
26 stepped hole
27 attachment means
28 sleeve
29 sleeve
30 tapped hole | A Sandwich panel with a core structure, in particular with a honeycomb-shaped core structure, and plane-parallel cover layers applied to both sides of this core structure, to form a floor surface in a fuselage airframe of an aircraft, the core structure having at least one recess into which at least one reinforcing structure is integrated, wherein the at least one reinforcing structure is formed with at least one core, said core having at least one recess into which a stopper is introduced, into which at least one attachment element can be introduced to attach at least one further component to the sandwich panel, and a plurality of prepreg strips which each have a uniform fibre running direction being wound around the core. In addition, the invention relates to a method for the production of a sandwich panel according to the invention. | 8 |
TECHNICAL FIELD
[0001] This invention relates to vehicular heating, ventilation and air conditioning module air control valves.
BACKGROUND OF THE INVENTION
[0002] The air flow control valves used automotive air conditioning and ventilation systems (typically abbreviated as “HVAC systems”) generally have a large, generally box shaped plenum or housing containing an evaporator (cold air source), heater core (hot air source) and several air directing and handling mechanisms that determine the mix of hot and cold air streams, so as to achieve a desired temperature, and also the ultimate exit point of tempered air within the vehicle interior, generally referred to as mode control.
[0003] A typical HVAC system is illustrated in FIG. 1 . Box shaped housing 10 contains an evaporator 12 and heater core 14 , arranged so that forced air (from a non illustrated blower) all flows through evaporator 12 , and then through heater core 14 (or not) in a proportion determined by the relative position of a swinging door type temperature valve 16 . As illustrated, temperature door 16 is in a mid position, so that a stream of both hot and cold air travel upwardly to a common area above which are located several potential exit ports into the vehicle interior. Typically, these comprise an uppermost defroster outlet 18 , a midlevel air outlet 20 , and lowermost, floor directed, heater outlet 22 . These various outlets are best distinguished by their location, rather than the temperature of the air that is directed to them, since that air may have any temperature, achieved by mixing the two air streams. Achieving a thorough air mix has been a continuing problem, however, because of a tendency for the distinct cold and hot air streams to remain stratified.
[0004] Another continuing problem has been providing for mode control, that is, the selective opening and closing of the three possible air outlets, in a fashion that is effective in terms of sealing efficiency, occupied space, and cost. The most common opening and closing mechanisms found in production are flapper door type valves, as illustrated in FIG. 1 at 24 , 26 and 28 , respectively. Such doors are pivoted back and forth by individual motor and gear drives, which act about an axle at the rear edge of the doors. As such the sealing force applied at the remote outer edge of the doors is potentially compromised. An analogy would be closing a book by pinching the covers together at a point near the spine. The closing force would be strongest near the spine, but questionable at the outer edges of the pages. The flapper door closing force issue is also affected by the common practice of using a layer of foam on the door, which must be compressed against the lip of the opening by the closing force applied to the door.
[0005] Many alternatives to flapper door valves have been proposed. Among these are continuous belts, so called film valves, in which a belt of flexible material is rolled back and forth in order to cover and uncover vent] openings. Film valves are effective, but costly, and can require a substantial redesign of the housing or module to accommodate them. Other proposals have included rotating barrels, butterfly valves, arcuate sliding doors, and articulated, “roll top desk” type panels. One distinctive design, disclosed in U.S. Pat. No. 5,228,475 is a swinging panel that pulls flat against the lip of an opening, and thereby provides even, strong sealing force. However, it swings up and down between two adjacent openings, rather than covering and uncovering a single opening to a greater or lesser extent. All of the aforementioned proposals are generally not capable of being simply substituted for flapper type doors to open and close individual vent openings, with little or no change to the layout of the housing itself.
SUMMARY OF THE INVENTION
[0006] The subject invention provides an alternative to a flapper door that can be used in a standard housing, but which provides for a stronger, more even sealing force, as well as providing improved air mixing.
[0007] In the preferred embodiment disclosed, a cam on a rotary shaft pushes and pulls an internally guided, flat sealing panel toward or away from a vent opening, moving generally parallel to the plane of the vent opening. The degree of opening can be controlled by how far the cam is turned, and the sealing force is applied evenly, since the sealing panel is pushed straight into the vent opening, without favoring one side or the other of the opening. The vent opening itself can be the same shape, and in the same location as in a conventional, flapper door housing. In addition, multiple sealing panels can be moved back and forth simultaneously, by multiple cams on a single shaft. The sealing panels, set back from the vent opening and preventing a direct outflow of air, can cause a swirling, vortex pattern in the forced air as it encounters the rear of the sealing panels and then rushes around the edges of the panels, thereby helping to mix various air streams and reduce stratification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is cross section of a standard HVAC housing and heat exchangers with standard flapper doors controlling the three air outlets;
[0009] FIG. 2 is a cross section of the same HVAC housing, with the opening and closing valve of the invention substituted;
[0010] FIG. 3 is a perspective view of three valves according to the invention;
[0011] FIG. 4 through 8 are views showing various moved positions of the valves.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0012] Referring first to FIG. 2 , the environment in which the improved opening and closing valve of the subject invention is the same HVAC housing described above, indicated at 10 ′, with other identical or nearly identical features also identified with the same number primed. The invention is capable of being easily incorporated into such a standard HVAC housing, with little or no change. One change made to accommodate the invention is that the heater outlet 22 ′, rather than being directly opened and closed, is backed by a new, more vertically oriented sealing opening indicated at 30 . Each of the three outlets to be opened and closed, 18 ′, 20 ′ and 22 ′ ( 30 ) is defined by a substantially planar, rectangular perimeter edge, of the same type and size that was previously opened and closed by an individually operated flapper door. The outlets need not be absolutely planar. They could, for example, be a section of the surface of a cylinder. Either way, an opening will have a perimeter edge, typically four sided, and a pre determined linear path associated with that perimeter edge that can be considered “straight back and forth” relative to that perimeter edge. For example, in the case of a perimeter edge lying all in a plane, that path would be a straight line perpendicular to that plane. In the case of an opening that was a section of a cylinder, the path would lie on a radius of the cylinder section. The existence of such a pre determined geometrical line relative to the perimeter edge of the vent opening is used to good effect by the invention, details of which are described below.
[0013] Referring next to FIG. 3 , the opening and closing valve of the invention, a preferred embodiment of which is indicated generally at 32 , is used to open and close each of the air outlets 18 ′, 20 ′ and 22 ′ ( 30 ) noted above. The valve 32 is used in conjunction with the defroster outlet 18 ′, and is chosen only because it is the one most easily visible from the perspective of FIG. 3 . Each opening and closing valve 32 can be independently operated, although they are illustrated as being concurrently operated. Regardless, each valve 32 has basically the same components. Valve 32 includes a flat sealing panel 34 , the upper surface of which may carry a layer of foam or other sealing material, if desired. Alternatively, the perimeter edge of the outlet to be sealed could carry a compressible sealing material. Sealing panel 34 is flat because the perimeter edge of the defroster outlet 18 ′ that it opens and closes lies in a flat plane, and its outer edge is slightly larger in terms of surface area. An open guiding frame 36 is rigidly attached to the interior of the housing 10 ′ so that four corner channels 38 thereof are oriented generally perpendicular to the plane of the perimeter edge of defroster outlet 18 ′. The corner channels 38 closely, but not tightly, engage the corners of sealing panel 34 so that it can move straight back and forth, toward and away from the outlet 18 ′, far enough forward to seal tightly against it, and far enough back to create sufficient open area between panel 34 and the outlet 18 ′ to allow adequate air flow area around the edges of paentl 34 to exit outlet 18 ′. The back of panel 34 is supported by a pair of spaced, parallel stanchions 40 , each of which, in turn, is slidably received in a pair of parallel guide channels 42 that are rigidly attached to the fixed guide frame 36 . The guide channels 42 and corner channels 38 together cooperate to guide stanchions 40 and the sealing panel 34 supported thereon in the back and forth, linear path desired.
[0014] Referring next to FIGS. 3 and 4 , the actual movement is of panel 34 provided by a pair of parallel rotary cams 44 on a rotatable cam shaft 46 , which is pivoted freely through the guide channels 42 and turns back and forth on a fixed axis that is located behind the sealing panel 34 , perpendicular to the desired path of linear motion. Cam shaft 46 can be turned selectively by any suitable power source, such as an electric motor M mounted inside or outside the housing 10 ′, or a mechanically powered cable or flex shaft turned manually from inside the vehicle. Shaft 46 also passes through non-visible clearance slots in the stanchions 40 . Each cam 44 rides closely in a cam slot defined by a pair of cam shoes 48 on each stanchion 40 , located above and below the non-visible clearance slots. As cam shaft 46 turns, the rotary cams 44 push up or down on one of the spaced cam shoes 48 to move the stanchions 40 and sealing panel 34 back and forth, guided by the guide channels 42 and corner channels 38 , This moves the panel 34 to toward and away from the perimeter edge of defroster outlet 18 ′, sealing it closed ( FIG. 3 ), or pulling away to open it to a varying degree ( FIG. 4 , as shown by the dotted lines). The pressure of the edge of the rotary cams 44 against the upper cam shoes 48 , applied perpendicularly to the back of sealing panel 34 through the spaced stanchions 40 , is distributed strongly and evenly all around the perimeter edge of outlet 18 ′. Consequently, the sealing material is strongly and evenly compressed, with no concentration or diminution of force at any part of the perimeter edge.
[0015] Referring next to FIGS. 2 and 3 , more than one valve can be operated simultaneously from the single cam shaft 46 , if desired. As disclosed, the sealing mechanisms for the other two outlet openings 20 ′ and 22 ′ ( 30 ) are comprised of almost identical components, indicated by the same numbers with a prime for the mid level air outlet 20 ′ and by a double prime for the lower or heater outlet 22 ′ ( 30 ). The stanchions 40 ′ for sealing panel 34 ′ are nested just outside the stanchions 40 , while the stanchions 40 ″ for sealing panel 34 ″ are nested outside the stanchions 40 ′. So, too, the sets of rotary cams 44 , 44 ′ and 44 ″ are nested one within the other, and all fixed to the same shaft 46 . The only significant difference illustrated is that the guiding frame for the outermost stanchions 40 ″ supporting lowermost sealing panel 34 ″ consists simply of a pair of collars 50 fixed to the interior of housing 10 ′, through which the stanchions 40 ″ slide. This is strictly a matter of space savings and does not affect the basic structure or operation.
[0016] Referring next to FIGS. 5 through 8 various possible moved positions are shown. In general, when cam shaft 46 is turned, the relative orientation of the three sets of rotary cams 44 , 44 and 44 ″ on the shaft 46 cause the three sealing panels 34 , 34 ′ and 34 ″ to move toward or away from their respective air outlets 18 ′, 20 ′ and 22 ′( 30 ) to different degrees, simultaneously. This is an efficient scheme in terms of total components, although it limits flexibility in terms of being able to provide all possible combinations of opening or closing of the three outlets. Specifically, in FIG. 5 , only valve 34 ′ and midlevel outlet 20 ′ are open. In FIG. 6 , both valves 34 ′, 34 ″ and midlevel outlet 20 ′ and heater outlet 22 ′ are open. In FIG. 7 , valves 34 and 34 ″, and defroster outlet 18 ′ and heater outlet 22 ′ are open. In FIG. 8 , only valve 34 ″ and heater outlet 22 ′ are open. Of course, all three mechanisms could be operated independently by three separate, and separately powered, drive shafts. Or, a single power source, such as a motor, could drive three different cam shafts at different rates, through a gear mechanism. Regardless, all mechanisms will have the same basic advantage of sealing tightly and evenly all around the perimeter edges of the various outlet openings, and can be incorporated in a basically conventional housing without changing the shape or relative orientation of those outlet openings.
[0017] Referring to FIGS. 2 and 4 , another advantage of the invention is the effect that it can have in preventing the type of hot-cold air stream stratification described above, and in promoting mixing of the air streams. The temperature door 16 ′ still functions identically to that described above, and splits cold (upper) and hot (lower) air streams coming through the evaporator 12 ′ and heater core 14 ′. The cold and hot air streams now do not have as clear or unobstructed a flow path out through the various air outlet openings as before. While air streams can flow freely through and between the various sets of nested stanchions 40 , 40 ′ and 40 ″, they then hit the backs of the various sealing panels 34 , 34 ′, and 34 ″ attached thereto, which are located directly back from their respective outlet openings. Thus, for example, an upper, cold air stream hits the back of sealing panel 34 , and is temporarily blocked before it can swirl around the edges of sealing panel 34 and out defroster outlet 18 ′. Even when a sealing panel is retracted only a relatively short distance from a perimeter edge, adequate outflow area is provided, since all four edges of the outlet are uncovered, and uncovered to the same degree. This, as opposed to a conventional flapper door, which leaves the outlet edge to which it is pivoted blocked and the side edges adjacent thereto only partially unblocked. In a similar fashion, some of the cold air stream is deflected down and behind the adjacent sealing panel 34 ′. The lower, hot air stream, engaging the back of sealing panel 34 ′, is likewise temporarily blocked and partially deflected toward the adjacent sealing panel 34 . In a case where both the defroster outlet 18 ′ and mid level outlet 20 ′ are open, the hot and cold air streams that could have otherwise remain stratified as they exited are now well mixed, both by the blocking-deflecting action of the backs of the retracted sealing panels, and by the swirling action caused as the air rushes around the edges thereof. This additional mixing action is a free by product, in effect, of the structure used for the primary intent of providing a stronger, more even sealing force.
[0018] As noted above, variations of the embodiments disclosed could be made. Essentially any air outlet shape having a continuous perimeter edge is capable of being completely closed by sealing panel of matching shape, be it flat or curved, rectangular or round or other shape, moved toward and away from it the vent opening, in a linear path. The cam mechanism disclosed, by converting the rotary motion of the shaft located behind the panel into linear motion, moves the sealing panel in that linear path. Any such outlet opening, however shaped, will receive a strong and evenly distributed sealing force by a closure panel of matching shape, moved in the guided linear path shown. One, or two, or more vent openings can be handled, sometimes by a single cam shaft, if the relative orientations of the openings and their desired relative open and closed combinations, are amenable. Cam slots could be provided directly through the support stanchions 40 , rather than by separately formed and spaced cam shoes 48 . For smaller vent openings and proportionately smaller sealing panels, a single support stanchion could provide sufficient support and stability. Therefore, it will be understood that it is not intended to limit the invention to just the embodiments disclosed. | A novel air flow control valve for an air outlet in an HVAC housing provides for strong, even seal pressure all the way around the edge of the opening. In stead of a swinging door hinged at one edge of the opening, in which seal pressure is strong on the hinge edge but weaker on the opposite edge, a flat panel is moved straight toward and away from the opening. In the closed position, the sealing pressure is even all the way around. The sealing panel is moved back and forth by a rotary cam mechanism. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
This is a divisional of application Ser. No. 11/702,224 filed Feb. 5, 2007, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a magneto generator which generates electricity under the electromagnetic induction action of permanent magnets and magneto coils in accordance with the rotation of a flywheel.
2. Description of the Related Art
In the past, there has been known a magneto generator including a bowl-shaped flywheel that rotates about an axis of rotation, a plurality of arcuate permanent magnets that are fixedly secured to an inner peripheral wall surface of the flywheel in surface contact therewith, a stator core that is arranged at an inner side of the permanent magnets and has a plurality of teeth protruding to a radially outer side, and magneto coils that are formed of conductors wound around the teeth, respectively (see, for example, a first patent document: Japanese patent application laid-open No. 2003-348784 (FIG. 2)).
In the above-mentioned the magneto generator, cutting and abrasive machining are needed to produce the arcuate permanent magnets, so many man-hours of processing are required to produce the permanent magnets, and a large amount of machining margin of the permanent magnets to be cut or removed is also required, thus resulting in an accordingly increased amount of material of the permanent magnets to be used.
In addition, in recent years, magneto generators tend to increase their output power, so the amount of use of the permanent magnets (i.e., the amount of materials) used per generator is increased in accordance with the increasing frequency of the permanent magnets (magnetic poles) due to the multipolarization thereof and the increasing magnetic force due to the increased volume of the permanent magnets, as a result of which there arises a problem that the cost of the permanent magnets becomes high in cooperation with the increased man-hours of processing and the increased amount of margin materials to be cut or removed upon processing of the permanent magnets, thus resulting in an increased product cost.
SUMMARY OF THE INVENTION
Accordingly, the present invention is intended to obviate the problems as referred to above, and has for its object to obtain a magneto generator which is capable of reducing the man-hours of processing and the amount of use (i.e., the amount of material) of permanent magnets used per generator.
Bearing the above object in mind, a magneto generator according to the present invention includes: a bowl-shaped flywheel that rotates about an axis of rotation; a plurality of permanent magnets that are fixedly secured to an inner peripheral wall surface of the flywheel; a stator core that is arranged at an inner side of the permanent magnets and has a plurality of teeth protruding to a radially outer side; and magneto coils that are formed of conductors wound around the teeth, respectively. Each of the permanent magnets is composed of a plurality of magnet pieces that are formed by dividing a hexahedral magnet main body with a division surface extending in a radial direction.
According to a magneto generator of the present invention, it is possible to reduce the man-hours of processing and the amount of permanent magnets (the amount of material) used per generator.
The above and other objects, features and advantages of the present invention will become more readily apparent to those skilled in the art from the following detailed description of preferred embodiments of the present invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view showing a magneto generator according to a first embodiment of the present invention.
FIG. 2 is a cross sectional side view of the magneto generator of FIG. 1 .
FIG. 3 is a partial cross sectional front view of a rotor of FIG. 1 .
FIG. 4 is a cross sectional side view of the rotor of FIG. 3 .
FIG. 5 is a view showing a procedure of forming a permanent magnet of FIG. 3 .
FIG. 6 is a view showing a procedure of forming a permanent magnet according to a conventional example.
FIG. 7 is a view showing a clearance or gap between a flywheel and a permanent magnet according to the first embodiment of the present invention in comparison with that of the conventional example.
FIG. 8 is a front elevational view showing a magneto generator according to a second embodiment of the present invention.
FIG. 9 is a view showing a procedure of forming a permanent magnet of FIG. 8 .
FIG. 10 is a side elevational view showing a magneto generator according to a third embodiment of the present invention.
FIG. 11 is a view showing a procedure of forming a permanent magnet of FIG. 10 .
FIG. 12 is a partial cross sectional front view of a rotor of a magneto generator according to a fourth embodiment of the present invention.
FIG. 13 is a view showing a procedure of forming a permanent magnet of FIG. 12 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, preferred embodiments of the present invention will be described in detail while referring to the accompanying drawings. Throughout respective figures, the same or corresponding members or parts are identified by the same reference numerals and characters.
Embodiment 1
Referring to the drawings and first to FIG. 1 , therein is shown a magneto generator according to a first embodiment of the present invention. FIG. 2 is a cross sectional side elevational view of the magneto generator of FIG. 1 , and FIG. 3 is a partial cross sectional front view of a rotor 1 of FIG. 1 . FIG. 4 is a cross sectional side elevational view of the rotor 1 of FIG. 3 .
This magneto generator is provided with the rotor 1 connected with an internal combustion engine, and a stator 2 mounted on a bracket (not shown) arranged inside the rotor 1 .
The rotor 1 includes a bowl-shaped flywheel 3 that is connected through a boss portion 4 with a rotation shaft (not shown) which is driven to rotate by an internal combustion engine, permanent magnets 6 that are arranged on an inner peripheral wall surface of the flywheel 3 at intervals in a circumferential direction, a cylindrical guard ring 7 that is in intimate contact with an inner side of each of the permanent magnets 6 , and a molding material 8 that serves to fixedly secure the guard ring 7 and the individual permanent magnets 6 to the inner peripheral wall surface of the flywheel 3 while integrally connecting or binding the guard ring 7 and the individual permanent magnets 6 with one another.
The stator 2 has a hollow cylindrical stator core 10 and three-phase magneto coils 9 . On the outer peripheral portion of the stator core 10 , there are formed a plurality of teeth 11 that radially protrude in a radially outer direction at equal circumferential intervals.
The stator core 10 having the plurality of teeth 11 formed on its outer peripheral portion is composed of a laminated iron core 12 which is formed of a multitude of thin hollow magnetic steel plates in the form of cold rolled steel plates laminated one over another in the direction of the axis of rotation, and a first end plate 13 and a second end plate 14 superposed on the opposite side surfaces of the laminated core 12 , respectively, in intimate contact therewith.
The first end plate 13 and the second end plate 14 of a hollow configuration made of cold rolled steel sheet, etc., have their outer peripheral portions bent toward the magneto coils 9 so as to hold the magneto coils 9 .
Three through holes 15 are formed through the first and second end plates 13 , 14 and the laminated iron core 12 in parallel to the axis of rotation. The laminated iron core 12 and the first and second end plates 13 , 14 are integrated with one another by means of bolts (not shown) inserted through the through holes 15 and nuts (not shown) threaded on the bolts, respectively.
The magneto coils 9 are formed by winding conductors having their surfaces coated with enamel on the circumferential side surfaces of the teeth 11 of the stator core 10 , and an insulating material 16 with an epoxy type powder coating is applied to the circumferential side surfaces of the teeth 11 around which the conductors are wound.
The magneto coils 9 have their lead wires 17 of the individual phases extended from the stator core 10 and covered with first protective tubes 18 . The individual phase lead wires 17 are electrically connected with leads 19 , respectively, for leading to electrical equipment (not shown) in the first protective tubes 18 . The leads 19 extending in a tangential direction of the stator 2 are covered with a second protective tube 20 .
Each of the permanent magnets 6 comprises a pair of magnet pieces 23 that are formed by dividing a magnet main body 21 of a hexahedral shape composed of a rare earth permanent magnet at its center with a division surface 22 extending in a diametral or radial direction, as shown in FIG. 5 .
The individual permanent magnets 6 are arranged in such a manner that one type of permanent magnets 6 , which have an N pole at a radially inner side and an S pole at a radially outer side, and another type of permanent magnets 6 , which have an S pole at an radially inner side and an N pole at a radially outer side, are disposed in an alternate manner in a circumferential direction.
In this manner, the plurality of permanent magnets 6 are polarized in such a manner that adjoining permanent magnets have mutually opposite polarities, whereby in an inner space of the rotor 1 , there is generated a magnetic field, the direction of which changes alternately.
In the magneto generator as constructed above, the flywheel 3 is caused to rotate in association with the rotation of the rotation shaft (not shown) which is driven to rotate by the internal combustion engine, whereby electric power is generated in the magneto coils 9 by means of an alternating field generated by the permanent magnets 6 . An AC output thus generated is rectified by an unillustrated rectifier diode, and fed to a load such as a battery mounted on a vehicle.
According to the magneto generator of the above construction, each of the permanent magnets 6 comprises one pair of magnet pieces 23 that are formed by dividing the hexahedral magnet main body 21 composed of a rare earth permanent magnet at its center with the division surface 22 extending in the diametral or radial direction. Accordingly, each of the permanent magnets 6 is simpler in configuration or shape in comparison with the case where an arcuate permanent magnet 24 is produced by cutting a magnet main body 21 of a hexahedral shape, as shown in FIG. 6 . As a result, the man-hours of processing therefor can be reduced, and the amount of margin of the material to be cut or removed upon machining can also be reduced, thus making it possible to decrease the amount of permanent magnets to be used.
In addition, as shown in FIG. 7 , a gap (g) between the flywheel 3 and a permanent magnet 6 can be greatly reduced as compared with a gap (G) between the flywheel 3 and the magnet main body 21 in the case of using the magnet main body 21 of the hexahedral shape without dividing it. Thus, a magnetic loss can be reduced.
Further, an inner radius (r) of the guard ring 7 when the permanent magnets 6 are used can be made larger as compared with an inner radius (R) of the guard ring 7 when the magnet main body 21 is used. As a result, a space for the stator 2 located at the inner side of the flywheel 3 (such as, for example, a space for the windings of the magneto coils 9 ) can be easily ensured.
Embodiment 2
FIG. 8 is a partial front elevational view that shows a rotor 1 of a magneto generator according to a second embodiment of the present invention.
In this second embodiment, as shown in FIG. 9 , a slit 25 is formed in an upper side surface of a magnet main body 21 . The construction of this second embodiment other than the above is similar to that of the first embodiment.
According to the magneto generator of this second embodiment, the slit 25 is formed in the magnet main body 21 beforehand, so there is obtained the following advantageous effect. That is, upon division of the magnet main body 21 into two pieces, the magnet main body 21 is divided into two with the slit 25 being set as a base point, and hence the magnet main body 21 can be divided at a predetermined location.
Embodiment 3
FIG. 10 is a partial cross sectional front view showing a rotor 1 of a magneto generator according to a third embodiment of the present invention.
In this third embodiment, a slit 26 is formed in a lower side surface of a magnet main body 21 , as shown in FIG. 11 . The construction of this third embodiment other than the above is similar to that of the first embodiment.
According to the magneto generator of this third embodiment, since the slit 26 is formed in the magnet main body 21 beforehand, there is obtained the following advantageous effect. That is, upon division of the magnet main body 21 into two pieces, the magnet main body 21 is divided into two with the slit 26 being set as a base point, so the magnet main body 21 can be divided at a predetermined location.
Here, note that a pair of slits may be formed in the opposite (i.e., upper and lower) surfaces of the magnet main body 21 .
In addition, a slit or slits may be formed in a side surface or opposite side surfaces of the magnet main body 21 , or a slit may be formed over the entire peripheral surfaces of the magnet main body 21 .
Embodiment 4
FIG. 12 is a partial cross sectional front view of a rotor 1 of a magneto generator according to a fourth embodiment of the present invention.
In this fourth embodiment, a flywheel 27 has an inner peripheral wall surface of a polygonal shape. The construction of this fourth embodiment other than the above is similar to that of the first embodiment.
According to this fourth embodiment, as shown in FIG. 13 , a gap between a flywheel 27 and a magnet piece 23 can be made zero, so a magnetic loss can be reduced, thus making it possible to improve an output current of the magneto generator. In addition, such a zero gap has a function as a detent for the permanent magnets 6 at the time when the flywheel 27 rotates.
Although in the above-mentioned respective embodiments, each of the permanent magnets 6 is composed of a pair of magnet pieces 23 that are formed by dividing the magnet main body 21 into two pieces, it may of course be composed of three or more magnet pieces that are formed by dividing the magnet main body 21 into three or more pieces.
In addition, the permanent magnets 6 are not limited to rare earth permanent magnets but may be other types of permanent magnets such as for example ferrite magnets.
Moreover, although in the above-mentioned respective embodiments, the permanent magnets 6 and the guard ring 7 are fixedly secured or fastened to the flywheel 3 or 27 by means of the molding material 8 , there may instead be used other fastening elements such as, for example, an element for fastening the permanent magnets 6 by caulking a caulking portion formed at an opening portion of the flywheel or an element for fastening the permanent magnets 6 by bonding them to the inner peripheral surface of the flywheel.
While the invention has been described in terms of preferred embodiments, those skilled in the art will recognize that the invention can be practiced with modifications within the spirit and scope of the appended claims. | A method for assembling a magneto generator, the method including forming a plurality of permanent magnets, wherein at least one of the plurality of the permanent magnets is formed by dividing, in a radial direction, a magnet main body into a plurality of magnet pieces, mounting the formed plurality of the permanent magnets on an inner circumferential wall surface of a bowl-shaped flywheel, disposing a stator core having a plurality of teeth that project radially outward, inside said mounted plurality of the permanent magnets, and winding conductive wire onto each of the plurality of the teeth, thereby producing a generating coil. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present application relates to a container, and more particularly to an insulated container which can sense and count the number of times beverages and other content that have been placed into the container.
[0003] 2. Description of Related Art
[0004] Note that the points discussed below may reflect the hindsight gained from the disclosed inventions, and are not necessarily admitted to be prior art.
[0005] Insulated containers have been widely used in keeping food or beverages in certain temperature, either ice cold or heated, for picnics or other outdoor activities. The container is usually a rectangular box having a hinged lid that is made of double layered plastic in the body and lid, with thermo foam insulation preventing heat exchange.
[0006] The rectangular box can be of different sizes, depending on its use for the number of people. For large family or a party of a crowd of more than ten, the container can have a dimension wider, deeper and longer than 2 feet, which could contain more than 100 cans of beer or other drinks.
[0007] Conventionally, people make a mental note of how many individual drinks such as, for example, cans of beers, soda, milk, etc. having been placed into the container which may be a cooler, and check on the cooler for how many times it has been refilled with another can of beer, soda, etc. In the slurry of activities, people may become so tired or occupied, they may forget about the food that is left in the container. And they often lose track on how many individual drinks such as cans of beers have been consumed. For caterers of a big festival, it may become a mission impossible for them to keep track of all the beverages that have been consumed.
[0008] Therefore, there is a need for a container/cooler that helps keep track of the number of beverages being consumed or food that might be left over in the container, either to ease the task of management of a festival, or to serve as a reminder for people to remain sober or in control.
SUMMARY OF THE INVENTION
[0009] The present application discloses a container for holding a can of beer or soda of a container of milk, etc. where the container may or may not also be a cooler and includes an embedded sensor and at least two counters where one counter counts the total number of times a new can has been placed into the container from the time that the container was first used up to the present, and the second counter that can be reset at any time to start a new count of the number of times a can has been placed in the container.
[0010] In one embodiment, a sensor senses an addition or removal of an item from the container, a signal is generated and sent to a digital counter for recording. A microprocessor in the counter contains a software program which records and counts the signal status and changes the counter to the next up count.
[0011] In one embodiment, a second counter is included which has a “reset” button to start a new round of counting. The counter displayer may also displays the length of time along with the total number of counts of beverages that has been placed into the container.
[0012] With a sensor and at least two separate counter displays installed in a liquid container which may or may not be a cooler, people can keep track of the number individual drinks such as beers that have been placed in the container from the very beginning of it life and the number of drinks that are being consumed at a festival or party; and where party caterers can ease the task of managing a party by simply checking the counters of on the containers.
[0013] The more important features of the invention have thus been outlined in order that the more detailed description that follows may be better understood and in order that the present contribution to the art may better be appreciated. Additional features of the invention will be described hereinafter and will form the subject matter of the claims that follow.
[0014] Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0015] As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
[0016] The foregoing has outlined, rather broadly, the preferred feature of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing or modifying other structures for carrying out the same purposes of the present invention and that such other structures do not depart from the spirit and scope of the invention in its broadest form.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Other aspects, features, and advantages of the present invention will become more fully apparent from the following detailed description, the appended claim, and the accompanying drawings in which similar elements are given similar reference numerals.
[0018] FIG. 1 schematically shows an example cylindrical container which may be a cooler that has a sensor and at least two counter displays where one of the displays shows the total number of individual servings of beverages which have been dispensed from the container, and a second display which can be reset to show the number of individual servings of beverages which have been dispensed from the time the display was reset.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] The numerous innovative teachings of the present application will be described with particular reference to presently preferred embodiments (by way of example, and not of limitation). The present application describes several inventions, and none of the statements below should be taken as limiting the claims generally.
[0020] For simplicity and clarity of illustration, the drawing figures illustrate the general manner of construction, and description and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the invention. Additionally, elements in the drawing figures are not necessarily drawn to scale, some areas or elements may be expanded to help improve understanding of embodiments of the invention.
[0021] The terms “first,” “second,” “third,” “fourth,” and the like in the description and the claims, if any, may be used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable. Furthermore, the terms “comprise,” “include,” “have,” and any variations thereof, are intended to cover non-exclusive inclusions, such that a process, method, article, apparatus, or composition that comprises a list of elements is not necessarily limited to those elements, but may include other elements not expressly listed or inherent to such process, method, article, apparatus, or composition.
[0022] It is contemplated for the insulated container to be any shape and made of any material, any configuration, and any size.
[0023] In reference to FIG. 1 , in the thermo wall of the body of a cylindrical container 1 are at least one sensor 2 and at least two counter displays 3 embedded inside where one of the counter displays can be reset. Sensor 2 may be located either at the entry opening of the container 1 , or at the bottom of the container 1 , depending on the sensing mechanism adopted by the manufacturer. The two counters 3 are embedded in the wall of the container and the counter displays are exposed to the open air on the outside surface of the container so that they can be read from a distance.
[0024] In a preferred embodiment, a photo sensor and counter circuit, such as an example described in U.S. Pat. No. 4,555,624, the entirety of which is hereby incorporated by reference, may be installed. The photo sensor may have two portions, an emitter and a receiver. The emitting portion emits electromagnetic radiation, for example, a laser light, and the receiving portion receives a reflection of the radiation from a passing object and produces an output signal in proportion to the amount of received radiation. When an object, such as a can of a beverage passes the photo sensor the reflected electromagnetic radiation is much higher than the background noise producing a large spike in the signal. The receiver can be equipped with a plurality of photo-sensitive receiving elements spaced laterally along the wall. The receiver signal can be either directly connected with a counter circuit board and microprocessor that contains software programs which record and count the state of signals each time a change is detected.
[0025] Or the receiver can be electronically connected with switches, during operation the switches generate signals indicative of the placement of objects into storage or removal of such objects from storage. The switch elements change states (off-to-on) when an electromagnetic signal is received. The signals indicating changes in the status of the switches are detected by a signal processing circuit which converts the signals to an appropriate form to be received and counted by a microprocessor of the counter. The counter then stores a count which is displayed on a displayer along with the time passed.
[0026] In an example, the counter assembly can be configured to have a set time period which counts down to zero. The counter assembly fits within the device body and includes a foam ring that forms the top of the device to expose a plurality of counter buttons. One of the buttons may be an “On/Reset” button, another button for an “Increase time” function. Power to the counting device is turned on by pressing the On/Reset button, the display, upon power on, defaults to display count repetition and minutes passed.
[0027] The sensor and counting system may be powered by a battery or electricity from an electrical cord. Other sensors, such as a thermo sensor or pressure sensor may also be installed, and sensed results can be displayed on the displayer.
[0028] As will be recognized by those skilled in the art, the innovative concepts described in the present application can be modified and varied over a large range of applications, and accordingly the scope of patented subject matter is not limited by any of the specific exemplary teachings given. It is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.
[0029] None of the description in the present application should be read as implying that any particular element, step, or function is an essential element which must be included in the claim scope: THE SCOPE OF PATENTED SUBJECT MATTER IS DEFINED ONLY BY THE ALLOWED CLAIMS. Moreover, none of these claims are intended to invoke paragraph six of 35 USC section 112 unless the exact words “means for” are followed by a participle.
[0030] While there have been shown and described and pointed out the fundamental novel features of the invention as applied to the preferred embodiments, it will be understood that the foregoing is considered as illustrative only of the principles of the invention and not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are entitled. | A thermo insulated beverage container having a sensor and a counting device. The sensor senses the number of beverages that have been placed into the container and the counting device records the sensor signal as a count repetition and displays the count on a displayer which is a count of the total number of beverages that have been placed into the container from the beginning and a count of the total number of beverages that have been placed into the container from the time that the counter was reset. | 1 |
FIELD OF INVENTION
The invention relates generally to a novel class of retinoids and more specifically to methods of preparation, pharmaceutical compositions, and methods of disease treatment utilizing pharmaceutical compositions comprising these compounds.
BACKGROUND OF THE INVENTION
Cancer is a complex disease characterized by genetic mutations that lead to uncontrolled cell growth. Cancerous cells are present in all organisms and under normal circumstances their excessive growth is tightly regulated by various physiological factors. One such regulatory process is apoptosis or programmed cell death. When the internal machinery of a cell detects abnormalities in cell division and growth, a signal is propagated within the cell, activating suicide proteins that kill the afflicted cell and prevent its proliferation. Such an apoptotic signal can be triggered, for example, when a ligand or drug interacts with a receptor or protein in the cell.
Most agents that induce apoptosis in cancer cells (e.g. Doxorubicin and Vincristine) are extremely toxic and cause a number of undesirable side effects. The toxicity associated with these therapies is a result of the non-specific interaction of the drug with the DNA of non-cancerous cells (e.g. intestinal and red blood cells). In order to circumvent such undesirable side effects, more selective compounds have been designed that inhibit one or more signaling proteins, growth factors and/or receptors involved in cancer cell proliferation. Examples include monoclonal antibodies for breast cancer (e.g. Herceptin) and Non-Hodgkin's Lymphoma (e.g. Rituxan), as well anti-angiogenic drugs for chronic myeloid leukemia (e.g. Gleevec). Since patient populations are genetically heterogeneous, it follows that a single selective therapy will not work in all cases, and as a result, cancer drugs are often used in combination. As such, there is a continual need for improved treatments.
Retinoids are analogs of vitamin A and regulate cell growth, differentiation, and apoptosis. Retinoids bind to and activate two classes of Nuclear Retinoid receptors: the retinoic acid receptors (RARα, RARβ, RARγ) and retinoic X receptors (RXRα, RXRβ, RXRγ). These receptors bind to specific sequences of DNA and thereby regulate gene expression. The RAR and RXR receptor isoforms are expressed differently during development and differentiation. These various isoforms can either homodimerize or heterodimerize leading to a variety of protein complexes that regulate different sets of retinoid-induced genes. Activation of each receptor class results in modulation of various biological functions such as cell differentiation, embryonic development, and cell proliferation. Clinical studies have shown that retinoic acid and its synthetic analogs can inhibit the growth and invasion of cancer cells, and induce them to undergo apoptosis, thereby eradicating various types of cancers.
The novel compounds of this invention modulate the activity of Nuclear Retinoid receptors. These novel compounds are thus useful for regulating cell differentiation and cell cycle processes as well as other cellular signaling processes controlled or regulated by hormones and vitamins such as the thyroid hormone, vitamin D, all-trans retinoic acid and 9-cis-retinoic acid. Hence, conditions and/or diseases that are regulated by the aforementioned entities may be treated using the compounds of this invention. Examples of such conditions include for example cancer, mammary cancer, prostate cancer, kidney cancer, Karposi's sarcoma, colon cancer, cervical cancer, lung cancer, cutaneous T-cell lymphoma, cancer of the head and neck, cancers of the aerodigestive pathway, skin cancer, bladder cancer, sarcomas, leukoplakias, acute promyelocytic leukemia, acne, psoriasis, aging, wrinkling, diabetes, hyperglycemia, bone calcification, thyroid conditions, and the like.
Compounds that modulate the activity of RAR receptors are structural analogs of all-trans-retinoic acid. On the other hand compounds that modulate the activity of RXR receptors are structural analogs of 9-cis-retinoic acid (e.g. Bexarotene). The aforementioned modulators of Nuclear Retinoid receptors bear a carboxylic acid group in a specific position of the molecule. This acidic group forms a salt bridge to a basic residue in the binding pocket of the Nuclear Retinoid receptors. Research in this field indicates that removal of this acidic group drastically reduces the potency or the modulator. There are however, other amino acid residues in the binding pocket that can interact with the modulator. None of the modulators of Nuclear Retinoid receptors described to date take advantage of these critical interactions.
Another drawback of the current state of the art is the limited aqueous solubility of the selective Nuclear Retinoid receptor modulators. Said modulators mimic the structures of retinoic acids in order to conform to the three-dimensional structure and the hydrophobic nature of the respective binding pockets. In general, introduction of solubilizing substituents has resulted in lower in vitro binding affinity or increased in vivo metabolism and toxicity.
There exists therefore a need to improve upon the prior art in order to enhance the clinical profile of such therapeutics. Such improvements may be carried out by introducing specially designed functional groups at specific positions on the molecular backbone of the modulator. The novel compounds of this invention address this issue and display enhanced in vitro profiles when compared to compounds of the prior art.
BREIF DESCRIPTION OF THE FIGURES
FIG. 1 depicts the growth inhibitory effect of 4 compounds on human melanoma cells (A375). The figure clearly shows the enhanced activity of example 8, example 10 and example 11 when compared to Bexarotene (4-[1-(3,5,5,8,8-pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-benzoic acid).
FIG. 2 depicts the growth inhibitory effect of 4 compounds on human melanoma cells (A375). The figure clearly shows the enhanced activity of example 12, example 13 and example 14 when compared to Bexarotene (4-[1-(3,5,5,8,8-pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-benzoic acid).
FIG. 3 depicts the growth inhibitory effect of 3 compounds on human hepatic carcinoma cells (HepG2). The figure clearly shows the enhanced activity of example 8, and example 11 when compared to Bexarotene (4-[1-(3,5,5,8,8-pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-benzoic acid).
FIG. 4 depicts the growth inhibitory effect of 3 compounds on human hepatic carcinoma cells (HepG2). The figure clearly shows the enhanced activity of example 12, and example 13 when compared to Bexarotene (4-[1-(3,5,5,8,8-pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-benzoic acid).
FIG. 5 depicts the growth inhibitory effect of 3 compounds on human colon cancer cells (LS174T). The figure clearly shows the enhanced activity of example 8 and example 11 when compared to Bexarotene (4-[1-(3,5,5,8,8-pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-benzoic acid).
FIG. 6 depicts the growth inhibitory effect of 4 compounds on human colon cancer cells (LS174T). The figure clearly shows the enhanced activity of example 12, example 13 and example 14 when compared to Bexarotene (4-[1-(3,5,5,8,8-pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-benzoic acid).
FIG. 7 depicts the growth inhibitory effect of 4 compounds on human head and neck squamous cell carcinoma cells (SCC 103). The figure clearly shows the enhanced activity of example 8, example 10 and example 11 when compared to Bexarotene (4-[1-(3,5,5,8,8-pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-benzoic acid).
FIG. 8 depicts the growth inhibitory effect of 4 compounds on human head and neck squamous cell carcinoma cells (SCC 103). The figure clearly shows the enhanced activity of example 12, example 13 and example 14 when compared to Bexarotene (4-[1-(3,5,5,8,8-pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-benzoic acid).
FIG. 9 depicts the binding affinity of example 8 to RXRγ
SUMMARY OF THE INVENTION
The invention provides novel therapeutic agents for the treatment of cancer, metabolic diseases and skin disorders in mammalian subjects. These novel agents bear specially designed functional groups at specific positions on the molecular backbone of the modulator. These modifications provide additional interactions between the compounds of this invention and certain amino acid residues in the binding pocket of the Retinoid Nuclear receptors. As a result, the compounds of this invention show enhanced in vitro profiles when compared to previously known compounds.
The invention also provides novel compounds that interact with one or more cellular receptors and are useful in the modulation of gene expression.
Furthermore, the invention also provides novel compounds that are useful in controlling cell cycle, and cell differentiation processes regulated by certain hormones, such as for example the thyroid hormone and the like, and/or certain vitamins, such as for example vitamin D and the like, and/or certain retinoids, such as for example 9-cis-retinoic acid and the like.
Furthermore, the invention also provides novel compounds that are useful in inducing apoptosis in mammalian cells.
Furthermore, the invention also provides novel chemical compositions and discloses synthetic methodologies to prepare the same.
In one aspect the invention relates to novel compounds comprising the structural formula A
wherein:
R 1 is
Z is selected from the group comprising CH, and nitrogen; Y 4 is selected from the group comprising substituted or unsubstituted C 1-6 alkyl, C 1-6 alkyl, C 0-5 alkyloxy-C 0-5 alkyl, C 0-5 alkylthio-C 0-5 alkyl, and C 0-5 alkylamino-C 0-5 alkyl; Y can be attached to any position on Y 4 and Y is selected from the group comprising cyano, —COOR 21 , —CONR 22 R 23 , —CONR 21 NR 22 R 23 , heteroaryl, formulae A 1 , A 2 , A 3 , A 4 , A 5 ,
wherein:
Y 3 is selected from the group comprising C 2-8 alkyl, and C 2-8 substituted alkyl; Z 2 , Z 5 , Z 7 and Z 11 are independently selected from the group comprising C═O, C═S, C═NR 17 , C═NNR 22 R 23 , C═NOR 17 , and CR 24 R 25 ; Z 1 , Z 3 , Z 4 , Z 6 , Z 8 , Z 9 and Z 10 are independently selected from the group comprising O, S, N, —NH, alkylamino, arylamino, and CR 24 R 25 , but cannot be O or S if Z 1 , Z 3 , Z 4 , Z 6 , Z 8 , Z 9 or Z 10 is the point of attachment to Y 4 , and Z 3 and Z 4 cannot both be O at the same time, and Z 8 and Z 9 cannot both be O at the same time, and Z 9 and Z 10 cannot both be O at the same time, and Z 3 , Z 4 , Z 8 , Z 9 or Z 10 can form double bonds to each other provided that none are O or S; R 6 is selected from the group comprising —OH, alkyloxy, aryloxy, alkylcarboxy, arylcarboxy, —SH, alkylthio, arylthio, —NH 2 , alkylamino, arylamino, N-aryl-N-alkylamino, —NHNH 2 , alkylhydrazino, arylhydrazino, N-aryl-N-alkylhydrazino, —NHOR 17 , —O(P═O)(OR 17 )(OR 18 ), —OCH 2 O(P═O)(OR 17 )(OR 18 ), and —OSO 3 R 17 ; R 15 and R 16 are independently selected from the group comprising —OH, alkyloxy, aryloxy, —NH 2 , alkylamino, arylamino, N-aryl-N-alkylamino, —NHNH 2 , alkylhydrazino, arylhydrazino, N-aryl-N-alkylhydrazino, —NHOR 17 , alkyl, and aryl; R 17 and R 18 are independently selected from the group comprising hydrogen, alkyl, and aryl; R 21 , R 22 and R 23 are independently selected from hydrogen, alkyl, aryl, or R 22 and R 23 are taken together with the nitrogen to which they are attached forming a saturated cyclic or unsaturated cyclic system containing 3 to 8 carbon atoms with at least one substituent as defined herein; R 24 and R 25 are independently selected from the group comprising hydrogen, halogen, alkyl, and aryl; ** represents the point of attachment of Y to Y 4
R 2 is selected from the group comprising
wherein:
Y 1 and Y 2 are independently selected from the group comprising O, S, NH, alkylamino, and CR 24 R 25 or Y 1 is O, S or NH, alkylamino and Y 2 is CR 24 R 25 , with the proviso that Y 1 and Y 2 cannot both be O, S, NH or alkylamino if n is 0 or 1; R 8 and R 9 are independently selected from the group comprising hydrogen, halogen and alkyl; or R 8 and R 9 may be linked together to form a substituted or unsubstituted C 3-6 cycloalkyl; R 10 and R 11 are independently selected from the group comprising hydrogen, halogen and alkyl; * represents the point of attachment of the R 2 to the molecule of formula A
R 3 substituents are independently selected from the group comprising alkyl, alkyloxy, and halogen;
R 4 is selected from the group comprising alkyl, aryl, heteroaryl, and adamantyl; R 5 is selected from the group comprising alkyl, alkyloxy, alkylthio, aryl, and heteroaryl; or R 4 and R 5 may be linked together to form a substituted or unsubstituted 5- or 6-membered cycloalkyl or cycloalkenyl ring, where said substituents are selected from the group comprising —OH, ═O, halogen, alkyl, and where 1 or 2 of the carbon atoms on said 5- or 6-membered cycloalkyl or cycloalkenyl ring may be optionally replaced by W where W is selected from the group comprising O, S N, NH, alkylamino, and arylamino;
m and n are independently 0, 1, 2 or 3, and pharmaceutically acceptable salts of the thereof.
The non-limiting examples shown in schemes 1-4, illustrate some methods for carrying out the preparative process of the invention. LG represents a leaving group as defined herein.
In another aspect, the invention relates to pharmaceutical compositions containing the novel compounds of the invention and to methods of using these compounds for modulating and controlling cell cycle, cell differentiation and apoptosis processes regulated by certain hormones, such as for example the thyroid hormone and the like, and/or certain vitamins, such as for example vitamin D and the like, and/or certain retinoids, such as for example 9-cis-retinoic acid and the like.
In another aspect, the invention relates to pharmaceutical compositions containing the novel compounds of the invention and to methods of using these compounds for modulating and controlling cell cycle, cell differentiation and apoptosis processes regulated by certain genes, such as for example the Fibroblast Growth Fact Binding Protein mRNA, and the like, and/or certain Signal Transducers and Activators of Transcription, such as for example STAT3, and the like, and/or certain proteins, such as for example Cyclin Dependent Kinase (CDK), Transforming Growth Factor alpha (TGF-α), and the like, and/or certain receptors, such as for example Transforming Growth Factor Receptor (TGFR), Endothelial Growth Factor Receptor (EGFR), Retinoid X Receptor (RXR) and the like.
In another aspect, the invention relates to pharmaceutical compositions containing the novel compounds of the invention and to methods of using these compounds to modulate selective gene expression by one or more cellular receptors.
In another aspect, the invention relates to pharmaceutical compositions containing the novel compounds of the invention and to methods of treating diseases and/or conditions using the same. Examples of such disorders include proliferative disorders, differentiation disorders, cancer, inflammatory diseases, cardiovascular diseases, plasma HDL levels, apolipoprotein A1 metabolism, hyperlipidemia, lipid metabolism, lipid homeostasis, hyperlipidemia, skin-related processes, autoimmune diseases, fatty acid metabolism, malignant cell development, premalignant lesions, programmed cell death, endocrinological processes, AP-1 metabolism and the like.
In another aspect, the invention relates to pharmaceutical compositions containing the novel compounds of the invention and to methods of treating diseases and/or conditions using the same. Example of diseases and/or conditions include cancer, mammary cancer, prostate cancer, kidney cancer, Karposi's sarcoma, colon cancer, cervical cancer, lung cancer, cutaneous T-cell lymphoma, cancer of the head and neck, cancers of the aerodigestive pathway, skin cancer, bladder cancer, sarcomas, leukoplakias, acute promyelocytic leukemia, acne, psoriasis, aging, wrinkling, diabetes, hyperglycemia, bone calcification, thyroid conditions, and the like.
In yet another aspect, the invention relates to pharmaceutical compositions containing the novel compounds of the invention in combination with other therapeutic agents and to methods of treating diseases and/or conditions using the same. Example of diseases and/or conditions include cancer, mammary cancer, prostate cancer, kidney cancer, Karposi's sarcoma, colon cancer, cervical cancer, lung cancer, cutaneous T-cell lymphoma, cancer of the head and neck, cancers of the aerodigestive pathway, skin cancer, bladder cancer, sarcomas, leukoplakias, acute promyelocytic leukemia and the like. Examples of other therapeutic agents include Busulfan, Carboplatin, Cisplatin, Cyclophosphamide, Cytosine arabinoside, Etoposide, 5-Fluorouracil, Melphalan, Methotrexate, Mitoxantrone, Taxol, Interferon, Toremifene, Arzoxifene, Raloxifene, Tamoxifen, and the like.
The invention further provides pharmaceutical compositions containing one or more of the novel compounds as well as pharmaceutically acceptable pro-drugs and salts of such compounds.
Additional aspects of the invention are set forth in part in the detailed description which follows, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention.
DETAILED DESCRIPTION OF THE INVENTION
In one embodiment of the invention, there are provided compounds comprising the structural formula A:
wherein:
a. R 1 is
b. Z is selected from the group comprising CH, and nitrogen
c. Y 4 is selected from the group comprising substituted or unsubstituted C 1-6 alkyl, C 1-6 alkyl, C 0-5 alkyloxy-C 0-5 alkyl, C 0-5 alkylthio-C 0-5 alkyl, and C 0-5 alkylamino-C 0-5 alkyl
d. Y can be attached to any position on Y 4 and Y is selected from the group comprising cyano, —COOR 21 , —CONR 22 R 23 , —CONR 21 NR 22 R 23 , heteroaryl, formulae A 1 , A 2 , A 3 , A 4 , A 5 ,
wherein:
i) Y 3 is selected from the group comprising C 2-8 alkyl, and C 2-8 substituted alkyl, ii) Z 2 , Z 5 , Z 7 and Z 11 are independently selected from the group comprising C═O, C═S, C═NR 17 , C═NNR 22 R 23 , C═NOR 17 , and CR 24 R 25 iii) Z 1 , Z 3 , Z 4 , Z 6 , Z 8 , Z 9 and Z 10 are independently selected from the group comprising O, S N, —NH, alkylamino, arylamino, and CR 24 R 25 , but cannot be O or S if Z 1 , Z 3 , Z 4 , Z 6 , Z 8 , Z 9 or Z 10 is the point of attachment to Y 4 , and Z 3 and Z 4 cannot both be O at the same time, and Z 8 and Z 9 cannot both be O at the same time, and Z 9 and Z 10 cannot both be O at the same time, and Z 3 , Z 4 , Z 8 , Z 9 or Z 10 can form double bonds to each other provided that none are O or S. iv) R 6 is selected from the group comprising —OH, alkyloxy, aryloxy, alkylcarboxy, arylcarboxy, —SH, alkylthio, arylthio, —NH 2 , alkylamino, arylamino, N-aryl-N-alkylamino, —NHNH 2 , alkylhydrazino, arylhydrazino, N-aryl-N-alkylhydrazino, —NHOR 17 , —O(P═O)(OR 17 )(OR 18 ), —OCH 2 O(P═O)(OR 17 )(OR 18 ), and —OSO 3 R 17 , v) R 15 and R 16 are independently selected from the group comprising —OH, alkyloxy, aryloxy, —NH 2 , alkylamino, arylamino, N-aryl-N-alkylamino, —NHNH 2 , alkylhydrazino, arylhydrazino, N-aryl-N-alkylhydrazino, —NHOR 17 , alkyl, and aryl, vi) R 17 and R 18 are independently selected from the group comprising hydrogen, alkyl, and aryl, vii) R 21 , R 22 and R 23 are independently selected from hydrogen, alkyl, aryl, or R 22 and R 23 are taken together with the nitrogen to which they are attached forming a saturated cyclic or unsaturated cyclic system containing 3 to 8 carbon atoms with at least one substituent as defined herein. viii) R 24 and R 25 are independently selected from the group comprising hydrogen, halogen, alkyl, and aryl, ix) ** represents the point of attachment of Y to Y 4 e. R 2 is selected from the group comprising
wherein:
i) Y 1 and Y 2 are independently selected from the group comprising O, S NH, alkylamino, and CR 24 R 25 or Y 1 is O, S or NH, alkylamino and Y 2 is CR 24 R 25 , with the proviso that Y 1 and Y 2 cannot both be O, S, NH or alkylamino if n is 0 or 1, and ii) R 8 and R 9 are independently selected from the group comprising hydrogen, halogen and alkyl; or R 8 and R 9 may be linked together to form a substituted or unsubstituted C 3-6 cycloalkyl; iii) R 10 and R 11 are independently selected from the group comprising hydrogen, halogen and alkyl; iv) * represents the point of attachment of the R 2 to the molecule of formula A f. R 3 substituents are independently selected from the group comprising alkyl, alkyloxy, and halogen, g. R 4 is selected from the group comprising alkyl, aryl, heteroaryl, and adamantyl; R 5 is selected from the group comprising alkyl, alkyloxy, alkylthio, aryl, and heteroaryl; or R 4 and R 5 may be linked together to form a substituted or unsubstituted 5- or 6-membered cycloalkyl or cycloalkenyl ring, where said substituents are selected from the group comprising —OH, ═O, halogen, alkyl, and where 1 or 2 of the carbon atoms on said 5- or 6-membered cycloalkyl or cycloalkenyl ring may be optionally replaced by W where W is selected from the group comprising O, S N, NH, alkylamino, and arylamino; h. m and n are independently 0, 1, 2 or 3,
and pharmaceutically acceptable salts of the thereof.
In another embodiment of the invention, there are provided compounds having the structure, selected from the group comprising formulae B 1 , B 2 , B 3 , B 4 , B 5 , B 6 , B 7 , B 8 , B 9 , B 10 , B 11 , and B 12
wherein R 1 , R 2 and R 3 are as described above and R 13 is selected from the group comprising O, S (CH 3 ) 2 C and CH 2 , and R 14 is hydrogen or methyl.
The compounds according to this invention may contain one or more asymmetric carbon atoms and can thus occur as racemates and racemic mixtures, single enantiomers, diastereomeric mixtures or individual diastereomers. The term “stereoisomer” refers to a chemical compound having the same molecular weight, chemical composition, and constitution as another, but with the atoms grouped differently. That is, certain identical chemical moieties are at different orientations in space and, therefore, when pure, have the ability to rotate the plane of polarized light. However, some pure stereoisomers may have an optical rotation that is so slight that it is undetectable with present instrumentation. The compounds described herein may have one or more asymmetrical carbon atoms and therefore include various stereoisomers. All such isomeric forms of these compounds are expressly included in the present invention.
Each stereogenic carbon may be of R or S configuration. Although the specific compounds exemplified in this application may be depicted in a particular configuration, compounds having either the opposite stereochemistry at any given chiral center or mixtures thereof are also envisioned. When chiral centers are found in the derivatives of this invention, it is to be understood that this invention encompasses all possible stereoisomers.
The terms “optically pure compound” or “optically pure isomer” refers to a single stereoisomer of a chiral compound regardless of the configuration of the said compound.
For purpose of this application, all sugars are referenced using conventional three-letter nomenclature. All sugars are assumed to be in the D-form unless otherwise noted, except for fucose, which is in the L-form. Further, all sugars are in the pyranose form.
The compounds according to this invention may occur as a mixture of tautomers. The term “tautomer” or “tautomerism” refer to one of two or more structural isomers that exist in equilibrium and are readily converted from one isomeric form to another. Examples of include keto-enol tautomers, such as acetone/propen-2-ol and the like, ring-chain tautomers, such as glucose/2,3,4,5,6-pentahydroxy-hexanal and the like. The compounds described herein may have one or more tautomers and therefore include various isomers. All such isomeric forms of these compounds are expressly included in the present invention. The following example of tautomerism is provided for reference:
The following example of nomenclature and numbering system is provided for reference.
4-[1-(3,5,5,8,8-Pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-phenyl acetic acid
The term “substantially homogeneous” refers to collections of molecules wherein at least 80%, preferably at least about 90% and more preferably at least about 95% of the molecules are a single compound or a single stereoisomer thereof.
As used herein, the term “attached” signifies a stable covalent bond, certain preferred points of attachment being apparent to those skilled in the art.
The terms “optional” or “optionally” refer to occurrence or non-occurrence of the subsequently described event or circumstance, and that the description includes instances where said event or circumstance occurs and instances where it does not. In such context, the sentence “optionally substituted alkyl group” means that the alkyl group may or may not be substituted and the description includes both a substituted and an unsubstituted alkyl group.
The term “effective amount” of a compound refers a non-toxic but sufficient amount of the compound that provides a desired effect. This amount may vary from subject to subject, depending on the species, age, and physical condition of the subject, the severity of the disease that is being treated, the particular compound used, its mode of administration, and the like. Therefore, it is difficult to generalize an exact “effective amount”, yet, a suitable effective amount may be determined by one of ordinary skill in the art.
The term “pharmaceutically acceptable” refers to a compound, additive or composition that is not biologically or otherwise undesirable. For example, the additive or composition may be administered to a subject along with a compound of the invention without causing any undesirable biological effects or interacting in an undesirable manner with any of the other components of the pharmaceutical composition in which it is contained.
The term “pharmaceutically acceptable salts” includes hydrochloric salt, hydrobromic salt, hydroiodic salt, hydrofluoric salt, sulfuric salt, citric salt, maleic salt, acetic salt, lactic salt, nicotinic salt, succinic salt, oxalic salt, phosphoric salt, malonic salt, salicylic salt, phenylacetic salt, stearic salt, pyridine salt, ammonium salt, piperazine salt, diethylamine salt, nicotinamide salt, formic salt, urea salt, sodium salt, potassium salt, calcium salt, magnesium salt, zinc salt, lithium salt, cinnamic salt, methylamino salt, methanesulfonic salt, picric salt, tartaric salt, triethylamino salt, dimethylamino salt, tris(hydroxymethyl)aminomethane salt and the like. Additional pharmaceutically acceptable salts are known to those of skill in the art.
When used in conjunction with a compound of this invention, the terms “elicite”, “eliciting, “modulator”, “modulate”, “modulating”, “regulator”, “regulate” or “regulating” selective gene expression refer to a compound that can act as an activator, an agonist, a pan-agonist or an antagonist of gene expression by a particular receptor, such as for example a Retinoid X Receptor and the like.
The terms “therapeutic agent” and “chemotherapeutic agent”, refer to a compound or compounds and pharmaceutically acceptable compositions thereof that are administered to mammalian subjects as prophylactic or remedy in the treatment of a disease or medical condition. Such compounds may be administered to the subject via oral formulation, transdermal formulation or by injection.
The term “Lewis acid” refers to a molecule that can accept an unshared pair of electrons and as such would be obvious to one of ordinary skill and knowledge in the art. The definition of “Lewis acid” includes but is not limited to: boron trifluoride, boron trifluoride etherate, boron trifluoride tetrahydrofuran complex, boron trifluoride tert-butyl-methyl ether complex, boron trifluoride dibutyl ether complex, boron trifluoride dehydrate, boron trifluoride di-acetic acid complex, boron trifluoride dimethyl sulfide complex, boron trichloride, boron trichloride dimethyl sulfide complex, boron tribromide, boron tribromide dimethyl sulfide complex, boron triiodide, triimethoxyborane, triethoxyborane, trimethylaluminum, triethylaluminum, aluminum trichloride, aluminum trichloride tetrahydrofuran complex, aluminum tribromide, titanium tetrachloride, titanium tetrabromide, titanium iodide, titanium tetraethoxide, titanium tetraisopropoxide, scandium (III) trifluoromethanesulfonate, yttrium (III) trifluoromethanesulfonate, ytterbium (III) trifluoromethanesulfonate, lanthanum (III) trifluoromethanesulfonate, zinc (II) chloride, zinc (II) bromide, zinc (II) iodide, zinc (II) trifluoromethanesulfonate, zinc (II) sulfate, magnesium sulfate, lithium perchlorate, copper (II) trifluoromethanesulfonate, copper (II) tetrafluoroborate and the like. Certain Lewis acids may have optically pure ligands attached to the electron acceptor atom, as set forth in Corey, E. J. Angewandte Chemie, International Edition (2002), 41(10), 1650-1667; Aspinall, H. C. Chemical Reviews (Washington, DC, United States) (2002), 102(6), 1807-1850; Groger, H. Chemistry—A European Journal (2001), 7(24), 5246-5251; Davies, H. M. L. Chemtracts (2001), 14(11), 642-645; Wan, Y. Chemtracts (2001), 14(11), 610-615; Kim, Y. H. Accounts of Chemical Research (2001), 34(12), 955-962; Seebach, D. Angewandte Chemie, International Edition (2001), 40(1), 92-138; Blaser, H. U. Applied Catalysis, A: General (2001), 221(1-2), 119-143; Yet, L. Angewandte Chemie, International Edition (2001), 40(5), 875-877; Jorgensen, K. A. Angewandte Chemie, International Edition (2000), 39(20), 3558-3588; Dias, L. C. Current Organic Chemistry (2000), 4(3), 305-342; Spindler, F. Enantiomer (1999), 4(6), 557-568; Fodor, K. Enantiomer (1999), 4(6), 497-511; Shimizu, K. D.; Comprehensive Asymmetric Catalysis I-III (1999), 3, 1389-1399; Kagan, H. B. Comprehensive Asymmetric Catalysis I-III (1999),1, 9-30; Mikami, K. Lewis Acid Reagents (1999), 93-136 and all references cited therein. Such Lewis acids maybe used by one of ordinary skill and knowledge in the art to produce optically pure compounds from achiral starting materials.
The term “acylating agent” refers to a molecule that can transfer an alkylcarbonyl, substituted alkylcarbonyl or aryl carbonyl group to another molecule. The definition of “acylating agent” includes but is not limited to ethyl acetate, vinyl acetate, vinyl propionate, vinyl butyrate, isopropenyl acetate, 1-ethoxyvinyl acetate, trichloroethyl butyrate, trifluoroethyl butyrate, trifluoroethyl laureate, S-ethyl thiooctanoate, biacetyl monooxime acetate, acetic anhydride, acetyl chloride, succinic anhydride, diketene, diallyl carbonate, carbonic acid but-3-enyl ester cyanomethyl ester, amino acid and the like.
The term “nucleophile” or “nucleophilic reagent” refers to a negatively charged or neutral molecule that has an unshared pair of electrons and as such would be obvious to one of ordinary skill and knowledge in the art. The definition of “nucleophile” includes but is not limited to: water, alkylhydroxy, alkoxy anion, arylhydroxy, aryloxy anion, alkylthiol, alkylthio anion, arylthiol, arylthio anion, ammonia, alkylamine, arylamine, alkylamine anion, arylamine anion, hydrazine, alkyl hydrazine, arylhydrazine, alkylcarbonyl hydrazine, arylcarbonyl hydrazine, hydrazine anion, alkyl hydrazine anion, arylhydrazine anion, alkylcarbonyl hydrazine anion, arylcarbonyl hydrazine anion, cyanide, azide, hydride, alkyl anion, aryl anion and the like.
The term “electrophile” or “electrophilic reagent” refers to a positively charged or neutral molecule that has an open valence shell and as such would be obvious to one of ordinary skill and knowledge in the art. The definition of “electrophile” includes but is not limited to: hydronium, acylium, lewis acids, such as for example, boron trifluoride and the like, halogens, such as for example Br 2 and the like, carbocations, such as for example tert-butyl cation and the like, diazomethane, trimethylsilyldiazomethane, alkyl halides, such as for example methyl iodide, benzyl bromide and the like, alkyl triflates, such as for example methyl triflate and the like, alkyl sulfonates, such as for example ethyl toluenesulfonate, butyl methanesulfonate and the like, acyl halides, such as for example acetyl chloride, benzoyl bromide and the like, acid anhydrides, such as for example acetic anhydride, succinic anhydride, maleic anhydride and the like, isocyanates, such as for example methyl isocyanate, phenylisocyanate and the like, chloroformates, such as for example methyl chloroformate, ethyl chloroformate, benzyl chloroformate and the like, sulfonyl halides, such as for example methanesulfonyl chloride, p-tolunesulfonyl chloride and the like, silyl halides, such as for example trimethylsilyl chloride, tertbutyldimethyl silyll chloride and the like, phosphoryl halide such as for example dimethyl chlorophosphate and the like, alpha-beta-unsaturated carbonyl compounds such as for example acrolein, methyl vinyl ketone, cinnamaldehyde and the like.
The term “leaving group” refers to any atom (or group of atoms) that is stable in its anion or neutral form after it has been displaced by a nucleophile and as such would be obvious to one of ordinary skill and knowledge in the art. The definition of “leaving group” includes but is not limited to: water, methanol, ethanol, chloride, bromide, iodide, methanesulfonate, tolylsulfonate, trifluoromethanesulfonate, acetate, trichloroacetate, benzoate and the like.
The term “oxidant” refers to any reagent that will increase the oxidation state of a carbon atom in the starting material by either adding an oxygen atom to this carbon or removing an electron from this carbon and as such would be obvious to one of ordinary skill and knowledge in the art. The definition of “oxidant” includes but is not limited to: osmium tetroxide, ruthenium tetroxide, ruthenium trichloride, potassium permanganate, meta-chloroperbenzoic acid, hydrogen peroxide, dimethyl dioxirane and the like.
The term “metal ligand” refers to a molecule that has an unshared pair of electrons and can coordinate to a metal atom and as such would be obvious to one of ordinary skill and knowledge in the art. The definition of “metal ligand” includes but is not limited to: water, alkoxy anion, alkylthio anion, ammonia, trialkylamine, triarylamine, trialkylphosphine, triarylphosphine, cyanide, azide and the like.
The term “reducing reagent” refers to any reagent that will decrease the oxidation state of a carbon atom in the starting material by either adding a hydrogen atom to this carbon or adding an electron to this carbon and as such would be obvious to one of ordinary skill and knowledge in the art. The definition of “reducing reagent” includes but is not limited to: borane-dimethyl sulfide complex, 9-borabicyclo[3.3.1.]nonane (9-BBN), catechol borane, lithium borohydride, sodium borohydride, sodium borohydride-methanol complex, potassium borohydride, sodium hydroxyborohydride, lithium triethylborohydride, lithium n-butylborohydride, sodium cyanoborohydride, calcium (II) borohydride, lithium aluminum hydride, diisobutylaluminum hydride, n-butyl-diisobutylaluminum hydride, sodium bis-methoxyethoxyaluminum hydride, triethoxysilane, diethoxymethylsilane, lithium hydride, lithium, sodium, hydrogen Ni/B, and the like. Certain acidic and Lewis acidic reagents enhance the activity of reducing reagents. Examples of such acidic reagents include: acetic acid, methanesulfonic acid, hydrochloric acid, and the like. Examples of such Lewis acidic reagents include: trimethoxyborane, triethoxyborane, aluminum trichloride, lithium chloride, vanadium trichloride, dicyclopentadienyl titanium dichloride, cesium fluoride, potassium fluoride, zinc (II) chloride, zinc (II) bromide, zinc (II) iodide, and the like.
The term “coupling reagent” refers to any reagent that will activate the carbonyl of a carboxylic acid and facilitate the formation of an ester or amide bond. The definition of “coupling reagent” includes but is not limited to: acetyl chloride, ethyl chloroformate, dicyclohexylcarbodiimide (DCC), diisopropyl carbodiiimide (DIC), 1-ethyl-3-(3-dimethylaminopropyl) carbodiimide (EDCl), N-hydroxybenzotriazole (HOBT), N-hydroxysuccinimide (HOSu), 4-nitrophenol, pentafluorophenol, 2-(1H-benzotriazole-1-yl)-1,1,3,3-tetramethyluronium tetrafluoroborate (TBTU), O-benzotriazole-N,N,N′N′-tetramethyluronium hexafluorophosphate (HBTU), benzotriazole-1-yl-oxy-tris-(dimethylamino)-phosphonium hexafluorophosphate (BOP), benzotriazole-1-yl-oxy-tris-pyrrolidinophosphonium hexafluorophosphate, brom-trispyrrolidino-phosphonium hexafluorophosphate, 2-(5-norbornene-2,3-dicarboximido)-1,3,3-tetramethyluronium tetrafluoroborate (TNTU), O-(N-succinimidyl)-1,1,3,3-tetramethyluronium tetrafluoroborate (TSTU), tetramethylfluoroformamidinium hexafluorophosphate and the like.
The term “removable protecting group” or “protecting group” refers to any group which when bound to a functionality, such as the oxygen atom of a hydroxyl or carboxyl group or the nitrogen atom of an amino group, prevents reactions from occurring at these functional groups and which protecting group can be removed by conventional chemical or enzymatic steps to reestablish the functional group. The particular removable protecting group employed is not critical.
The definition of “hydroxyl protecting group” includes but is not limited to:
a) Methyl, tert-butyl, allyl, propargyl, p-chlorophenyl, p-methoxyphenyl, p-nitrophenyl, 2,4-dinitrophenyl, 2,3,5,6-tetrafluoro-4-(trifluoromethyl)phenyl, methoxymethyl, methylthiomethyl, (phenyldimethylsilyl)methoxymethyl, benzyloxymethyl, p-methoxy-benzyloxymethyl, p-nitrobenzyloxymethyl, o-nitrobenzyloxymethyl, (4-methoxyphenoxy)methyl, guaiacolmethyl, tert-butoxymethyl, 4-pentenyloxymethyl, tert-butyldimethylsiioxymethyl, thexyldimethylsiloxymethyl, tert-butyldiphenylsiloxymethyl, 2-methoxyethoxymethyl, 2,2,2-trichloroethoxymethyl, bis(2-chloroethoxy)methyl, 2-(trimethylsilyl)ethoxymethyl, menthoxymethyl, 1-ethoxyethyl, 1-(2-chloroethoxy)ethyl, 1-[2-(trimethylsilyl)ethoxy]ethyl, 1-methyl-1-ethoxyethyl, 1-methyl-1-benzyloxyethyl, 1-methyl-1-benzyloxy-2-fluoroethyl, 1-methyl-1-phenoxyethyl, 2,2,2-trichloroethyl, 1-dianisyl-2,2,2-trichloroethyl, 1,1,1,3,3,3-hexafluoro-2-phenylisopropyl, 2-trimethylsilylethyl, 2-(benzylthio)ethyl, 2-(phenylselenyl)ethyl, tetrahydropyranyl, 3-bromotetrahydropyranyl, tetrahydrothiopyranyl, 1-methoxycyclohexyl, 4-methoxytetrahydropyranyl, 4-methoxytetrahydrothiopyranyl, 4-methoxytetrahydropyranyl S,S-dioxide, 1-[(2-chloro-4-methyl)phenyl]-4-methoxypiperidin-4-yl, 1-(2-fluorophenyl)-4-methoxypiperidin-4-yl, 1,4-dioxan-2-yl, tetrahydrofuranyl, tetrahydrothiofuranyl and the like; b) Benzyl, 2-nitrobenzyl, 2-trifluoromethylbenzyl, 4-methoxybenzyl, 4-nitrobenzyl, 4-chlorobenzyl, 4-bromobenzyl, 4-cyanobenzyl, 4-phenylbenzyl, 4-acylaminobenzyl, 4-azidobenzyl, 4-(methylsulfinyl)benzyl, 2,4-dimethoxybenzyl, 4-azido-3-chlorobenzyl, 3,4-dimethoxybenzyl, 2,6-dichlorobenzyl, 2,6-difluorobenzyl, 1-pyrenylmethyl, diphenylmethyl, 4,4′-dinitrobenzhydryl, 5-benzosuberyl, triphenylmethyl (Trityl), α-naphthyldiphenylmethyl, (4-Methoxyphenyl)-diphenyl-methyl, di-(p-methoxyphenyl)-phenylmethyl, tri-(p-methoxyphenyl)methyl, 4(4′-bromophenacyloxy)-phenyldiphenylmethyl, 4,4′,4″-tris(4,5-dichlorophthalimidophenyl)methyl, 4,4′,4″-tris(levulinoyloxyphenyl)methyl, 4,4′-dimethoxy-3″-[N-(imidazolylmethyl)]trityl, 4,4′-dimethoxy-3″-[N-(imidazolylethyl)carbamoyl]trityl, 1,1-bis(4-methoxyphenyl)-1′-pyrenylmethyl, 4-(17-tetrabenzo[a,c,g,l]fluorenylmethyl)-4,4′-dimethoxytrityl, 9-anthryl, 9-(9-phenyl)xanthenyl, 9-(9-phenyl-10-oxo)anthryl and the like; c) Trimethylsilyl, triethylsilyl, triisopropylsilyl, dimethylisopropylsilyl, diethylisopropylsilyl, dimethylhexylsilyl, tert-butyldimethylsilyl, tert-butyldiphenylsilyl, tribenzylsilyl, tri-p-xylylsilyl, triphenylsilyl, diphenylmethylsilyl, di-tert-butylmethylsilyl, tris(trimethylsilyl)silyl, (2-hydroxystyryl)dimethylsilyl, (2-hydroxystyryl)diisopropylsilyl, tert-butylmethoxyphenylsilyl, tert-butoxydiphenylsilyl and the like; d) —C(O)R 20 , where R 20 is selected from alkyl, substituted alkyl, aryl and more specifically R 20 =hydrogen, methyl, ethyl, tert-butyl, adamantyl, crotyl, chloromethyl, dichloromethyl, trichloromethyl, trifluoromethyl, methoxymethyl, triphenylmethoxymethyl, phenoxymethyl, 4-chlorophenoxymethyl, phenylmethyl, diphenylmethyl, 4-methoxycrotyl, 3-phenylpropyl, 4-pentenyl, 4-oxopentyl, 4,4-(ethylenedithio)pentyl, 5-[bis(4-methoxyphenyl)hydroxymethylphenoxy]-4-oxopentyl, phenyl, 4methylphenyl, 4-nitrophenyl, 4-fluorophenyl, 4-chlorophenyl, 4-methoxyphenyl, 4-phenylphenyl, 2,4.6-trimethylphenyl, α-naphthyl, benzoyl and the like; e) —C(O)OR 20 , where R 20 is selected from alkyl, substituted alkyl, aryl and more specifically R 20 =methyl, methoxymethyl, 9-fluorenylmethyl, ethyl, 2,2,2-trichloromethyl, 1,1-dimethyl-2,2,2-trichloroethyl, 2-(trimethylsilyl)ethyl, 2-(phenylsulfonyl)ethyl, isobutyl, tert-Butyl, vinyl, allyl, 4-nitrophenyl, benzyl, 2-nitrobenzyl, 4-nitrobenzyl, 4-methoxybenzyl, 2,4-dimethoxybenzyl, 3,4-dimethoxybenzyl, 2-(methylthiomethoxy)ethyl, 2-dansenylethyl, 2-(4-nitrophenyl)ethyl, 2-(2,4-dinitrophenyl)ethyl, 2-cyano-1-phenylethyl, thiobenzyl, 4-ethoxy-1-naphthyl and the like.
The definition of “amino protecting group” includes but is not limited to:
a) 2-methylthioethyl, 2-methylsulfonylethyl, 2-(p-toluenesulfonyl)ethyl, [2-(1,3-dithianyl)]methyl, 4-methylthiophenyl, 2,4-dimethylthiophenyl, 2-phosphonioethyl, 1-methyl-1-(triphenylphosphonio)ethyl, 1,1-dimethyl-2-cyanoethyl, 2-dansylethyl, 2-(4-nitrophenyl)ethyl, 4-phenylacetoxybenzyl, 4-azidobenzyl, 4-azidomethoxybenzyl, m-chloro-p-acyloxybenzyl, p-(dihydroxyboryl)benzyl, 5-benzisoxazolylmethyl, 2-(trifluoromethyl)-6-chromonytmethyl, m-nitrophenyl, 3.5-dimethoxybenzyl, 1-methyl-1-(3,5-dimethoxyphenyl)ethyl, o-nitrobenzyl, α-methylnitropiperonyl, 3,4-dimethoxy-6-nitrobenzyl, N-benzenesulfenyl, N-o-nitrobenzenesulfenyl, N-2,4-dinitrobenzenesulfenyl, N-pentachlorobenzenesulfenyl. N-2-nitro-4-methoxybenzenesulfenyl, N-triphenylmethylsulfenyl, N-1-(2,2,2-trifluoro-1,1-diphenyl)ethylsulfenyl, N-3nitro-2-pyridinesulfenyl, N-p-toluenesulfonyl, N-benzenesulfonyl, N-2,3,6-trimethyl4-methoxybenzenesulfonyl, N-2,4,6-trimethoxybenzene-sulfonyl, N-2,6-dimethyl-4-methoxybenzenesulfonyl, N-pentamethylbenzenesulfonyl, N-2,3,5.6-tetramethyl-4-methoxybenzenesulfonyl and the like; b) —C(O)OR 20 , where R 20 is selected from alkyl, substituted alkyl, aryl and more specifically R 20 =methyl, ethyl, 9-fluorenylmethyl, 9-(2-sulfo)fluorenylmethyl. 9-(2,7-dibromo)fluorenylmethyl, 17-tetrabenzo[a,c,g,i]fluorenylmethyl. 2-chloro-3-indenylmethyl, benz[f]inden-3-ylmethyl, 2,7-di-t-butyl-[9-(10, 10-dioxo-10,10,10,10-tetrahydrothloxanthyl)]methyl, 1,1-dioxobenzo[b]thiophene-2-ylmethyl, 2,2,2-trichloroethyl, 2-trimethylsilylethyl, 2-phenylethyl, 1-(1-adamantyl)-1-methylethyl, 2-chloroethyl, 1.1-dimethyl-2-haloethyl, 1,1-dimethyl-2,2-dibromoethyl, 1,1-dimethyl-2,2,2-trichloroethyl, 1-methyl-1-(4-biphenylyl)ethyl, 1-(3,5-di-tert-butylphenyl)-1-methylethyl, 2-(2′-pyridyl)ethyl, 2-(4′-pyridyl)ethyl, 2,2-bis(4′-nitrophenyl)ethyl, N-(2-pivaloylamino)-1,1-dimethylethyl, 2-[(2-nitrophenyl)dithio]-1-phenylethyl, tert-butyl, 1-adamantyl, 2-adamantyl, Vinyl, allyl, 1-isopropylallyl, cinnamyl, 4-nitrocinnamyl, 3-(3′-pyridyl)prop-2-enyl, 8-quinolyl, N-Hydroxypiperidinyl, alkyldithio, benzyl, p-methoxybenzyl, p-nitrobenzyl, p-bromobenzyl, p-chlorobenzyl, 2,4-dichlorobenzyl, 4-methylsulfinylbenzyl, 9-anthrylmethyl, diphenylmethyl, tert-amyl, S-benzyl thiocarbamate, butynyl, p-cyanobenzyl, cyclobutyl, cyclohexyl, cyclopentyl, cyclopropylmethyl, p-decyloxybenzyl, diisopropylmethyl, 2,2-dimethoxycarbonylvinyl, o-(N,N′-dimethylcarboxamido)benzyl, 1,1-dimethyl-3-(N,N′-dimethylcarboxamido)propyl, 1,1-dimethylpropynyl, di(2-pyridyl)methyl, 2-furanylmethyl, 2-iodoethyl, isobornyl, isobutyl, isonicotinyl, p-(p′-methoxyphenylazo)benzyl, 1-methylcyclobutyl, 1-methylcyclohexyl, 1-methyl-1-cyclopropylmethyl, 1-methyl-1-(p-phenylazophenyl)ethyl, 1-methyl-1-phenylethyl, 1-methyl-1-4′-pyridylethyl, phenyl, p-(phenylazo)benzyl, 2,4,6-tri-methylphenyl, 4-(trimethylammonium)benzyl, 2,4,6-trimethylbenzyl and the like.
The definition of “carboxyl protecting group” includes but is not limited to:
2-N-(morpholino)ethyl, choline, methyl, methoxyethyl, 9-Fluorenylmethyl, methoxymethyl, methylthiomethyl, tetrahydropyranyl, tetrahydrofuranyl, methoxyethoxymethyl, 2-(trimethylsilyl)ethoxymethyl, benzyloxymethyl, pivaloyloxymethyl, phenylacetoxymethyl, triisopropylsilylmethyl, cyanomethyl, acetol, p-bromophenacyl. α-methylphenacyl, p-methoxyphenacyl, desyl, carboxamidomethyl, p-azobenzenecarboxamido-methyl, N-phthalimidomethyl, (methoxyethoxy)ethyl, 2,2,2-trichloroethyl, 2-fluoroethyl, 2-chloroethyl, 2-bromoethyl, 2-iodoethyl, 4-chlorobutyl, 5-chloropentyl, 2-(trimethylsilyl)ethyl, 2-methylthioethyl, 1,3-dithianyl-2-methyl, 2-(p-nitrophenylsulfenyl)ethyl, 2-(p-toluenesulfonyl)ethyl, 2-(2′-pyridyl)ethyl, 2-(p-methoxyphenyl)ethyl, 2-(diphenylphosphino)ethyl, 1-methyl-1-phenylethyl, 2-(4-acetyl-2-nitrophenyl)ethyl, 2-cyanoethyl, heptyl, tert-butyl, 3-methyl-3-pentyl, dicyclopropylmethyl, 2,4-dimethyl-3-pentyl, cyclopentyl, cyclohexyl, allyl, methallyl, 2-methylbut-3-en-2-yl, 3-methylbut-2-(prenyl), 3-buten-1-yl, 4-(trimethylsilyl)-2-buten-1-yl, cinnamyl, α-methylcinnamyl, propargyl, phenyl, 2,6-dimethylphenyl, 2,6-diisopropylphenyl, 2,6-di-tert-butyl-4-methylphenyl, 2,6-di-tert-butylmethoxyphenyl, p-(methylthio)phenyl, pentafluorophenyl, benzyl, triphenylmethyl, diphenylmethyl, bis(o-nitrophenyl)methyl, 9-anthrylmethyl, 2-(9,10-dioxo)anthrylmethyl. 5-dibenzosuberyl, 1-pyrenylmethyl, 2-(trifluoromethyl)-6-chromonylmethyl, 2,4,6-trimethylbenzyl, p-bromobenzyl, o-nitrobenzyl, p-nitrobenzyl, p-methoxybenzyl, 2.6-dimethoxybenzyl, 4-(methylsulfinyl)benzyl, 4-Sulfobenzyl, 4-azidomethoxybenzyl, 4-(a/-[1-(4,4-dimethyl-2,6-dioxocyclohexylidene)-3-methylbutyl]aminobenzyl, piperonyl, 4-picolyl, trimethylsilyl, triethylsilyl, tert-butyldimethylsilyl, isopropyldimethylsilyl, phenyldimethylsilyl, di-tert-butylmethylsilyl, triisopropylsilyl and the like.
The term “Amino acid” refers to any of the naturally occurring amino acids, as well as synthetic analogs and derivatives thereof. Alpha-Amino acids comprise a carbon atom to which is bonded an amino group, a carboxy group, a hydrogen atom, and a distinctive group referred to as a “side chain”. The side chains of naturally occurring amino acids are well known in the art and include, for example, hydrogen (e.g., as in glycine), alkyl (e.g., as in alanine, valine, leucine, isoleucine, proline), substituted alkyl (e.g., as in threonine, serine, methionine, cysteine, aspartic acid, asparagine, glutamic acid, glutamine, arginine, and lysine), arylalkyl (e.g., as in phenylalanine), substituted arylalkyl (e.g., as in tyrosine), heteroarylalkyl (e.g., as in tryptophan, histidine) and the like. One of skill in the art will appreciate that the term “amino acid” can also include beta-, gamma-, delta-, omega-amino acids, and the like. Unnatural amino acids are also known in the art, as set forth in, Natchus, M. G. Organic Synthesis: Theory and Applications (2001), 5, 89-196; Ager, D. J. Current Opinion in Drug Discovery & Development (2001), 4(6), 800; Reginato, G. Recent Research Developments in Organic Chemistry (2000), 4(Pt. 1), 351-359; Dougherty, D. A. Current Opinion in Chemical Biology (2000), 4(6), 645-652; Lesley, S. A. Drugs and the Pharmaceutical Sciences (2000), 101(Peptide and Protein Drug Analysis), 191-205; Pojitkov, A. E. Journal of Molecular Catalysis B: Enzymatic (2000), 10(1-3), 47-55; Ager, D. J. Speciality Chemicals (1999), 19(1), 10-12, and all references cited therein. Stereoisomers (e.g., D-amino acids) of the twenty conventional amino acids, unnatural amino acids such as alpha, alpha-disubstituted amino acids and other unconventional amino acids may also be suitable components for compounds of the present invention. Examples of unconventional amino acids include: 4-hydroxyproline, 3-methylhistidine, 5-hydroxylysine, and other similar amino acids and imino acids (e.g., 4-hydroxyproline).
The term “N-protected amino acid” refers to any amino acid which has a protecting group bound to the nitrogen of the amino functionality. This protecting group prevents reactions from occurring at the amino functional group and can be removed by conventional chemical or enzymatic steps to reestablish the amino functional group. The particular protecting group employed is not critical.
The term “O-protected amino acid” refers to any amino acid which has a protecting group bound to the oxygen of the carboxyl functionality. This protecting group prevents reactions from occurring at the carboxyl functional group and can be removed by conventional chemical or enzymatic steps to reestablish the carboxyl functional group.
The particular protecting group employed is not critical.
The term “Prodrug” refers to an agent that is converted into the parent drug in vivo. Prodrugs are often useful because, in some situations, they may be easier to administer than the parent drug. They may, for instance, be bioavailable by oral administration whereas the parent drug is not. The prodrug may also have improved solubility in pharmaceutical compositions over the parent drug. A prodrug may be converted into the parent drug by various mechanisms, including enzymatic processes and metabolic hydrolysis. See Harper, “Drug Latentiation” in Jucker, ed. Progress in Drug Research 4:221-294 (1962); Morozowich et al., “Application of Physical Organic Principles to Prodrug Design” in E. B. Roche ed. Design of Biopharmaceutical Properties through Prodrugs and Analogs, APHA Acad. Pharm. Sci. (1977); Bioreversible Carriers in Drug in Drug Design, Theory and Application, E. B. Roche, ed., APHA Acad. Pharm. Sci. (1987); Design of Prodrugs, H. Bundgaard, Elsevier (1985); Wang et al. “Prodrug approaches to the improved delivery of peptide drug” in Curr. Pharm. Design. 5(4):265-287 (1999); Pauletti et al. (1997) Improvement in peptide bioavailability: Peptidomimetics and Prodrug Strategies, Adv. Drug. Delivery Rev. 27:235-256; Mizen et a). (1998) “The Use of Esters as Prodrugs for Oral Delivery of .beta.-Lactam antibiotics,” Pharm. Biotech. 11,:345365; Gaignault et al. (1996) “Designing Prodrugs and Bioprecursors I. Carrier Prodrugs,” Pract. Med. Chem. 671-696; Asghamejad, “Improving Oral Drug Transport”, in Transport Processes in Pharmaceutical Systems, G. L. Amidon, P. I. Lee and E. M. Topp, Eds., Marcell Dekker, p. 185-218 (2000); Balant et al., “Prodrugs for the improvement of drug absorption via different routes of administration”, Eur. J. Drug Metab. Pharmacokinet., 15(2): 143-53 (1990); Balimane and Sinko, “Involvement of multiple transporters in the oral absorption of nucleoside analogues”, Adv. Drug Delivery Rev., 39(1-3): 183-209 (1999); Browne, “Fosphenytoin (Cerebyx)”, Clin. Neuropharmacol. 20(1): 1-12 (1997); Bundgaard, “Bioreversible derivatization of drugs—principle and applicability to improve the therapeutic effects of drugs”, Arch. Pharm. Chemi 86(1): 1-39 (1979); Bundgaard H. “Improved drug delivery by the prodrug approach”, Controlled Drug Delivery 17: 179-96 (1987); Bundgaard H. “Prodrugs as a means to improve the delivery of peptide drugs”, Adv. Drug Delivery Rev. 8(1): 1-38 (1992); Fleisher et al. “Improved oral drug delivery: solubility limitations overcome by the use of prodrugs”, Adv. Drug Delivery Rev. 19(2): 115-130 (1996); Fleisher et al. “Design of prodrugs for improved gastrointestinal absorption by intestinal enzyme targeting”, Methods Enzymol. 112 (Drug Enzyme Targeting, Pt. A): 360-81, (1985); Farquhar D, et al., “Biologically Reversible Phosphate-Protective Groups”, J. Pharm. Sci., 72(3): 324-325 (1983); Freeman S, et al., “Bioreversible Protection for the Phospho Group: Chemical Stability and Bioactivation of Di(4-acetoxy-benzyl) Methylphosphonate with Carboxyesterase,” J. Chem. Soc., Chem. Commun., 875-877 (1991); Friis and Bundgaard, “Prodrugs of phosphates and phosphonates: Novel lipophilic alpha-acyloxyalkyl ester derivatives of phosphate- or phosphonate containing drugs masking the negative charges of these groups”, Eur. J. Pharm. Sci. 4: 49-59 (1996); Gangwar et al., “Pro-drug, molecular structure and percutaneous delivery”, Des. Biopharm. Prop. Prodrugs Analogs, [Symp.] Meeting Date 1976, 409-21. (1977); Nathwani and Wood, “Penicillins: a current review of their clinical pharmacology and therapeutic use”, Drugs 45(6): 866-94 (1993); Sinhababu and Thakker, “Prodrugs of anticancer agents”, Adv. Drug Delivery Rev. 19(2): 241-273 (1996); Stella et al., “Prodrugs. Do they have advantages in clinical practice?”, Drugs 29(5): 455-73 (1985); Tan et al. “Development and optimization of anti-HIV nucleoside analogs and prodrugs: A review of their cellular pharmacology, structure-activity relationships and pharmacokinetics”, Adv. Drug Delivery Rev. 39(1-3): 117-151 (1999); Taylor, “Improved passive oral drug delivery via prodrugs”, Adv. Drug Delivery Rev., 19(2): 131-148 (1996); Valentino and Borchardt, “Prodrug strategies to enhance the intestinal absorption of peptides”, Drug Discovery Today 2(4): 148-155 (1997); Wiebe and Knaus, “Concepts for the design of anti-HIV nucleoside prodrugs for treating cephalic HIV infection”, Adv. Drug Delivery Rev.: 39(1-3):63-80 (1999); Waller et al., “Prodrugs”, Br. J. Clin. Pharmac. 28: 497-507 (1989).
The terms “halogen”, “halide” or “halo” include fluorine, chlorine, bromine, and iodine.
The terms “alkyl” and “substituted alkyl” are interchangeable and include substituted and unsubstituted C 1 -C 10 straight chain saturated aliphatic hydrocarbon groups, substituted and unsubstituted C 2 -C 10 straight chain unsaturated aliphatic hydrocarbon groups, substituted and unsubstituted C 4 -C 10 branched saturated aliphatic hydrocarbon groups, substituted and unsubstituted C 4 -C 10 branched unsaturated aliphatic hydrocarbon groups, substituted and unsubstituted C 3 -C 8 cyclic saturated aliphatic hydrocarbon groups, substituted and unsubstituted C 5 -C 8 cyclic unsaturated aliphatic hydrocarbon groups having the specified number of carbon atoms. For example, the definition of “alkyl” shall include but is not limited to: methyl (Me), ethyl (Et), propyl (Pr), butyl (Bu), pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, ethenyl, propenyl, butenyl, penentyl, hexenyl, heptenyl, octenyl, nonenyl, decenyl, undecenyl, isopropyl (i-Pr), isobutyl (i-Bu), tert-butyl (t-Bu), sec-butyl (s-Bu), isopentyl, neopentyl, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclopentenyl, cyclohexenyl, cycloheptenyl, cyclooctenyl, methylcyclopropyl, ethylcyclohexenyl, butenylcyclopentyl, adamantyl, norbornyl and the like. Alkyl substituents are independently selected from the group comprising halogen, —OH, —SH, —NH 2 , —CN, —NO 2 , ═O, ═CH 2 , trihalomethyl, carbamoyl, arylC 0-10 alkyl, heteroarylC 0-10 alkyl, C 1-10 alkyloxy, arylC 0-10 alkyloxy, C 1-10 alkylthio, arylC 0-10 alkylthio, C 1-10 alkylamino, arylC 0-10 alkylamino, N-aryl-N-C 0-10 alkylamino, C 1-10 alkylcarbonyl, arylC 0-10 alkylcarbonyl, C 1-10 alkylcarboxy, arylC 0-10 alkylcarboxy, C 1-10 alkylcarbonylamino, arylC 0-10 alkylcarbonylamino, tetrahydrofuryl, morpholinyl, piperazinyl, hydroxypyronyl, —C 0-10 alkylCOOR 21 and —C 0-10 alkylCONR 22 R 23 wherein R 21 , R 22 and R 23 are independently selected from hydrogen, alkyl, aryl, or R 22 and R 23 are taken together with the nitrogen to which they are attached forming a saturated cyclic or unsaturated cyclic system containing 3 to 8 carbon atoms with at least one substituent as defined herein.
The term “alkyloxy” (e.g. methoxy, ethoxy, propyloxy, allyloxy, cyclohexyloxy) represents a substituted or unsubstituted alkyl group as defined above having the indicated number of carbon atoms attached through an oxygen bridge. The term “alkyloxyalkyl” represents an alkyloxy group attached through an alkyl or substituted alkyl group as defined above having the indicated number of carbon atoms.
The term “alkylthio” (e.g. methylthio, ethylthio, propylthio, cyclohexenylthio and the like) represents a substituted or unsubstituted alkyl group as defined above having the indicated number of carbon atoms attached through a sulfur bridge. The term “alkylthioalkyl” represents an alkylthio group attached through an alkyl or substituted alkyl group as defined above having the indicated number of carbon atoms.
The term “alkylamino” (e.g. methylamino, diethylamino, butylamino, N-propyl-N-hexylamino, (2-cyclopentyl)propylamino, hexenylamino, and the like) represents one or two substituted or unsubstituted alkyl groups as defined above having the indicated number of carbon atoms attached through an amine bridge. The substituted or unsubstituted alkyl groups maybe taken together with the nitrogen to which they are attached forming a saturated cyclic or unsaturated cyclic system containing 3 to 10 carbon atoms with at least one substituent as defined above. The term “alkylaminoalkyl” represents an alkylamino group attached through a substituted or unsubstituted alkyl group as defined above having the indicated number of carbon atoms.
The term “alkylhydrazino” (e.g. methylhydrazino, diethylhydrazino, butylhydrazino, (2-cyclopentyl)propylhydrazino, cyclohexanehydrazino, and the like) represents one or two substituted or unsubstituted alkyl groups as defined above having the indicated number of carbon atoms attached through a nitrogen atom of a hydrazine bridge. The substituted or unsubstituted alkyl groups maybe taken together with the nitrogen to which they are attached forming a saturated cyclic or unsaturated cyclic system containing 3 to 10 carbon atoms with at least one substituent as defined above. The term “alkylhydrazinoalkyl” represents an alkylhydrazino group attached through a substituted or unsubstituted alkyl group as defined above having the indicated number of carbon atoms.
The term “alkylcarbonyl” (e.g. cyclooctylcarbonyl, pentylcarbonyl, 3-hexenylcarbonyl and the like) represents a substituted or unsubstituted alkyl group as defined above having the indicated number of carbon atoms attached through a carbonyl group. The term “alkylcarbonylalkyl” represents an alkylcarbonyl group attached through a substituted or unsubstituted alkyl group as defined above having the indicated number of carbon atoms.
The term “alkylcarboxy” (e.g. heptylcarboxy, cyclopropylcarboxy, 3-pentenylcarboxy and the like) represents an alkylcarbonyl group as defined above wherein the carbonyl is in turn attached through an oxygen. The term “alkylcarboxyalkyl” represents an alkylcarboxy group attached through an alkyl group as defined above having the indicated number of carbon atoms.
The term “alkylcarbonylamino” (e.g. hexylcarbonylamino, cyclopentylcarbonyl-aminomethyl, methylcarbonylaminophenyl and the like) represents an alkylcarbonyl group as defined above wherein the carbonyl is in turn attached through the nitrogen atom of an amino group. The nitrogen group may itself be substituted with a substituted or unsubstituted alkyl or aryl group. The term “alkylcarbonylaminoalkyl” represents an alkylcarbonylamino group attached through a substituted or unsubstituted alkyl group as defined above having the indicated number of carbon atoms.
The term “alkylcarbonylhydrazino” (e.g. ethylcarbonylhydrazino, tert-butylcarbonylhydrazino and the like) represents an alkylcarbonyl group as defined above wherein the carbonyl is in turn attached through the nitrogen atom of a hydrazino group.
The term “aryl” represents an unsubstituted, mono-, di- or trisubstituted monocyclic, polycyclic, biaryl aromatic groups covalently attached at any ring position capable of forming a stable covalent bond, certain preferred points of attachment being apparent to those skilled in the art (e.g., 3-phenyl, 4-naphtyl and the like). The aryl substituents are independently selected from the group comprising halogen, —OH, —SH, —CN, —NO 2 , trihalomethyl, hydroxypyronyl, C 1-10 alkyl, arylC 0-10 alkyl, C 0-10 alkyloxyC 0-10 alkyl, arylC 0-10 alkyloxyC 0-10 alkyl, C 0-10 alkylthioC 0-10 alkyl, arylC 0-10 alkylthioC 0-10 alkyl, C 0-10 alkylaminoC 0-10 alkyl, arylC 0-10 alkylaminoC 0-10 alkyl, N-aryl-N—C 0-10 alkylaminoC 0-10 alkyl, C 1-10 alkylcarbonylC 0-10 alkyl, arylC 0-10 alkylcarbonylC 0-10 alkyl, C 1-10 alkylcarboxyC 0-10 alkyl, arylC 0-10 alkylcarboxyC 0-10 alkyl, C 1-10 alkylcarbonylaminoC 0-10 alkyl, arylC 0-10 alkylcarbonylaminoC 0-10 alkyl, —C 0-10 alkylCOOR 21 , and —C 0-10 alkylCONR 22 R 23 wherein R 21 , R 22 and R 23 are independently selected from hydrogen, alkyl, aryl or R 22 and R 23 are taken together with the nitrogen to which they are attached forming a saturated cyclic or unsaturated cyclic system containing 3 to 8 carbon atoms with at least one substituent as defined above.
The definition of “aryl” includes but is not limited to phenyl, biphenyl, naphthyl, dihydronaphthyl, tetrahydronaphthyl, indenyl, indanyl, azulenyl, anthryl, phenanthryl, fluorenyl, pyrenyl and the like.
The term “arylalkyl” (e.g. (4-hydroxyphenyl)ethyl, (2-aminonaphthyl)hexenyl and the like) represents an aryl group as defined above attached through a substituted or unsubstituted alkyl group as defined above having the indicated number of carbon atoms.
The term “arylcarbonyl” (e.g. 2-thiophenylcarbonyl, 3-methoxyanthrylcarbonyl and the like) represents an aryl group as defined above attached through a carbonyl group.
The term “arylalkylcarbonyl” (e.g. (2,3-dimethoxyphenyl)propylcarbonyl, (2-chloronaphthyl)pentenyl-carbonyl and the like) represents an arylalkyl group as defined above wherein the alkyl group is in turn attached through a carbonyl.
The term “aryloxy” (e.g. phenoxy, naphthoxy, 3-methylphenoxy, and the like) represents an aryl or substituted aryl group as defined above having the indicated number of carbon atoms attached through an oxygen bridge. The term “aryloxyalkyl” represents an aryloxy group attached through a substituted or unsubstituted alkyl group as defined above having the indicated number of carbon atoms.
The term “arylthio” (e.g. phenylthio, naphthylthio, 3-bromophenylthio, and the like) represents an aryl or substituted aryl group as defined above having the indicated number of carbon atoms attached through a sulfur bridge. The term “arylthioalkyl” represents an arylthio group attached through a substituted or unsubstituted alkyl group as defined above having the indicated number of carbon atoms.
The term “arylamino” (e.g. phenylamino, diphenylamino, naphthylamino, N-phenyl-N-naphthylamino, o-methylphenylamino, p-methoxyphenylamino, and the like) represents one or two aryl groups as defined above having the indicated number of carbon atoms attached through an amine bridge. The term “arylaminoalkyl” represents an arylamino group attached through a substituted or unsubstituted alkyl group as defined above having the indicated number of carbon atoms. The term “arylalkylamino” represents an aryl group attached through an alkylamino group as defined above having the indicated number of carbon atoms. The term “N-aryl-N-alkylamino” (e.g. N-phenyl-N-methylamino, N-naphthyl-N-butylamino, and the like) represents one aryl and one a substituted or unsubstituted alkyl group as defined above having the indicated number of carbon atoms independently attached through an amine bridge.
The term “arylhydrazino” (e.g. phenylhydrazino, naphthylhydrazino, 4-methoxyphenylhydrazino, and the like) represents one or two aryl groups as defined above having the indicated number of carbon atoms attached through a hydrazine bridge. The term “arylhydrazinoalkyl” represents an arylhydrazino group attached through a substituted or unsubstituted alkyl group as defined above having the indicated number of carbon atoms. The term “arylalkylhydrazino” represents an aryl group attached through an alkylhydrazino group as defined above having the indicated number of carbon atoms. The term “N-aryl-N-alkylhydrazino” (e.g. N-phenyl-N-methylhydrazino, N-naphthyl-N-butylhydrazino, and the like) represents one aryl and one a substituted or unsubstituted alkyl group as defined above having the indicated number of carbon atoms independently attached through an amine atom of a hydrazine bridge.
The term “arylcarboxy” (e.g. phenylcarboxy, naphthylcarboxy, 3-fluorophenylcarboxy and the like) represents an arylcarbonyl group as defined above wherein the carbonyl is in turn attached through an oxygen bridge. The term “arylcarboxyalkyl” represents an arylcarboxy group attached through a substituted or unsubstituted alkyl group as defined above having the indicated number of carbon atoms.
The term “arylcarbonylamino” (e.g. phenylcarbonylamino, naphthylcarbonylamino, 2-methylphenylcarbonylamino and the like) represents an arylcarbonyl group as defined above wherein the carbonyl is in turn attached through the nitrogen atom of an amino group. The nitrogen group may itself be substituted with an a substituted or unsubstituted alkyl or aryl group. The term “arylcarbonylaminoalkyl” represents an arylcarbonylamino group attached through a substituted or unsubstituted alkyl group as defined above having the indicated number of carbon atoms. The nitrogen group may itself be substituted with a substituted or unsubstituted alkyl or aryl group.
The term “arylcarbonylhydrazino” (e.g. phenylcarbonylhydrazino, naphthylcarbonylhydrazino, and the like) represents an arylcarbonyl group as defined above wherein the carbonyl is in turn attached through the nitrogen atom of a hydrazino group.
The terms “heteroaryl”, “heterocycle” or “heterocyclic” refers to a monovalent unsaturated group having a single ring or multiple condensed rings, from 1 to 8 carbon atoms and from 1 to 4 hetero atoms selected from nitrogen, sulfur or oxygen within the ring. The heteroaryl groups in this invention can be optionally substituted with 1 to 3 substituents selected from the group comprising: halogen, —OH, —SH, —CN, —NO 2 , trihalomethyl, hydroxypyronyl, C 1-10 alkyl, arylC 0-10 alkyl, C 0-10 alkyloxyC 0-10 alkyl, arylC 0-10 alkyloxyC 0-10 alkyl, C 0-10 alkylthioC 0-10 alkyl, arylC 0-10 alkylthioC 0-10 alkyl, C 0-10 alkylaminoC 0-10 alkyl, arylC 0-10 alkylaminoC 0-10 alkyl, N-aryl-N-C 0-10 alkylaminoC 0-10 alkyl, C 1-10 alkylcarbonylC 0-10 alkyl, arylC 0-10 alkylcarbonylC 0-10 alkyl, C 1-10 alkylcarboxyC 1-10 alkyl, arylC 0-10 alkylcarboxyC 0-10 alkyl, C 1-10 alkylcarbonylaminoC 0-10 alkyl, arylC 0-10 alkylcarbonylaminoC 0-10 alkyl, —C 0-10 alkylCOOR 21 , and —C 0-10 alkylCONR 22 R 23 wherein R 21 , R 22 and R 23 are independently selected from hydrogen, alkyl, aryl, or R 22 and R 23 are taken together with the nitrogen to which they are attached forming a saturated cyclic or unsaturated cyclic system containing 3 to 8 carbon atoms with at least one substituent as defined above.
The definition of “heteroaryl” includes but is not limited to thienyl, benzothienyl, isobenzothienyl, 2,3-dihydrobenzothienyl, furyl, pyranyl, benzofuranyl, isobenzofuranyl, 2,3-dihydrobenzofuranyl, pyrrolyl, pyrrolyl-2,5-dione, 3-pyrrolinyl, indolyl, isoindolyl, 3H-indolyl, indolinyl, indolizinyl, indazolyl, phthalimidyl (or isoindoly-1,3-dione), imidazolyl, 2H-imidazolinyl, benzimidazolyl, pyridyl, pyrazinyl, pyradazinyl, pyrimidinyl, triazinyl, quinolyl, isoquinolyl, 4H-quinolizinyl, cinnolinyl, phthalazinyl, quinazolinyl, quinoxalinyl, 1,8-naphthyridinyl, pteridinyl, carbazolyl, acridinyl, phenazinyl, phenothiazinyl, phenoxazinyl, chromanyl, benzodioxolyl, piperonyl, purinyl, pyrazolyl, triazolyl, tetrazolyl, thiazolyl, isothiazolyl, benzthiazolyl, oxazolyl, isoxazolyl, benzoxazolyl, oxadiazolyl, thiadiazolyl, pyrrolidinyl-2,5dione, imidazolidinyl-2,4-dione, 2-thioxo-imidazolidinyl-4-one, imidazolidinyl-2,4-dithione, thiazolidinyl-2,4-dione, 4-thioxo-thiazolidinyl-2-one, piperazinyl-2,5-dione, tetrahydro-pyridazinyl-3,6-dione, 1,2-dihydro-[1,2,4,5]tetrazinyl-3,6-dione, [1,2,4,5]tetrazinanyl-3,6-dione, dihydro-pyrimidinyl-2,4-dione, pyrimidinyl-2,4,6-trione and the like. For the purposes of this application, the terms “heteroaryl”, “heterocycle” or “heterocyclic” do not include carbohydrate rings (i.e. mono- or oligosaccharides).
The term “saturated heterocyclic” represents an unsubstituted, mono-, di- or trisubstituted monocyclic, polycyclic saturated heterocyclic group covalently attached at any ring position capable of forming a stable covalent bond, certain preferred points of attachment being apparent to those skilled in the art (e.g., 1-piperidinyl, 4-piperazinyl and the like).
The saturated heterocyclic substituents are independently selected from the group comprising halo, —OH, —SH, —CN, —NO 2 , trihalomethyl, hydroxypyronyl, C 1-10 alkyl, arylC 0-10 alkyl, C 0-10 alkyloxyC 0-10 alkyl, arylC 0-10 alkyloxyC 0-10 alkyl, C 0-10 alkylthioC 0-10 alkyl, arylC 0-10 alkylthioC 0-10 alkyl, C 0-10 alkylaminoC 0-10 alkyl, arylC 0-10 alkylaminoC 0-10 alkyl, N-aryl-N-C 0-10 alkylaminoC 0-10 alkyl, C 1-10 alkylcarbonylC 0-10 alkyl, arylC 0-10 alkylcarbonylC 0-10 alkyl, C 1-10 alkylcarboxyC 0-10 alkyl, arylC 0-10 alkylcarboxyC 0-10 alkyl, C 1-10 alkylcarbonylaminoC 0-10 alkyl, arylC 0-10 alkylcarbonylaminoC 0-10 alkyl, —C 0-10 alkylCOOR 21 , and —C 0-10 alkylCONR 22 R 23 wherein R 21 , R 22 and R 23 are independently selected from hydrogen, alkyl, aryl, or R 22 and R 23 are taken together with the nitrogen to which they are attached forming a saturated cyclic or unsaturated cyclic system containing 3 to 8 carbon atoms with at least one substituent as defined above.
The definition of saturated heterocyclic includes but is not limited to pyrrolidinyl, pyrazolidinyl, piperidinyl, 1,4-dioxanyl, morpholinyl, 1,4-dithienyl, thiomorpholinyl, piperazinyl, quinuclidinyl, and the like.
The term “alpha-beta-unsaturated carbonyl” refers to a molecule that has a carbonyl group directly attached to a double or triple bonded cabon and which would be obvious to one of ordinary skill and knowledge in the art. The definition of alpha-beta-unsaturated carbonyl includes but is not limited to acrolein, methyl vinyl ketone, and the like.
Invention compounds having structure A include
and pharmaceutically acceptable salts of the thereof
In another embodiment of the invention, there are provided pharmaceutical compositions comprising at least one of the compounds of the invention, as well as pharmaceutically acceptable pro-drugs and salts of such compounds, in a pharmaceutically acceptable vehicle, for enteral, parenteral, topical or ocular administration.
In another embodiment of the invention, there are provided pharmaceutical compositions comprising an effective regulating amount of at least one of the compounds of the invention in combination with a pharmaceutically acceptable vehicle, for control of cellular processes, cellular differentiation, cellular proliferation or apoptosis.
In another embodiment of the invention, there are provided pharmaceutical compositions comprising in a pharmaceutically acceptable vehicle suitable for enteral, parenteral, or topical administration, one or more compounds of the invention for treating a mammalian subject wherein said wherein said compound exerts its therapeutic effects via the in vivo modulation of lipid metabolism, lipid homeostasis, hyperlipidemia, skin-related processes, autoimmune diseases, fatty acid metabolism, malignant cell development, premalignant lesions, programmed cell death, endocrinological processes, or AP-1 metabolism.
In another embodiment of the invention, there are provided pharmaceutical compositions comprising at least one of the compounds of the invention, in a pharmaceutically acceptable vehicle, for the treatment of carcinomas. Examples of carcinomas include mammary cancer, prostate cancer, kidney cancer, Karposi's sarcoma, colon cancer, cervical cancer, lung cancer, cutaneous T-cell lymphoma, cancer of the head and neck, cancers of the aerodigestive pathway, skin cancer, bladder cancer, sarcomas, leukoplakias, acute promyelocytic leukemia, and the like.
In another embodiment of the invention, there are provided pharmaceutical compositions comprising at least one the compounds of the invention in combination with other chemotherapeutic agents, in a pharmaceutically acceptable vehicle, for the treatment of carcinomas. Examples of chemotherapeutic agents contemplated for use in the practice of this particular invention include Busulfan, Carboplatin, Cisplatin, Cyclophosphamide, Cytosine arabinoside, Etoposide, 5-Fluorouracil, Melphalan, Methotrexate, Mitoxantrone, Taxol, Interferon, Toremifene, Arzoxifene, Raloxifene, Tamoxifen, and the like.
In another embodiment of the invention, there are provided pharmaceutical compositions comprising at least one the compounds of the invention in combination with one or more antiestrogenic agents, in a pharmaceutically acceptable vehicle, for the treatment of mammary carcinoma. Examples of antiestrogenic agents contemplated for use in the practice of this particular invention include Toremifene, Arzoxifene, Raloxifene, Tamoxifen, and the like.
In another embodiment of the invention, there are provided cosmeceutical compositions comprising at least one the compounds of the invention, in a cosmetically acceptable vehicle, for dermal indications.
Before the present compounds, compositions and methods are disclosed and described, It is to be understood that this invention is not limited to specific synthetic methods, specific pharmaceutical carriers, or to particular pharmaceutical formulations or administration regimens, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.
It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a bicyclic aromatic compound” includes mixtures of bicyclic aromatic compounds, reference to “a pharmaceutical carrier” includes mixtures of two or more such carriers, and the like.
Certain pharmaceutically acceptable salts of the invention are prepared by treating the novel compounds of the invention with an appropriate amount of pharmaceutically acceptable base. Representative pharmaceutically acceptable bases are ammonium hydroxide, sodium hydroxide, potassium hydroxide, lithium hydroxide, calcium hydroxide, magnesium hydroxide, ferrous hydroxide, zinc hydroxide, copper hydroxide, aluminum hydroxide, ferric hydroxide, isopropylamine, trimethylamine, diethylamine, triethylamine, tripropylamine, ethanolamine, 2-dimethylaminoethanol, 2-diethylaminoethanol, lysine, arginine, histidine, and the like. The reaction is conducted in water, alone or in combination with an inert, water-miscible organic solvent, at a temperature of from about 0° C. to about 100° C., preferably at room temperature. The molar ratio of compounds of structural formula A to base used is chosen to provide the ratio desired for any particular salts. For preparing, for example, the ammonium salts of the starting material, compounds of formula A can be treated with approximately one equivalent of the pharmaceutically acceptable base to yield a neutral salt. When calcium salts are prepared, approximately one-half a molar equivalent of base is used to yield a neutral salt, while for aluminum salts, approximately one-third a molar equivalent of base will be used.
The compounds of the invention according to formula A, including the pharmacologically acceptable pro-drugs or salts thereof, are useful to elicit, modulate and/or regulate selective gene expression by cellular receptors and provide control over cellular growth, proliferation and differentiation processes regulated by certain hormones or vitamins such as for example all-trans-retinoic acid, 13-cis-retinoic acid, 9cis-retinoic acid, vitamin D, thyroid hormone and the like. As noted above, the compounds of the invention are thus useful in the treatment of conditions and/or diseases that are regulated by the aforementioned entities. Examples of such conditions include for example cancer, mammary cancer, prostate cancer, kidney cancer, Karposi's sarcoma, colon cancer, cervical cancer, lung cancer, cutaneous T-cell lymphoma, cancer of the head and neck, cancers of the aerodigestive pathway, skin cancer, bladder cancer, sarcomas, leukoplakias, acute promyelocytic leukemia, acne, psoriasis, aging, wrinkling, diabetes, hyperglycemia, bone calcification, thyroid conditions, and the like
The compounds of the invention may be conveniently formulated into pharmaceutical compositions composed of one or more of the compounds together with a pharmaceutically acceptable vehicle as described in Remington's Pharmaceutical Sciences, latest edition, by E. W. Martin (Mack Publ. Co., Easton Pa.).
The compounds of the invention may be administered orally, parenterally (e.g., intravenously), by intramuscular injection, by intraperitoneal injection, topically, transdermally, or the like, although oral or topical administration is typically preferred. The amount of active compound administered will, of course, be dependent on the subject being treated, the subject's weight, the manner of administration and the judgment of the prescribing physician. The dosage will be in the range of about 2 microgram per kilogram per day to 4 milligram per kilogram per day.
Depending on the intended mode of administration, the pharmaceutical compositions may be in the form of solid, semi-solid or liquid dosage forms, such as, for example, tablets, suppositories, pills, capsules, powders, liquids, suspensions, lotions, creams, gels and the like, preferably in unit dosage form suitable for single administration of a precise dosage. The compositions will include, as noted above, an effective amount of the selected drug in combination with a pharmaceutically acceptable vehicle and, in addition, may include other medicinal agents, pharmaceutical agents, carriers, adjuvants, diluents and the like.
For solid compositions, conventional non-toxic solid carriers include, for example, pharmaceutical grades of mannitol, lactose, starch, magnesium stearate, sodium saccharin, talc, cellulose, glucose, sucrose, magnesium carbonate, and the like. Liquid pharmaceutically administrable-compositions can, for example, be prepared by dissolving, dispersing, etc., an active compound as described herein and optional pharmaceutical adjuvants in an excipient, such as, for example, water, saline, aqueous dextrose, glycerol, ethanol, and the like, to thereby form a solution or suspension. If desired, the pharmaceutical composition to be administered may also contain minor amounts of nontoxic auxiliary substances such as wetting or emulsifying agents, pH buffering agents and the like, for example, sodium acetate, sorbitan monolaurate, triethanolamine sodium acetate, triethanolamine oleate, etc. Actual methods of preparing such dosage forms are known, or will be apparent, to those skilled in this art; for example, see Remington's Pharmaceutical Sciences, referenced above.
For oral administration, fine powders or granules may contain diluting, dispersing, and/or surface active agents, and may be presented in water or in a syrup, in capsules or sachets in the dry state, or in a non-aqueous solution or suspension wherein suspending agents may be included, in tablets wherein binders and lubricants may be included, or in a suspension in water or a syrup. Wherever required, flavoring, preserving, suspending, thickening, or emulsifying agents may also be included. Tablets and granules are preferred oral administration forms, and these may be coated.
Parenteral administration, if used, is generally characterized by injection. Injectables can be prepared in conventional forms, either as liquid solutions or suspensions, solid forms suitable for solution or suspension in liquid prior to injection, as emulsions, or as sustained release delivery system.
EXAMPLES
Used herein, the following abbreviations have the following meanings: Me refers to methyl (CH 3 —), Et refers to ethyl (CH 3 CH 2 —) i-Pr refers to isopropyl ((CH 3 ) 2 CH 2 —), t-Bu or tert-butyl refers to tertiary butyl ((CH 3 ) 3 CH—), Ph refers to phenyl, Bn refers to benzyl (PhCH 2 —), Bz refers to benzoyl (PhCO—), MOM refers to methoxymethyl, Ac refers to acetyl, TMS refers to trimethylsilyl, TBS refers to ter-butyldimethylsilyl, Ms refers to methanesulfonyl (CH 3 SO 2 —), Ts refers to p-toluenesulfonyl (p-CH 3 PhSO 2 —), Tf refers to trifluoromethanesulfonyl (CF 3 SO 2 —), TfO refers to trifluoromethanesulfonate (CF 3 SO 3 —), DMF refers to N,N-dimethylformamide, DCM refers to dichloromethane (CH 2 Cl 2 ), THF refers to tetrahydrofuran, EtOAc refers to ethyl acetate, Et 2 O refers to diethyl ether, MeCN refers to acetonitrile (CH 3 CN), NMP refers to 1-N-methyl-2-pyrrolidinone, DMA refers to N,N-dimethylacetamide, DMSO refers to dimethylsulfoxide, DCC refers to 1,3-dicyclohexyldicarbodiimide, EDCl refers to 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide, Boc refers to tert-butylcarbonyl, Fmoc refers to 9-fluorenylmethoxycarbonyl, TBAF refers to tetrabutylammonium fluoride, TBAl refers to tetrabutylammonium iodide, TMEDA refers to N,N,N,N-tetramethylethylene diamine, Dess-Martin periodinane or Dess Martin reagent refers to 1,1,1-triacetoxy-1,1-dihydro-1,2-benziodoxol-3(1H)-one, DMAP refers to 4-N,N-dimethylaminopyridine, (i-Pr) 2 NEt or DIEA or Hunig's base refers to N,N-diethylisopropylamine, DBU refers to 1,8-Diazabicyclo[5.4.0]undec-7-ene, (DHQ) 2 AQN refers to dihydroquinine anthraquinone-1,4-diyl diether, (DHQ) 2 PHAL refers to dihydroquinine phthalazine-1,4-diyl diether, (DHQ) 2 PYR refers to dihydroquinine 2,5-diphenyl-4,6-pyrimidinediyl diether, (DHQD) 2 AQN refers to dihydroquinidine anthraquinone-1,4diyl diether, (DHQD) 2 PHAL refers to dihydroquinidine phthalazine-1,4diyl diether, (DHQD) 2 PYR refers to dihydroquinidine 2,5-diphenyl-4,6-pyrimidinediyl diether, LDA refers to lithium diisopropylamide, LiTMP refers to lithium 2,2,6,6-tetramethylpiperdinamide, n-BuLi refers to n-butyllithium, t-BuLi refers to tert-butyl lithium, IBA refers to 1-hydroxy-1,2-benziodoxol-3(1H)-one 1-oxide, OsO 4 refers to osmium tetroxide, m-CPBA refers to meta-chloroperbenzoic acid, DMD refers to dimethyl dioxirane, PDC refers to pyridinium dichromate, NMO refers to N-methyl morpholine-N-oxide, NaHMDS refers to sodium hexamethyldisilazide, LiHMDS refers to lithium hexamethyldisilazide, HMPA refers to hexamethylphosphoramide, TMSCl refers to trimethylsilyl chloride, TMSCN refers to trimethylsilyl cyanide, TBSCl refers to tert-butyldimethylsilyl chloride, TFA refers to trifluoroacetic acid, TFAA refers to trifluoroacetic anhydride, AcOH refers to acetic acid, Ac 2 O refers to acetic anhydride, AcCl refers to acetyl chloride, TsOH refers to p-toluenesulfonic acid, TsCl refers to p-toluenesulfonyl chloride, MBHA refers to 4-methylbenzhydrylamine, BHA refers to benzhydrylamine, ZnCl 2 refers to zinc (II) dichloride, BF 3 refers to boron trifluoride, Y(OTf) 2 refers to yttrium (III) trifluoromethanesulfonate, Cu(BF 4 ) 2 refers to copper (II) tetrafluoroborate, LAH refers to lithium aluminum hydride (LiAlH 4 ), NaHCO 3 refers to sodium bicarbonate, K 2 CO 3 refers to potassium carbonate, NaOH refers to sodium hydroxide, KOH refers to potassium hydroxide, LiOH refers to lithium hydroxide, HCl refers to hydrochloric acid, H 2 SO 4 refers to sulfuric acid, MgSO 4 refers to magnesium sulfate, and Na 2 SO 4 refers to sodium sulfate. 1H NMR refers to proton nuclear magnetic resonance, 13C NMR refers to carbon 13 nuclear magnetic resonance, NOE refers to nuclear overhauser effect, NOESY refers to nuclear overhauser and exchange spectroscopy, COSY refers to homonuclear correlation spectroscopy, HMQC refers to proton detected heteronuclear multiplet-quantum coherence, HMBC refers to heteronuclear multiple-bond connectivity, s refers to singlet, br s refers to broad singlet, d refers to doublet, br d refers to broad doublet, t refers to triplet, q refers to quartet, dd refers to double doublet, m refers to multiplet, ppm refers to parts per million, IR refers to infrared spectrometry, MS refers to mass spectrometry, HRMS refers to high resolution mass spectrometry, El refers to electron impact, FAB refers to fast atom bombardment, Cl refers to chemical ionization, HPLC refers to high pressure liquid chromatography, TLC refer to thin layer chromatography, R f refers to, R t refers to retention time, GC refers to gas chromatography, min is minutes, h is hours, rt or RT is room temperature, g is grams, mg is milligrams, L is liters, mL is milliliters, mol is moles and mmol is millimoles.
For all of the following examples, standard work-up and purification methods can be utilized and will be obvious to those skilled in the art. Synthetic methodologies can be used to practice the invention are shown in Schemes 1-4. These Schemes are intended to describe the applicable chemistry through the use of specific examples and are not necessarily indicative of the full scope of the invention.
Example 1
1,1,4,4,6-pentamethyl-1,2,3,4-tetrahydronaphthalene
To 2,5-dimethyl-2,5-hexanediol (10 g, 68.5 mmol) in a 500 mL flask was added reagent grade concentrated HCl (150 mL) and the solution was stirred at ambient temperature for 1 h. Water (100 mL) and CH 2 Cl 2 (100 mL) were then added slowly and the layers were separated. The aqueous layer was washed with additional CH 2 Cl 2 (100 mL). The combined organic layers were dried over MgSO 4 and filtered thru silica gel pad. The solvent was removed to yield 10.9 g (87%) of 2,5-dichloro-2,5-dimethylhexane. The dichloride was dissolved in 150 mL of CH 2 Cl 2 and 9.6 mL of toluene (90 mmol) was added. AlCl 3 (390 mg, 2.9 mol) was added in portions over 5 min at ambient temperature. HCl is evolved and the solution turns dark red. The reaction was placed in an ice-bath and quenched with deionized water (120 mL). Hexane (150 mL) was added and the organic layer was removed. The aqueous layer was washed with additional hexane (150 mL). The combined organic layers were washed with water (200 mL) and brine (100 mL) and dried over MgSO 4 . The solvent was removed in vacuo to give 1,1,4,4,6-pentamethyl-1,2,3,4-tetrahydronaphthalene as a colorless oil that crystallized after storage at −20° C.
Yield: 12 g (91%); low melting white solid; R f =0.7 in 100% hexane.
1 H NMR (CDCl 3 , 300 MHz) δ 1.32 (s, 12H), 1.7 (s, 4H), 2.34 (s, 3H), 6.85 (dd, 1H), 7.14 (d, 1H), 7.22 (d, 1H)
13 C NMR (CDCl 3 , 75 MHz) δ 21.54, 32.26, 32.32, 34.29, 34.51, 35.57, 35.63, 126.64, 126.75, 127.21, 134.93, 142.00, 144.83
Example 2
4-(3,5,5,8,8-Pentamethyl-5,6,7,8-tetrahydro-naphthalene-2-carbonyl)-benzoic acid methyl ester
To a solution of 1,1,4,4,6-pentamethyl-1,2,3,4-tetrahydronaphthalene (470 mg, 2.33 mmol) in 10 mL of CHCl 3 was added the acid chloride shown (462 mg, 2.33 mmol), followed by AlCl 3 (930 mg, 6.97 mmol) at room temperature. The mixture was stirred at room temperature under nitrogen for 20 minutes. Water (10 mL) was added, and the product was extracted with CH 2 Cl 2 three times. The combined organic fraction was dried over Na 2 SO 4 , filtered and purified by silica gel chromatography to yield 830 mg of the desired methyl ester product.
Yield: 0.83 g (98%); white solid; R f =0.6 in 10% EtOAc/hexanes 1 H NMR (CDCl 3 , 300 MHz) δ 1.22 (6H, s), 1.34 (6H, s), 1.71 (4H, s), 2.38 (3H, s), 3.97 (3H, s), 7.23 (1H, s), 7.29 (1H, s), 7.91 (2H, d), 8.22 (2H, d)
Example 3
4-(3,5,5,8,8-Pentamethyl-5,6,7,8-tetrahydro-naphthalene-2-carbonyl)-benzoic acid
To a solution of 4-(3,5,5,8,8-Pentamethyl-5,6,7,8-tetrahydro-naphthalene-2carbonyl)-benzoic acid methyl ester (820 mg, 2.25 mmol) in 10 mL of THF and 10 mL of MeOH was added NaOH (22 mL of 1N solution, 22 mmol). The mixture was stirred at room temperature overnight. The mixture was acidified with HCl (23 mL of 1N solution, 23 mmol). The product was extracted with CH 2 Cl 2 twice and EtOAc twice. The combined organic fraction was dried over Na 2 SO 4 , filtered and was used in the next step without purification.
Yield: 0.62 g (79%); white solid; R f =0.45 in 1:1 EtOAc/hexanes
1 H NMR (CDCl 3 , 300 MHz) δ 1.23 (6H, s), 1.34 (6H, s), 1.72 (4H, s), 2.38 (3H, s), 7.23 (1H, s), 7.28 (1H, s), 7.91 (2H, d), 8.22 (2H, d)
Example 4
4-[1-(3,5,5,8,8-Pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-benzoic acid
To a solution of 4-(3,5,5,8,8-Pentamethyl-5,6,7,8-tetrahydro-naphthalene-2-carbonyl)-benzoic acid (620 mg, 1.77 mmol) in 10 mL of THF was added MeMgCl (1.4 mL of a 3M THF solution, 4.2 mmol) at 0° C. The mixture was stirred at 0° C. for 10 min. Another portion of MeMgCl (1.4 mL of a 3M THF solution, 4.2 mmol) was added. The mixture was stirred at 0° C. for 30 min. The excess MeMgCl was quenched with the slow addition of water. 1N HCl was added until the mixture became acidic. The methyl tertiary alcohol product was extracted with CH 2 Cl 2 twice and with EtOAc twice. The combined organic fraction was dried over Na 2 SO 4 , filtered, and concentrated in vacuo. Hexane is added to the mixture, which was filtered. The same procedure was repeated with CH 2 Cl 2 . The filtrates were discarded. EtOAc was added to the residue, and the filtrate was collected, concentrated in vacuo to give 403.3 mg of the crude tertiary alcohol, which was used in the next step without purification.
To the tertiary alcohol obtained above was added 20 mL of toluene and p-TsOH monohydrate (250 mg, 1.31 mmol). The mixture was refluxed with a Dean-Stark trap under nitrogen for 2 hours. Water was added to the mixture, and the product was extracted with EtOAc. The combined organic fraction was dried over Na 2 SO 4 , filtered and concentrated in vacuo. To remove the impurities, hexane is added to the mixture, which was filtered. The filtering procedure was repeated with CH 2 Cl 2 . The filtrates were discarded. EtOAc was then added to the residue, which was filtered again to collect the filtrate. The combined filtrate was concentrated in vacuo to give 373 mg of the product.
Yield: 0.37 g (60% over two steps); white solid; R f =0.6 in 1:1 EtOAc/hexanes.
1 H NMR (CDCl 3 , 300 MHz) δ 1.29 (6H, s), 1.33(6H, s), 1.72 (4H, s), 1.96(3H, s), 5.35 (1H, d), 5.84 (1H, d), 7.09 (1H, s), 7.13 (1H, s), 7.38 (2H, d), 8.02 (2H, d)
Example 5
{4-[1-(3,5,5,8,8-Pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-phenyl}-methanol
To a solution of 4-[1-(3,5,5,8,8-Pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-benzoic acid in 10 mL of THF was added 300 mg of LiAlH 4 at 0° C. The mixture was stirred at room temperature overnight. The excess LiAlH 4 was quenched with EtOAc (3 mL). The mixture was stirred for 30 min. 1N HCl was added. A sequence of extraction with EtOAc, filtering, concentration in vacuo and column chromatography yielded 180 mg of the desired alcohol and 103 mg of its acetate. The acetate formed was dissolved in 2 mL of THF, 1 mL of MeOH and 1 mL of H 2 O. NaOH (0.2 mL of a 1N solution, 0.2 mmol) was added. The mixture was stirred at room temperature for 1 hour. NH 4 Cl solution was added, and the alcohol product was extracted with EtOAc. After drying over MgSO 4 , filtering, concentration in vacuo and chromatography, 73.5 mg of the alcohol product was obtained. Total yield of the alcohol was therefore 253.5 mg.
Yield: 253.5 mg (85%); white solid; R f =0.35 (3:1 hexanes/EtOAc) 1 H NMR (CDCl 3 , 300 MHz) δ 1.29 (6H, s), 1.32 (6H, s), 1.72 (4H, s), 1.99 (3H, s), 4.69 (2H, s), 5.21 (1H, d), 5.73 (1H, d), 7.07 (1H, s), 7.13 (1H, s), 7.29 (4H, s)
Example 6
4-[1-(3,5,5,8,8-Pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-phenyl-acetonitrile
To a solution of {4-[1-(3,5,5,8,8-pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-phenyl}-methanol (15.5 mg, 0.046 mmol) in 2 mL of CH 2 Cl 2 was added NEt 3 (0.019 mL, 0.136 mmol), followed by Methanesulfonyl chloride (0.007 mL, 0.091 mmol) at 0° C. The mixture was stirred at 0° C. for 15 min, and was concentrated in vacuo. The mesylate obtained was used in the next step without purification.
To the mixture was added 1 mL of DMF and 2 mL of DMSO, followed by 200 mg of KCN. The mixture was stirred at 50° C. for 30 min. After aqueous workup (ether) and purification by PTLC, 12.6 mg of the nitrile product was obtained.
Yield: 12.6 mg (79%); R f =0.9 (10% EtOAc/hexanes)
1 H NMR (CDCl 3 , 300 MHz) δ 1.29 (6H, s), 1.32 (6H, s), 1.71 (4H, s), 1.98 (3H, s), 4.59 (2H, s), 5.23 (1H, d), 5.74 (1H, d), 7.07 (1H, s), 7.12 (1H, s), 7.27 (2H, d), 7.31 (2H, d)
Example 7
2-{4-[1-(3,5,5,8,8-Pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-phenyl}-acetamide
To a solution of 4-[1-(3,5,5,8,8-pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-phenyl-acetonitrile (15 mg, 0.044 mmol) in 1 mL of t-BuOH was added NaOH (1 mL of 2N solution, 2 mmol). The mixture was heated at 100° C. for 24 hours. After acidification and extraction with EtOAc, the organic fraction was dried over Na 2 SO 4 , filtered and concentrated in vacuo. Purification by PTLC gave 5.2 mg of the amide product.
Yield: 5.2 mg (33%) 1 H NMR (CDCl 3 , 300 MHz) δ 1.30 (6H, s), 1.33 (6H, s), 1.72 (4H, s), 2.00 (3H, s), 4.7 (2H, s), 5.22 (1H, d), 5.74 (1H, d), 7.07 (1H, s), 7.13 (1H, s), 7.29 (4H, m)
Example 8
2-{4-[1-(3,5,5,8,8-Pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-benzyl}-malonamide
To a solution of {4-[1-(3,5,5,8,8-Pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-phenyl}-methanol (394 mg, 1.18 mmol) in 10 mL of CH 2 Cl 2 was added NEt 3 (0.5 mL, 3.59 mmol), followed by Methanesulfonyl chloride (0.18 mL, 2.33 mmol) at 0° C. The mixture was stirred at 0° C. for 15 min, and was concentrated in vacuo to give “mixture A”.
In a separate flask, malonamide (1.2 g, 11.8 mmol) and NaOH (420 mg, 10.5 mol) were dissolved in 10 mL of DMF and 2 mL of H 2 O. This mixture was added to “mixture A” and was stirred at room temperature overnight. NH 4 Cl solution was added, and the bis-amide product was extracted with EtOAc. After drying over Na 2 SO 4 , filtering, concentration in vacuo, and chromatography, 167.7 mg of the product was obtained.
Yield: 167.7 mg (34% over 2 steps); white semi-solid; R f =0.5 (10% MeOH/CH 2 Cl 2 )
1 H NMR (CDCl 3 , 300 MHz) δ 1.29 (6H, s), 1.32 (6H, s), 1.71 (4H, s), 1.97 (3H, s) 2.27 (4H, s), 3.46 (2H, s), 5.19 (1H, d), 5.72 (1H, d), 7.06 (1H, s), 7.13 (1H, s), 7.23 (4H, m) m/z=441 (M+Na)
Example 9
3-{4-[1-(3,5,5,8,8-Pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-benzyl}-imidazolidine-2,4-dione
To a solution of {4-[1-(3,5,5,8,8-Pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-phenyl}-methanol (37 mg, 0.11 mmol) in 3 mL of CH 2 Cl 2 was added NEt 3 (0.1 mL, 0.72 mmol), followed by methanesulfonyl chloride (0.05 mL, 0.65 mmol) at 0° C. The mixture was stirred at 0° C. for 15 min, and was concentrated in vacuo to give “mixture B”. In a separate flask, 10 mL of DMF was added to hydantoin (300 mg, 3.0 mmol). NaH (72 mg, 3.0 mmol) was added. The mixture was stirred at room temperature for 5 minutes, and was transferred to “mixture B”. The new mixture was stirred at room temperature overnight. NH 4 Cl solution was added, and the product was extracted with EtOAc. The organic fraction was dried over Na 2 SO 4 , filtered, concentrated in vacuo, and purified by PTLC to yield 20.1 mg of the product.
Yield: 20.1 mg (44% over 2 steps); white semi-solid; R f =0.6 (EtOAc) 1 H NMR (CDCl 3 , 300 MHz) δ 1.28 (6H, s), 1.31 (6H, s), 1.70 (4H, s), 1.97 (3H, s), 3.98 (2H, s), 4.66 (2H, s), 5.19 (1H, d), 5.33 (1H, broad), 5.70 (1H, d), 7.06 (1H, s), 7.09 (1H), s), 7.23 (2H, d), 7.33 (2H, d)
Example 10
3-{4-[1-(3,5,5,8,8-Pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-benzyl}-thiazolidine-2,4-dione
Adopting the procedure outlined for example 9 using 40.0 mg (0.12 mmol) of {4-[1-(3,5,5,8,8-Pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-phenyl}-methanol, 0.05 mL of Methanesulfonyl chloride, 0.10 mL of NEt 3 , 280 mg of thiazolidine-2,4-dione, and 57 mg of NaH, 20.1 mg of the product was obtained.
Yield: 20.1 mg (39% over 2 steps); oil
1 H NMR (CDCl 3 , 300 MHz) δ 1.28 (6H, s), 1.32 (6H, s), 1.71 (4H, s), 1.97 (3H, s), 3.95 (2H, s), 4.76 (2H, s), 5.21 (1H, d), 5.72 (1H, d), 7.06 (1H, s), 7.10 (1H, s), 7.24 (2H, d), 7.31 (2H, d)
Example 11
1-Methyl-3-{4-[1-(3,5,5,8,8-pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-benzyl}-imidazolidine-2,4-dione
Adopting the procedure outlined for example 9 using 40.0 mg (0.12 mmol) of {4-[1-(3,5,5,8,8-Pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-phenyl}-methanol, 0.05 mL of methanesulfonyl chloride, 0.10 mL of NEt 3 , 300 mg of 1-methyl-hydantoin, and 63 mg of NaH, 22.0 mg of the product was obtained.
Yield: 22.0 mg (43% over 2 steps); oil
1 H NMR (CDCl 3 , 300 MHz) δ 1.28 (6H, s), 1.31 (6H, s), 1.70 (4H, s), 1.97 (3H, s), 2.99 (3H, s), 3.86 (2H, s), 4.64 (2H, s), 5.19 (1H, d), 5.70 (1H, d), 7.06 (1H, s), 7.09 (1H, s), 7.22 (2H, d), 7.33 (2H, d)
Example 12
5,5-Dimethyl-3-{4-[1-(3,5,5,8,8-pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-benzyl}-imidazolidine-2,4-dione
Adopting the procedure outlined for example 9 using 40.0 mg (0.12 mmol) of {4-[1-(3,5,5,8,8-Pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-phenyl}-methanol, 0.05 mL of methanesulfonyl chloride, 0.10 mL of NEt 3 , 300 mg of 5,5-dimethylhydantoin, and 56 mg of NaH, 32.0 mg of the product was obtained.
Yield: 32.0 mg (60% over 2 steps); oil 1 H NMR (CDCl 3 , 300 MHz) δ 1.28 (6H, s), 1.31 (6H, s), 1.43 (6H, s), 1.70 (4H, s), 1.96 (3H, s), 4.64 (2H, s), 5.19 (1H, d), 5.70 (1H, d), 5.92 (1H, broad), 7.06 (1H, s), 7.10 (1H, s), 7.22 (2H, d), 7.26 (2H, d)
Example 13
3-{4-[1-(3,5,5,8,8-Pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-benzyl}-dihydro-pyrimidine-2,4-dione
Adopting the procedure outlined for example 9 using 40.0 mg (0.12 mmol) of {4-[1-(3,5,5,8,8-Pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-phenyl}-methanol, 0.05 mL of methanesulfonyl chloride, 0.10 mL of NEt 3 , 300 mg of dihydropyrimidine-2,4-dione, and 63 mg of NaH, 28.4 mg of the product was obtained.
Yield: 28.4 mg (55% over 2 steps); white semi-solid 1 H NMR (CDCl 3 , 300 MHz) δ 1.28 (6H, s), 1.32 (6H, s), 1.71 (4H, s), 1.98 (3H, s), 2.75 (2H, m), 3.39 (2H, m), 4.94 (2H, s), 5.17 (1H, m), 5.70 (1H, m), 6.12 (1H, broad), 7.06 (1H, s), 7.10 (1H, s), 7.20 (2H, d), 7.29 (2H, d)
Example 14
1,5,5-Trimethyl-3-{4-[1-(3,5,5,8,8-pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-benzyl}-imidazolidine-2,4-dione
Adopting the procedure outlined for example 9 using 40.0 mg (0.12 mmol) of {4-[1-(3,5,5,8,8-Pentamethyl-5,6,7,8-tetrahydro-naphthalen-2-yl)-vinyl]-phenyl}-methanol, 0.05 mL of Methanesulfonyl chloride, 0.10 mL of NEt 3 , 300 mg of 1,5,5-trimethyl-hydantoin, and 51 mg of NaH, 21.0 mg of the product was obtained.
Yield: 21.0 mg (38% over 2 steps); oil
1 H NMR (CDCl 3 , 300 MHz) δ 1.28 (6H, s), 1.31 (6H, s), 1.38 (6H, s), 1.70 (4H, s), 1.96 (3H, s), 2.88 (3H, s), 4.64 (2H, s), 5.18 (1H, d), 5.69 (1H, d), 7.06 (1H, s), 7.10 (1H, s), 7.22 (2H, d), 7.28 (2H, d)
Example 15
A375 Tumor Cell Proliferation Assay
A375 cells (5,000 per well in 90% RPMI-1640 plus 10% Fetal Bovine Serum [FBS]) were pre-incubated in a black clear bottom 96-well plate in an atmosphere of 5% CO 2 at 37° C. for 24 hours. Stock solutions of compounds in DMSO were diluted using a buffer and dilutions were added to each well. The final concentration DMSO in each well did not exceed 0.5%. The final assay pH was 7.4. The cells were incubated in RPMI-1 640 with each compound for an additional 72 to 168 hours. Alamar Blue was added and the plate was incubated for an additional 12 hours. Fluorescence intensity was measured using a Gemini plate reader with excitation at 530 nm and emission at 590 nm. A decrease of 50 percent or more (≧50%) in fluorescence intensity relative to vehicle treated controls is an indication of significant anti-cancer activity.
Reference Data
Compound
IC 50 (μM)
TGI (M)
LC 50 (μM)
Doxorubicin
0.19
0.30
8.00
Mitomycin
4.20
8.00
10.0
IC 50 (50% Inhibitory Concentration): Test compound concentration where the increase in number or mass of cells from time 0 to 72 to 168 hours is reduced 50% relative to the corresponding vehicle controls.
TGI (Total Growth Inhibition): Test compound concentration where the increase in number or mass of cells after 72 to 168 hours is reduced to equal that at time t=0.
LC 50 (50% Lethal Concentration): Test compound concentration where the number or mass of cells after 72 to 168 hours is reduced 50% relative to that at time t=0.
Example 16
T47D Tumor Cell Proliferation Assay
T-47D cells (15,000 per well in 90% RPMI-1640 medium plus 10% Fetal Bovine Serum [FBS]) were pre-incubated in a black clear bottom 98-well plate in an atmosphere of 5% CO 2 at 37° C. for 24 hours. Stock solutions of compounds in DMSO were diluted using a buffer and dilutions were added to each well in the presence or absence 20 μM Tamoxifen. The final concentration DMSO in each well did not exceed 0.5%. The final assay pH was 7.4. The cells were incubated in RPMI-1640 with each compound for an additional 72 to 192 hours. Alamar Blue was added and the plate was incubated for an additional 12 hours. Fluorescence intensity was measured using a Gemini plate reader with excitation at 530 nm and emission at 590 nm. A decrease of 50 percent or more (≧50%) in fluorescence intensity relative to vehicle treated controls is an indication of significant anti-cancer activity.
Example 17
SCC103 Tumor Cell Proliferation Assay
SCC 103 cells (15,000 per well in 90% EMEM medium plus 10% Fetal Bovine Serum [FBS]) were pre-incubated in a black clear bottom 96-well plate in an atmosphere of 5% CO 2 at 37° C. for 24 hours. Stock solutions of compounds in DMSO were diluted using a buffer and dilutions were added to each well. The final concentration DMSO in each well did not exceed 0.5%. The final assay pH was 7.4. The cells were incubated in EMEM medium for an additional 72 hours. Alamar Blue (10% of culture volume) was added and the plate was incubated for an additional 12 hours. Fluorescence intensity was measured using a Gemini plate reader with excitation at 530 nm and emission at 590 nm. A decrease of 50 percent or more (≧50%) in fluorescence intensity relative to vehicle treated controls is an indication of significant anti-cancer activity.
Example 18
HepG2 Tumor Cell Proliferation Assay
HepG2 cells (5,000 per well in 90% EMEM medium plus 10% Fetal Bovine Serum [FBS]) were pre-incubated in a black clear bottom 98-well plate in an atmosphere of 5% CO 2 at 37° C. for 24 hours. Stock solutions of compounds in DMSO were diluted using a buffer and dilutions were added to each well. The final concentration DMSO in each well did not exceed 0.5%. The final assay pH was 7.4. The cells were incubated in EMEM medium for an additional 72 hours. Alamar Blue (10% of culture volume) was added and the plate was incubated for an additional 12 hours. Fluorescence intensity was measured using a Gemini plate reader with excitation at 530 nm and emission at 590 nm. A decrease of 50 percent or more (≧50%) in fluorescence intensity relative to vehicle treated controls is an indication of significant anti-cancer activity.
Example 19
Radioactive Ligand Binding Assay
[ 3 H]-9 cis-retinoic acid (29 Ci/mmol) and MicroSpin G-25 Columns were purchased from Amersham Biosciences (Piscataway, N.J.). Unlabeled 9-cis retinoic acid was purchased from Affinity BioReagents (Golden, Colo.). The retinoic acid receptor subtype RXRγ was purchased from BIOMOL (Plymouth Meeting, Pa.). Stock solution of 9cis-retinoic acid, was prepared as either 5 mM ethanol or DMSO stock solutions, and serial dilutions were carried out in 1:1 DMSO-ethanol. The assay buffer consisted of the following for receptor assay: 8% glycerol, 120 mM KCl, 8 mM Tris, 5 mM CHAPS, 4 mM DTT, and 0.24 mM PMSF, pH 7.4, at room temperature.
The receptor binding assay was performed with a final volume of 250 μL containing from 10 to 20 μg of protein, plus 10 nM [ 3 H]-9-cis-retinoic acid, RXRγ and varying concentrations of competing ligand (0-10 −5 M). Incubations were carried out at 4° C. for 18 h. Equilibrium under these conditions of buffer and temperature was achieved by 4 h. Non-specific binding was defined as that binding remaining in the presence of 1000 nM unlabeled 9-cis-retinoic acid. The receptor-ligand complex was separated from unincorporated [ 3 H]-9-cis-retinoic acid by applying the binding reaction solution to pre-spun MicroSpin G-25 Column and centrifuged at 735 G for 2 minutes in a microcentrifuge. The amount of receptor-ligand complex was determined by liquid scintillation counting of the purified receptor-ligand complex. After correcting for non-specific binding, the IC 50 value was determined. The IC 50 value is defined as the concentration of competing ligand required to decrease specific binding by 50%; the IC 50 value was determined graphically from a log-logit plot of the data. K d value for 9-cis-retinoic acid using a modified Cheng-Prussof equation as described by Motulsky.
Although the invention has been described with reference to the above examples, it will be understood that modifications and variations are encompassed within the spirit and scope of the invention. Accordingly, the invention is limited only by the following claims. | The present invention is directed to compounds having the structure wherein R 1 , R 2 , R 3 , R 4 , R 5 and m are as defined herein. The compounds of this invention are novel therapeutic agents for the treatment of cancer, metabolic diseases and skin disorders in mammalian subjects. These compounds are also useful modulators of gene expression. They exert their activity by interfering with certain cellular signal transduction cascades. The compounds of the invention are thus also useful for regulating cell differentiation and cell cycle processes that are controlled or regulated by various hormones or cytokines. In particular, the invention relates to compounds that induce apoptosis of cancer cells and therefore may be used for the treatment or prevention of cancer, including advanced cancers and pre-cancerous cells. The invention also discloses pharmaceutical compositions and methods of treatment of disease in mammals | 2 |
BACKGROUND OF THE INVENTION
This invention relates to automobile body structures and, more particularly, to an arrangement for retaining a free end portion of vehicle plastic body panel to a subjacent metal portion of the vehicle frame.
Various fastening arrangements have been used to secure flexible elastomeric vehicle body panels to a subjacent connector member. One arrangement for mounting a plastic fender panel is shown and described in U.S. Pat. No. 5,061,108 issued Oct. 29, 1991 to Bien et al. and assigned to the assignee of the present application. The Bien patent discloses one or more female connectors integrally formed on a fender panel engaging associated male connectors projecting from a supporting surface. One of the problems associated with such flexible plastic panel assemblies is to achieve front corner dimensional stability during heat cycling and design service life.
The U.S. Pat. No. 5,098,765 issued Mar. 24, 1992 to Bien, also assigned to the assignee of the present application, discloses another arrangement for attaching a plastic panel to an automotive body metal substructure enabling controlled distortion free thermal expansion and contraction of the panel relative to the vehicle frame. The '765 Bien patent concerns a plurality of self-adjusting plastic mounting blocks sized for initial insertion in a wide slot portion of an associated keyhole shaped expansion and contraction slot provided in the vehicle metal frame. The blocks are uniquely designed to enable the plastic panel and the blocks to slid relative to the metal frame thereby accommodating thermal movement of the panel.
The U.S. Pat. No. 4,573,733 issued Mar. 4, 1986 to Zaydel discloses an apparatus for mounting a vehicle plastic body panel upon an underlying metal substructure wherein one end of the panel is fixedly mounted on the substructure. The thermal growth of the panel induces longitudinal movement of a mounting member to permit distortion-free growth relative to the underlying metal substructure.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a clip and bracket fastening arrangement for ready mounting on a vehicle frame substructure enabling dimensional tolerance adjustment of the panel prior to final tightening insuring a satisfactory exterior appearance and thereafter accommodating thermal growth of the plastic panel relative to the substructure.
It is another object of the present invention to provide a panel clip and vehicle substructure bracket adjustable fastening arrangement for plastic fender panels as set forth above enabling inboard adjustment of a cantilevered end portion of a fender panel requiring a minimum of attaching hardware.
It is still another object of the present invention to provide a clip and bracket fastening arrangement for vehicle plastic body panels as set forth above wherein the clip adjustably supports and bracket on the panel as an off-line sub-assembly for subsequent conveyance thereof to a vehicle assembly line for ready three dimensional adjustable attachment to a vehicle body substructure.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features and advantages of the invention will appear from the following written description and the accompanying drawings in which:
FIG. 1 is a fragmentary perspective view of a vehicle front fender and the vehicle body structure to which the fender is secured;
FIG. 2 is a fragmentary exploded perspective view of a fender integral support panel and the fastening arrangement of the present invention;
FIG. 3 is a fragmentary perspective view of the interior vertical surface of the fender support panel with the fastening arrangement secured thereto;
FIG. 4 is a fragmentary side view looking outboard showing the fender support wall secured to the vehicle substructure by means of the fastening arrangement of the present invention;
FIG. 5 is a fragmentary vertical sectional view taken on the line 5--5 of FIG. 4;
FIG. 6 is a fragmentary vertical sectional view taken on the line 6--6 of FIG. 3;
FIG. 7 is a fragmentary horizontal sectional view taken on the line 7--7 of FIG. 4;
FIG. 8 is detail side view of the panel strap member shown in the fastening arrangement of FIG. 2;
FIG. 9 is a detail top view of the panel strap member of FIG. 8;
FIG. 10 is an enlarged detail side view of the bracket taken in the direction of arrow "FIG. 10" in FIG. 12;
FIG. 11 is a vertical section taken on the line 11--11 of FIG. 10;
FIG. 12 is an enlarged detail top view of the bracket of FIG. 10; and
FIG. 13 is a fragmentary side view taken on the line 13--13 of FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings and in particular to FIG. 1, there is shown a perspective view of a vehicle body fascia panel component, such as a fender, generally indicated at 10, adapted for mounting on a vehicle substructure metal frame 12. In the preferred embodiment, the fascia panel component right hand fender 10 is formed of elastomeric or composite plastic sheet material. Reference may be made to the above mentioned '108 and '765 patents for a detailed description of existing means for attaching a plastic fender to a vehicle.
As seen in FIGS. 1 and 2, the fender panel 10 comprises an exterior fascia panel portion 14 and a vertically disposed inboard planer support wall portion 16. It will be noted in FIG. 5 that the fascia panel portion 14 has an exterior convex surface 18 and an interior concave surface 20 while the support wall portion 16 has a hidden outboard surface 22 and an inboard surface 24. FIG. 1 shows the fender panel inboard wall portion 16 terminating at its lower end in an inboard extending horizontal stiffening shelf flange 26. The shelf flange 26 has its forward end terminating in a transverse edge 27 defining an under-cut horizontally disposed support wall free edge 28 as seen in FIG. 5. FIG. 3 depicts the shelf flange 26 supporting the fender panel 10 by overlying, in a flush or flatwise manner, an associated longitudinally extending body metal right hand frame rail 30. It will be noted that the fender support wall free edge 28 is spaced a predetermined dimension above the upper horizontal surface of frame rail 30.
With reference to FIGS. 3 and 6, there is shown a slidable fastening arrangement 31 comprising a self-tapping threaded screw fastener 32 extending through an oversize fastening hole 33 (FIG. 2) and an associated keyhole-shaped slot 34 (FIG. 1) in the frame rail 30. As seen in FIG. 6, the screw 32 is threaded into a patented plastic nut or block 35 slidably mounted in the keyhole-shaped slot 34. This arrangement allows the plastic fender 10 and its associated blocks 35 to slide fore and aft relative to the frame rail 30 to accommodate longitudinal thermal movement of the fender 10. Reference should be made to the above mentioned '765 Bien patent, the disclosure of which is incorporated by reference herein, for a detailed description of the keyhole-shaped slot 34 and the mounting block 35.
The panel retaining arrangement of the present invention uniquely provides three degrees of adjustability of forward cantilevered portion 38 of the fender panel; i.e., transverse, longitudinal and vertical, The retainer arrangement comprises a one-piece L-section angle bracket 41 and a U-shaped retaining clip 42 wherein each are fabricated from sheet metal. As best seen in FIG. 11, the angle bracket 41 is formed with a vertically upstanding head plate 43 bordered along its upper edge by an upper stiffening rib 44 and bordered along its lower terminus by a lower stiffening rib 45. The bracket is asymmetrical in that an aft portion of its lower stiffening rib 45 terminates in an inboard extending horizontal base plate 46. It will be appreciated in FIGS. 4 and 5 that the angle bracket 41 is a "handed" part in that it requires a right hand bracket member 41 be used in conjunction with the right hand fender panel 10. A left hand bracket (not shown), which is a mirror image of bracket 41, is provided for a left hand fender panel (not shown). It will be noted in FIG. 4 that the elongated head plate 43 terminates at a vertical forward terminal edge "a" and a vertical aft terminal edge "b".
The base plate 46 is adapted for adjustable lateral support when flush mounted on the upper surface of the right hand frame rail 30. FIGS. 2 and 10 show the elongated head plate 43 formed with a generally rectangular aperture 48 adjacent its longitudinal midpoint for a purpose to be explained. As seen in FIGS. 4 and 7, the aperture 48 has a vertical forward internal edge "c" and a vertical aft internal edge "d".
As seen in FIG. 9, the retaining clip 42 is generally U-shaped when viewed from above comprising an elongated vertically disposed flat web portion 50 terminating at each end in a mounting foot portion 52. The pair of mirror image feet 52 are off-set inboard from the plane of the web 50 by associated legs 54 bent inboard from the web 50. Upon the clip 42 being mounted on the support wall 16, the web defines an elongated slotted passage 55 (FIG. 7) having a predetermined width slightly greater than the thickness of the bracket head plate 43 providing for longitudinal slidable travel relative thereto. As seen in FIG. 5, the web 50 is channel shaped in vertical section defining upper 56 and lower 58 outboard extending horizontal flanges.
The L-section bracket 41 has its base plate 46 provided with an elongated adjustment slot 70 extending therethrough. It will be noted in FIG. 12 that the slot principal axis "A" intersects the head plate 43 at an acute angel "X" from the longitudinal. In the disclosed embodiment, the angle "X" is of the order of eighty degrees from the longitudinal axis of the head plate. A bolt 71 is adapted for reception in the bracket slot 70 and in an aligned hole 72 (FIG. 1) in the vehicle frame rail 30 providing a selectively adjustable connection between the bracket 41 and the vehicle frame 12.
After the fender panel is secured on the rail 30 by the attaching arrangements 31, but prior to final tightening of the nut 76 on the bolt 71, the leading portion 38 of the fender panel 10 is urged inboard relative to the body to its designed position. Thereafter the nut 76 is threaded on the bolt 71 and torqued down to positively secure the bracket 41 to the frame rail horizontal surface. It will be noted that the slot 70 is angled slightly from the normal to allow the forward portion 38 of the fender panel to conform to the streamlined design of the body forward end.
The fender panel 10 is adapted for ready assembly line installation by attaching the panel shelf flange 26 to the frame rail 30 by a plurality of the longitudinally slidable attaching arrangements 31. Thereafter, the bracket 41 and clip 42 adjustable fastening arrangement adjustably secures the cantilevered forward portion of the fender panel to its designed inboard location relative to the body.
With reference to FIGS. 5 and 7, it will be seen that applicants' novel bracket and clip assembly 40 and 41 is adapted for installation on the fender panel support wall 16 prior to its being mounted on the vehicle body during an assembly line operation. Thus, with the bracket head plate 43 located in flush flatwise contact with the panel wall outboard surface 22 the clip web 50 is positioned in overlying relation thereto such that the clip aft foot 52 is substantially centered in the aperture 48 (FIG. 13) with each foot mounting hole 62 aligned with an associated fastener hole 63 (FIG. 2) in the wall 16. It will be noted in FIG. 13 that the clip web 50 overlies a forward portion 43' of the bracket head plate 43 defined by head plate vertical forward exterior edge "a" and vertical forward internal edge "c" of the aperture 48. Thus as seen in FIG. 7, upon the pair of rivets 64 being inserted and secured in their associated fastener holes 63 the bracket head plate forward portion 43' is captured in the clip slotted clearance 55 allowing shipment of the fender panel together with the pre-assembled bracket 41 and clip 42. It will be noted that the aperture 48 is further defined by aft vertical internal edge "d" together with upper horizontal internal edge "e" and lower horizontal internal edge "f".
With reference to FIGS. 4, 5, and 11, it will be noted that the head plate 44 has formed in one inboard side thereof a pair of upper 44 and lower 45 outboard facing horizontally extending stiffening ribs coextensive with the head plate. It will be seen that the ribs 78 and 79 are concavely indented on the head plate inboard surface providing flush contact with support wall surface 24 while the ribs convexly protrude from the head plate outboard side.
The installation sequence for the fender panel 10 involves initially securing the fender panel shelf flange 26 in a flatwise slidable manner on the upper surface of the frame rail 30 by suitable fastening means such as the attaching arrangement shown at 31 in FIG. 6. Thereafter a bolt 71 is inserted through the bracket base plate slot 70 and an aligned hole 72 (FIG. 72) in the frame rail 30 and retained for inboard and outboard adjustment prior to final tightening of the nut 76. It will be appreciated that the fender panel support wall and clip 42 are free for limited longitudinal and vertical adjustment relative to the bracket head plate and the vehicle frame. This allows the installer to flex the forward-most cantilevered portion 30 of the fender 10 inboard to its predetermined design position relative to the vehicle body panel (not shown) prior to tightening the nut 76.
With reference to FIG. 7, it will be seen that with the clip and bracket retaining arrangement are shown secured in their neutral temperature position prior to any thermal growth of the fender panel. In this mode the bracket aperture forward internal edge "c" is spaced a predetermined dimension "c'" from the clip aft leg 54 while the aperture 48 internal aft edge "d" is spaced a predetermined dimension "d'" from the clip aft foot opposed edge 52. It will be noted that the dimensions "c'", and "d'" are substantially equal and permit distortion-free longitudinal growth or adjustment of the fender panel 10 and the clip 42 relative to the bracket 41 and the vehicle frame.
It will be appreciated that the centered position of the clip aft foot 52 allows vertical adjustment of the fender panel and clip reactive to the bracket and vehicle frame. Thus, the clip aft foot upper edge "h" is spaced a predetermined first dimension from the aperture upper internal edge "e" while the clip aft foot lower edge "i" is spaced a predetermined second dimension from the aperture lower internal edge "f". The first and second dimensions are substantially equal permitting distortion free vertical thermal growth of the fender panel relative to the vehicle frame.
With reference to FIG. 8, it will be seen that the web 50 is offset downwardly a dimension "Z" from the uppermost edges of the foot portions 52. It will be noted in FIG. 5 the internal clearance space between the support wall 16 and the inwardly curving facia fender panel 14 narrows toward their upper juncture. Thus, the downwardly offset web 50 compensates by lowering design position of the head plate relative to the upper juncture.
While the principles of the present invention in connection with the specific test device has been described, it is to be understood the foregoing detailed description has been made by way of example only and not as a limitation to the scope of the invention as set for in the accompanying claims. | A clip and bracket retainer arrangement for attaching a plastic panel to the subjacent frame of an automotive vehicle enabling controlled distortion free thermal expansion and contraction of the plastic panel relative to the frame. The attaching arrangement includes a retaining clip fixed on an outboard surface of a panel support wall and an L-sectioned bracket comprising a vertical head plate and a horizontal base plate mounted to the frame. The retaining clip, having a U-shape in horizontal cross section, comprises an elongated web formed with foot portion at each end of the clip web. The pair of foot portions extend out of the plane of the web for engagement with the support wall outboard surface defining an elongated slotted clearance therewith. The bracket head plate has a rectangular aperture intermediate its ends defining a forward plate portion adapted for captured in the slotted clearance permitting vertical and longitudinal distortion free thermal growth of the plastic panel and clip relative to the bracket and vehicle frame. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to European Application No. 06075061.9, filed 11 Jan. 2006, and such application is hereby incorporated by reference as if fully disclosed herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a ladder cord assembly for a Venetian blind, including a ladder cord and a connector, the connector being adapted for securing to a bottom rail of a Venetian blind.
[0004] 2. Description of the Relevant Art
[0005] It has been proposed to connect a ladder cord to a connector, which connector is connectable to a bottom rail of a Venetian blind. Such a proposal is known from U.S. Pat. No. 2,574,609, but in this arrangement the connector is attached to the bottom rail by screws and the opposite ends of the ladder each have to be separately clamped to the connector. This manner of attachment is both cumbersome and time consuming in production.
[0006] It is an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art. It is also an object of the present invention to provide alternative structures, which are less cumbersome in assembly and operation and which moreover, can be made relatively inexpensively. Alternatively it is an object of the invention to at least provide the public with a useful choice.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention provides a ladder cord assembly for a Venetian blind, including a ladder cord and a connector, the connector having a first portion for securing to a bottom rail of a Venetian blind and a second portion that is permanently connected to the ladder cord. Such a ladder cord assembly can be easily positioned in a Venetian blind assembly machine and can be readily connected with a bottom rail; either prior to or, after assembling of the slats has been completed. The connector can be permanently attached to the ladder cord at any stage of the production prior to the insertion of slats, while the ladder cords can still be manipulated with every available freedom.
[0008] In one advantageous embodiment of ladder cord assembly according to the invention, the connector comprises a groove for receiving an end portion of the ladder cord. Such a groove will enhance the exact positioning of the ladder cord ends in respect of the connector.
[0009] In another advantageous embodiment of the ladder cord assembly according to the invention, the connector further includes a slot for receiving a lift cord. This will enable the connection of a lift cord to a bottom rail to be combined with connecting the ladder cord. In a further preferred embodiment the slot is positioned in the connector such that its entrance becomes closed once the connector is inserted in an opening in a bottom rail. Such an arrangement would prevent the lift cord from accidentally becoming detached.
[0010] It is further advantageous for the ladder cord assembly according to the invention, if the first portion of the connector is adapted to be releasably secured to a bottom rail. This makes it possible to replace damaged or faulty ladder cords during the life of the Venetian blind.
[0011] With the ladder cord assembly according to the invention, it is also particularly advantageous if the second portion is fused to the ladder cord. In manufacture this enables a quick and secure attachment of the ladder cord to the connector. When using this type of attachment with the ladder cord assembly according to the invention, preferably the connector is of polycarbonate and the ladder cord of polyester.
[0012] The invention will now be described in reference to a selection of preferred embodiments as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective detail view of a lower end of ladder cord assembly according to the invention;
[0014] FIG. 2 is a perspective detail view of the ladder cord assembly of FIG. 1 , with a bottom rail and a lift cord in an arrangement just prior to making the final connection to a bottom rail of a Venetian blind;
[0015] FIG. 3 is a further perspective detail view showing the elements of FIG. 2 as finally connected to one another;
[0016] FIG. 4A is a bottom elevation of a second embodiment of connector for use in the ladder cord assembly of the invention;
[0017] FIG. 4B is a side elevation of the connector of FIG. 4A ;
[0018] FIG. 4C is an end elevation of the connector of FIG. 4A ; and
[0019] FIG. 5 is a perspective view from above of the connector of FIGS. 4A to 4 C, on a reduced scale.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] FIG. 1 shows a lower section of a ladder cord assembly in a Venetian blind, according to a first embodiment of the invention. A ladder cord 3 has opposite side cords 5 , 7 and a plurality of cross rungs 9 , 11 . In the embodiment illustrated, each cross rung 9 , 11 is comprised of a pair of individual cords 13 , 14 , 15 , 16 , but other forms will also be possible. Opposite ends 5 A, 7 A of the ladder side cords 5 , 7 are attached to a connector 17 . The connector 17 has a first portion 19 for securing to a bottom rail of a Venetian blind (not shown) and a second portion 21 for receiving the ladder cord ends 5 A, 7 A in a permanently affixed manner. The permanent fixation may be obtained by an adhesive, such as a suitable hot melt glue, but preferably is obtained by welding or fusing. In particular the second portion 21 of the connector 17 can be fused to the ladder cord ends 5 A, 7 A if the connector 17 is of polycarbonate and the ladder cord 3 is of polyester.
[0021] The first portion 19 has been shaped to be flexible with a first slot 23 , a second slot 25 , a third slot 27 and a fourth slot 29 . The first portion 19 is further provided with detent ridges 31 , 33 to provide, together with the first to fourth slots 23 , 25 , 27 , 29 , a snap-fit connection with an opening in a bottom rail (to be described in more detail below).
[0022] FIG. 2 shows the ladder cord assembly 1 in a position ready to be affixed to a bottom rail 34 together with a lift cord 35 . The lift cord 35 as seen in FIG. 2 has a knot 37 at its end. While the lift cord 35 can pass through the second slot 25 , the knot 37 will be retained within the cavity 32 (see FIG. 1 ). The bottom rail 34 further is provided with an opening 39 into which the first portion 19 of the connector 17 can be snap-fitted and retained afterwards.
[0023] FIG. 3 shows the resulting assembly after the elements shown in FIG. 2 have been connected to one another. With the lift cord 35 engaged in the second slot 25 and the connector 17 held in the opening 39 of the bottom rail 34 , all elements are securely connected. The bottom rail 34 can be raised by the lift cord 35 to collect the slats (not shown) each resting on one of the cross rungs 9 of the ladder cord 3 . By lifting and lowering the individual ladder side cords 5 , 7 these same slats (not shown) can be tilted for controlling light admittance, when the bottom rail 34 is in a lowered position. Although slats are deleted for clarity, it should be understood that in a Venetian blind, using the ladder cord assembly, each cross rung 9 (and 11 ) would be supporting a slat. Such a Venetian blind would also make use of at least two ladder cord assemblies 1 according to the invention.
[0024] FIGS. 4A, 4B and 4 C are bottom, side, and end elevations of a slightly modified embodiment of connector 117 . Like the connector shown in FIG. 1 , it has a first portion 119 for securing to a bottom rail of a Venetian blind (as described and shown in relation to the first embodiment) and a second portion 121 for receiving each of the opposite ladder side cord ends (not shown) in a permanently affixed manner in grooves 106 , 108 respectively. The permanent fixation is again, preferably, a fusion between a polycarbonate material of the connector 117 and a polyester material of the ladder cord (not shown). The first portion 119 has been shaped to be flexible with a first slot 127 and a second slot 129 . A third slot 125 is provided to allow entrance of a lift cord (not shown, but similar to lift cord 35 of FIG. 2 ) to pass into a cavity 132 . A knot, or beaded end, of the lift cord is adapted to be retained within a cavity 132 . The first portion 119 is further provided with detent ridges 131 , 133 to provide, together with the first and second slots 127 , 129 a snap-fit connection with an opening in a bottom rail (as already described above in relation to the first embodiment). In addition to the first embodiment the detent ridges 131 , 133 are rendered more flexible by being formed on arms 140 , 142 that are separated from the body of the first portion 119 by spaces 141 , 143 . A perspective view from above of the modified connector 117 on a somewhat reduced scale is illustrated in FIG. 5 .
[0025] It is thus believed that the operation and construction of the present invention will be apparent from the foregoing description. The term comprising when used in this description or the appended claims should not be construed in an exclusive or exhaustive sense but rather in an inclusive sense. Expressions such as: “means for . . . ” should be understood as: “component configured for . . . ” or “member constructed to . . . ” and should be construed to include equivalents for the structures disclosed. The use of expressions like: “critical”, “preferred”, “especially preferred” etc., is not intended to limit the invention. Features, which are not specifically or explicitly described or claimed, may be additionally included in the structure according to the present invention without deviating from its scope. The invention is further not limited to any embodiment herein described and, within the purview of the skilled person, modifications are possible which should be considered within the scope of the appended claims. Equally all kinematic inversions are to be considered within the scope of the present invention.
[0026] Directional and positional expressions, such as upper, lower, top, bottom, left, right, above, below, vertical, horizontal, clockwise, counter clockwise or like are generally used only to assist in understanding of the present invention as illustrated in the accompanying drawing figures. None of this should be construed to create limitations, as to position, orientation in actual use of the invention.
[0027] Similarly reference to either axially, radially or tangentially if used in the above is generally in relation to rotatable or cylindrical bodies of the elements described. Also where in the above reference is made to longitudinal or lateral this is in reference to the length or width directions respectively of elements, which have an oblong appearance in the accompanying drawings. Again this interpretation has only been used for ease of reference and should not be construed as a limitation of the shape of such elements. | A connector for connecting a ladder cord in a venetian blind to the bottom rail of the venetian blind includes two portions with one portion being securable to the bottom rail of the venetian blind and the other portion permanently connected to the ladder cord. Interconnection of the portions of the connector thereby secure the ladder cord to the bottom rail at preselected positioning. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to the use of hyaluronic acid for treating oral cavity aphthas.
STATE OF THE ART
[0002] Aphthas, better known as recurrent oral aphthous ulcerations (ROAU), are ulcerous pathologies of the oral mucosa which affect more than 20% of the population. The etiology of this ailment is yet to be defined. Aphthas are round or oval protuberant ulcers, surrounded by bright red areolas, on the smooth tissue of the mucosa. Almost all types of aphthas, including small ones, are capable of causing pain.
[0003] Of the susceptible individuals one in ten will have monthly episodes, whereas the majority have 3-4 episodes of new lesions per year occur. Untreated lesions in general last for 7-10 days and heal without leaving scars. In general, aphtha treatments are intended to ease symptoms, although many types of therapies for treating aphthas have been considered.
[0004] For example analgesics for topical use have been employed for relieving symptoms, and anti-inflammatories for reducing pathological changes, while anti-bacterials have been contemplated for controlling microbial contaminations and secondary infections.
[0005] Anti-bacterial agents include antibiotics (tetracycline) and antiseptics (clorhexidine).
[0006] Mouthwashes containing wide spectrum antibiotics have been able to reduce new ulcers, following a 10 day treatment. This effect is due to a reduced oral microflora thereby reducing the effects of a secondary infection.
[0007] However, antibiotics have a potentially undesirable mycotic effect and can give rise to allergic reactions.
[0008] Anti-bacterial mouthwashes can provide some benefit by controlling pain, reducing both the effects caused by a secondary infection and the duration of the ulcer. Clorhexidine can reduce the total number of days with ulceration, but has not been at all effective on the incidence or severity thereof. Furthermore, it frequently gives rise to colour changes on the teeth and tongue and upsets taste sensation.
[0009] Hyaluronic acid is a natural constituent of connective tissue.
[0010] EP-A1-0444492 describes the topical use of high molecular weight hyaluronic acid for treating inflammatory diseases of the oral cavity, such as gingivitis.
[0011] WO 0209637 discloses pharmaceutical compositions for the topical treatment of inflammatory diseases of the oral mucosa such as stomatitis, containing an association of hyaluronic acid, glycyrrhetinic acid and polyvinylpyrrolidone
SUMMARY OF THE INVENTION
[0012] The Applicant has found that hyaluronic acid is able to effectively cure oral cavity aphthas.
[0013] In this respect, the Applicant has surprisingly found that hyaluronic acid is not only able to alleviate the symptoms and reduce the duration of ulceration, as well as the severity thereof.
[0014] An aspect of the present invention is therefore the use of hyaluronic acid for preparing compositions, in particular for topical use, for treating oral cavity aphthas.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The compositions containing hyaluronic acid for use in accordance with the invention are preferably liquid, solid and/or semisolid preparations in the form of O/W (oil in water) and W/O (water in oil) emulsions, ointments and creams, pastes, gels, solutions, suspensions, dispersions, powders, tensiolytes, oleolytes, or any other Theological form suitable for use alone or in combination with the other forms, also in the form of tablets, pills, gums, or in the form of any other applicative solutions known in the art and suitable for topical use in the oral cavity.
[0016] Even more preferably, the topical compositions for use in accordance with the present invention are in the form of oral cavity gels, mouthwashes and sprays. Preferably hyaluronic acid is in the form of the sodium salt. Hyaluronic acid has preferably a molecular weight of between 800,000 and 4,000,000, even more preferably between 1,000,000 and 2,000,000.
[0017] The topical compositions of the present invention preferably contain hyaluronic acid in the form of the sodium salt at concentrations of between 0.01 and 10% by weight on the total weight of the composition, more preferably between 0.01 and 5% by weight.
[0018] Some illustrative but non-limiting examples of compositions for topical use based on sodium hyaluronate are given.
Composition 1: gel Sodium hyaluronate average molecular 0.240 w/w weight 1,500,000: Xylitol 7.500 w/w Sodium carboxymethylcellulose 4.500 w/w PEG 40 hydrogenated castor oil 1.000 w/w Glyceryl monolaurate 0.700 w/w Polycarbophil 0.800 w/w Lactic acid (Pharm.) 0.060 w/w Sodium lactate 0.100 w/w EDTA 0.050 w/w Sodium saccharinate 0.220 w/w Flavour 0.500 w/w Dichlorobenzylalcohol 0.500 w/w Colorant CI 42090 (FD&C BLUE 1) 0.00012 w/w Colorant CI 47005 (D&C YELLOW 10) 0.00028 w/w Sodium hydroxide to pH = 6.5 Water remainder to 100 Composition 2: mouthwash Sodium hyaluronate average molecular 0.025 w/w weight 1,500,000: Xylitol 7.500 w/w PEG 40 hydrogenated castor oil 0.600 w/w Polycarbophil 0.150 w/w Lactic acid (Pharm.) 0.060 w/w Sodium lactate 0.100 w/w EDTA 0.050 w/w Sodium saccharinate 0.018 w/w Flavour 0.100 w/w Dichlorobenzylalcohol 0.500 w/w Polysorbate 20 0.800 w/w Colorant CI 42090 (FD&C BLUE 1) 0.00012 w/w Colorant CI 47005 (D&C YELLOW 10) 0.00028 w/w Sodium hydroxide to pH = 6.5 Demineralized Water remainder to 100 Composition 3: spray Sodium hyaluronate 0.100 w/w Xylitol 7.500 w/w PEG 40 hydrogenated castor oil 0.500 w/w Dichlorobenzylalcohol 0.500 w/w Lactic acid (Pharm.) 0.060 w/w Sodium lactate 0.100 w/w EDTA 0.050 w/w Sodium saccharinate 0.220 w/w Flavour 0.200 w/w PVA 0.050 w/w Propylene glycol 4.000 w/w Sodium hydroxide to pH = 6.5 Demineralized water remainder to 100
Clinical Study
A) Study Design
[0019] This controlled study used a double blind, single centre, parallel group design to determine the efficacy of a gel formulation in relieving the symptoms in subjects with recurrent oral aphthous ulceration.
[0000] B) Study Population
[0000] B1) Number of Subjects
[0020] The investigator enrolled a sufficient number of subjects in the study to achieve a study population of 120 evaluable subjects (60 in each group) with ROAU.
[0000] B2) Subject-Selection Criteria
[0021] Inclusion Criteria To be eligible for study partecipation the subject had to meet the following criteria:
The subject must be between 18 and 65 years of age A history of ROAU >2 times per year Current aphthous ulcer/ulcers present for <3 day
B3) Exclusion Criteria
[0025] Any of the following conditions excluded subjects from eligibility for study partecipation:
Patients with underlying white blood cell disorder Patients taking systemic hemotherapy, immunosuppressants, or who sufer from drug-related recurrent aphthous ulceration Patients suffering from malignant disease Patients with uncorrected dietary defect Pregnant or breast feeding women A history of sensitivity of mouthwashes
B4) Prohibited/Allowable Medications
[0032] Prohibited Medications
Any topical or systemic treatment for ROAU including steroids and vitamins B1 and B6 other than study treatments Antiseptic mouthwashes Systemic chemotherapy, immunosuppressants Rx or OTC nonsteroidal anti-inflammatory drugs including, but not limited to aspirin, diclofenac, diflunisal, etodolac, ibuprofen, indomethacin, ketoprofen, ketorolac, nabumetone, naproxen, naproxen sodium, oxaprozin, piroxicam, or sulindac.
[0037] Allowable Medications
Any medication not specifically prohybited Paracetamol
C) Study Methodology
[0040] Subjects were recruited from an existing group of patients with ROAU who have been screened for known causative factors or when they present as new patients to the clinic. Existing patients or patients attending screening who do not have a current ulcer will be asked to contact the clinic at the time of onset of their next aphthous ulcer.
[0041] C1) Clinic Visit 1 (Day 1): Screened subjects meeting the selection criteria for the study described had the study explained to them and if they agreed to partecipate signed an informed consent form. They will be allocated a subsequential subject number. The subjects demographic history and history of ROAU were recorded together with details of their current episode of aphthous ulceration including the time and date of onset, number, size and position of mouth ulcers.
[0042] The study nurse explained to the subjects how to fill out the 10 cm visual analogue scale (VAS) used to score their level of discomfort or soreness arising from their mouth ulcer. Subjects recorded their discomfort from their ulcer prior to gel application (baseline). They applied the gel to the ulcerated area under supervision with 1-2 ml of their assigned gel having one of the following two composition:
Product name Ingredients Hyaluronic Acid Aqua, xylitol, cellulose gum, alcohol, PEG-40, Gel 0.2% Hydrogenated castor oil, sodium hyaluronate, Polyvinyl alcohol, polycarbophil, Dichlorobenzyl alcohol, aroma flavouring CI 40290 Placebo Aqua, xylitol, cellulose gum, alcohol, PEG-40, Hydrogenated castor oil, Polyvinyl alcohol, polycarbophil, Diclorobenzyl alcohol, aroma flavouring
[0043] Subjects recorded their discomfort immediately after application and at 5, 10, 15, 20, 30, 45 and 60 minutes. The time of gel application will be recorded in the CRF and the subjects log diary. A stopwatch was used to record time measurements.
[0044] The subject will be supplied with sufficient tubes of the gel to take home. The study nurse instructed the subject how to fill out a log diary. The subject continued to record their VAS scores in their log diary at 2, 3 and 4 hours postgel application. The subjects will apply the gel again after their evening meal and record their VAS score 1 hour post application.
[0045] Appendix A; Time table of Visits and Procedures
[0000] C2) Day 2-7
[0046] Subjects continued to apply the gel at home 2 to 3 time daily, after breakfast and after their evening meal (and 1 other time during the day, if desired) from days 2-7, even if their ulcer has healed. VAS scores was recorded in the subjects' log diaries 1 hour post application in the morning and evening. Subjects recorded the severity of their mouth ulcers, any unpleasant effects of their study treatment and the severity of their mouth ulcers. Any new ulcers occurring was recorded in their log diaries.
[0000] C3) Clinic Visit 2 (Day 8):
[0047] Subjects returned to the clinic to review their completed log diaries with the study nurse and return remaining study material. They were asked to score their overall assessment of the gel on a 5 point scale. Subjects will be questioned about the occurrence of any adverse events.
[0048] Information obtained relating to adverse events were recorded on the associated pages of the CRF. The size, number and position of lesions present on day 8 were recorded on the CRF.
[0049] The VAS entries on each subjects log diary were measured and transcribed to the associated pages of the CRF.
[0000] C4) Efficacy Assessments
[0050] Following entry to the study, the study nurse recorded the subject's demographic details and examined the subject to determine the size, number and position of ulcers and record time of onset of ulcer.
[0000] C5) Primary Efficacy Parameter
[0051] Subjects recorded their discomfort/soreness scores on a 10 cm visual analogue scale (VAS).
[0052] The boundaries of the scales were “worst possible” and “no soreness”.
[0053] Scores were completed at baseline and at 0, 5, 10, 15, 20, 30, 45 and 60 minutes post initial application. The gel application and completion of scores was done under supervised conditions in the Clinic. At the end of 60 minutes, the subjects continued to apply the gel at home 2 to 3 times daily and they were asked to record discomfort/soreness on the same VAS twice daily an hour after the morning and evening applications.
[0054] Two parameters were extrapolated from the serial VAS completed in the first hour:
[0000] a) Time in minutes to the maximum reduction in discomfort/soreness following dosing with the gel.
[0055] b) Serial VAS recorded in the first hour was compiled into a graph of discomfort soreness (mm) versus time (minutes). The area under the graph was measured using the trapezoidal method and recorded as AUC (0-60 minutes). This provided an overall assessment of each subjects discomfort/soreness experience throughout the initial observation period.
[0000] C6) Secondary Efficacy Parameter
[0056] At the end of the 7 day investigation period, subjects were asked if they have had any ulcer free days and their overall assessment of the gel based on the following scale:
[0000] Very good Good Moderate Poor Very Poor
[0000] D) Results
[0057] In this randomized blind clinical study it was evidenced that if compared to placebo composition the gel composition containing hyaluronic acid proved able to reduce significantly the number of ulcers already in the fifth day, and also evidenced an overall beneficial effect in every investigated ROAU symtphomatology. | Use of hyaluronic acid as the sole active ingredient for preparing compositions in particular for topical use for treating oral cavity aphthas. | 0 |
BACKGROUND OF THE INVENTION
The commercial production of phosphoric acid by the "wet process" generally comprises the digestion of ground phosphate rock containing apatite (3Ca 3 (PO 4 ) 2 .CaF 2 ) and/or tricalcium phosphate (Ca 3 (PO 4 ) 2 ). With dilute mineral acid (e.v. sulfuric acid) to produce a weak orthophosphoric acid solution in a calcium salt which is then separated from the solution by an appropriate technique. It has been found that if the sulfate ion concentration in the initial digestion tank is appreciable, the fluoride of the feed rock dissolves converting it to fluorosilisic acid which in turn dissolves the various clays and releases iron and aluminum and other impurities into the process stream.
Applicants have also noted the competing reactions which take place within the initial reactor vessel including solubilization of the phosphate by the phosphoric acid and the formation of gypsum by the sulfuric acid. This invention also deals with the removal of the sulfate ion in the phosphoric acid to a point where solubilization of the rock is both rapid and complete. In other words, the processing parameters have been adjusted to solubilize the greatest amount of rock with the minimum amount of calcium sulfate precipitation.
SUMMARY OF THE INVENTION
A process for producing phosphoric acid from rock phosphate is disclosed. In this process, finely divided rock phosphate, phosphoric acid having a minor content of sulfuric acid and water are fed into a first mixing zone in which the formation of a slurry is achieved. The slurry is continuously withdrawn from the first mixing zone and about 90% of this slurry is fed into a second mixing zone and the remainder of the slurry is fed into a third mixing zone. The slurry of the second mixing zone is mixed with about 102% to 104% of the quantity of sulfuric acid stoichiometrically required to precipitate the calcium ion contained in the slurry. Approximately 80% to 90% by weight of the slurry in the second mixing zone is returned to the first mixing zone and the remainder is fed to the third mixing zone. The slurry in the third mixing zone is continuously withdrawn and filtered in a filtering zone to separate a filter cake and filtrate having a P 2 O 5 content of about 40% by weight. A portion of the filtrate is withdrawn as final product. The filter cake is washed with water and this is added to a portion of the previously withdrawn filtrate to form a liquid having a P 2 O 5 content about 25% by weight. This liquid is returned to the first mixing zone to provide an initial feed of phosphoric acid.
The slurry located in the first mixing zone is periodically monitored as well as the sulfate ion concentration in the second mixing zone. These respective values can be adjusted and controlled by adjusting the rate of addition of slurry from the second to the first mixing zones to maintain the calcium ion concentration in the slurry of the first mixing zone in the range of 1.0% to 2.5% by weight and the sulfate ion concentrate the second mixing zone to between approximately 2% to 4% by weight.
DETAILED DESCRIPTION OF THE INVENTION
The present invention can be more thoroughly appreciated by viewing the appended drawing which is a flow sheet diagrammatically illustrating the various vessels, all of which are conventional, employed in the process of the present invention.
Phosphate rock is added to initial mixing vessel 1 diagrammatically shown by arrow 6. To this is added phosphoric acid which can be added to mixing vessel 1 from an independent source or as an output from the system shown in the drawing whereby phosphoric acid collected from filter 4 is recycled back to mixing vessel 1 via stream 13. This first step is called digestion and is governed by the following reaction:
Ca.sub.3 (PO.sub.4).sub.2 +4H.sub.3 PO.sub.4 →3Ca(H.sub.2 PO.sub.4).sub.2
Approximately 90% by weight of the slurry from the first mixing zone is passed into a second mixing zone 2 and the remaining slurry passed into yet another mixing zone 3. Thus, slurry exiting mixing zone 1 via stream 7 is split into streams 8 and 9, approximately 90% of the slurry passing through stream 8. The slurry in the second mixing zone is then combined with sulfuric acid shown entering mixing zone 2 via line 11 in an amount equal to about 102% to 104% of the quantity of acids stoichiometrically required to precipitate the calcium ion contained in the slurry. This reaction proceeds as follows:
3Ca(H.sub.2 PO.sub.4).sub.2 +3H.sub.2 SO.sub.4 +6H.sub.2 O→3CaSO.sub.4 2H.sub.2 O+6H.sub.3 PO.sub.4
3Ca(H.sub.2 PO.sub.4).sub.2 +3H.sub.2 SO.sub.4 +1-1/2H.sub.2 O→3CaSO.sub.4 1/2H.sub.2 O+6H.sub.3 PO.sub.4
Approximately 80 to 90% of the slurry exiting mixing chamber 2 passes by stream 12 through evaporator 5 and is recycled back to mixing chamber 1. It is by controlling this recycled stream that the respective concentrations of calcium ion and sulfate ion can be controlled within mixing vessel 1. The slurry passes through a flash evaporator 5 for cooling the slurry by evaporating some of the water. The remaining 10% to 20% of the slurry exiting mixing vessel 2 passes via stream 10 into vessel 3 which also receives slurry from mixing vessel 1 directly via line 9.
The output from mixing vessel 3 passes via line 14 to filter 4 to separate the filter cake and filtrate having a P 2 O 5 content about 40% by weight. A portion of the filtrate is withdrawn as a final product as shown by line 15. The filter cake can be washed with water to remove residual P 2 O 5 concentration of approximately 25% by weight which is then returned to mixing vessel 1 via line 13 to provide the phosphoric acid in the initial mixing vessel. Gypsum is removed from the system as shown by line 16.
The foundation of the invention lies in controlling the calcium ion concentration in the slurry in mixing vessel 1 while adjusting the sulfate ion concentration in mixing vessel 2 to specific values. It has been determined that those advantages outlined above in practicing the present invention can best be carried out when the calcium ion concentration in the slurry of mixing vessel 1 is in the range of 1.0% to 2.5% by weight while the rate of sulfuric acid addition to the second mixing vessel is carried out in order to maintain sulfate ion concentration in the slurry in said mixing vessel in the range of 2% to 4% by weight.
EXAMPLE
Approximately 3.4 tons of phosphate rock having a quality of approximately 30% P 2 O 5 was added to an initial mixing vessel together with 6.28 tons of phosphoric acid (25.2% P 2 O 5 ). The mixing vessel was maintained at approximately 160° F. The initial mixing vessel was also the recipient of a slurry from a second mixing vessel containing sulfate ions. The output from the initial mixing vessel being approximately 48 tons was split into two fluid streams, the first stream consisting of approximately 42.75 tons was fed into a second mixing vessel and the remainder, approximately 5.25 tons was fed to a third mixing vessel. In the second mixing vessel was also added approximately 3.31 tons of sulfuric acid which reacted with the slurry output from the first mixing vessel as described in the equations recited above.
The slurry output from the second mixing vessel was split into two fluid streams, the first consisting of approximately 39.6 tons of slurry which was passed through an evaporator, evaporating approximately 0.93 tons of water. The remaining 38.67 tons of slurry was injected into the initial mixing vessel and became a reaction product with the initial phosphate rock and phosphoric acid. The remaining 5.1 tons of slurry output from vessel 2 was fed to vessel 3. The output from vessel 3, approximately 10.85 tons of slurry was fed to a filter which in turn yielded approximately 6.67 tons of gypsum and filtrate of phosphoric acid. This system yielded approximately 2.5 tons 40% phosphoric acid while the filter cake was washed and mixed with phosphoric acid product to recycle approximately 6.28 tons of phosphoric acid (25.2% P 2 O 5 ) to the initial mixing vessel. | A process is described for producing high purity phosphoric acid of 40% P 2 O 5 concentration from phosphate rock. The process is controlled to achieve the desired results by monitoring and controlling the sulfuric acid content at various processing stations resulting in the control of gypsum formation and the minimization of freed impurities in the phosphate rock. | 2 |
BACKGROUND OF THE INVENTION
The ribonucleotide reductase enzyme of herpes simplex virus consists of 2 components which must remain associated for the enzyme to convert ribonucleotide diphosphates to deoxy ribonucleotide diphosphates. The enzyme is known to be required for herpes simplex virus replication. Dutia et al., Nature 321:439-441 (1986) and Cohen et al., Nature 321:441-443 (1986) both disclosed that the nonapeptide, Tyr Ala Gly Ala Val Val Asn Asp Leu, inhibited in vitro the activity of this enzyme. In addition Dutia et al., op. cit., also disclosed that its 8-desalanine homolog, Tyr Gly Ala Val Val Asn Asp Leu, also inhibited in vitro the activity of this enzyme.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide novel peptides which inhibit the activity of the ribonucleotide reductase enzyme of herpes simplex virus. Another object is to provide inhibitory peptides that contain a D-amino acid that inhibit this conversion. These and other objects of the present invention will be apparent from the following description.
SUMMARY OF THE INVENTION
A series of hexa- and nonapeptides each of which contains a D-amino acid has been found to inhibit the activity of the ribonucleotide reductase enzyme of herpes simplex virus in vitro.
DETAILED DESCRIPTION
It has now been found that the peptides of the present invention inhibit the activity of the ribonucleotide reductase enzyme of herpes simplex virus in vitro. This enzyme is required for replication of the herpes simplex virus.
In the present invention the amino acids listed below are identified both by conventional 3 letter and single letter abbreviations as indicated below:
______________________________________Alanine Ala AAsparagine Asn NAspartic Acid Asp DGlycine Gly GLeucine Leu LTyrosine Tyr YValine Val V______________________________________
The peptides of the present invention are the following:
______________________________________A V V N dD LA V V dN D LA V dV N D LdA V V N D LdY V V N D LY A G A V V dN D LY A G dA V V N D LY A dA A V V N D LY dA G A V V N D LdY A G A V V N D L______________________________________
The polypeptides of the present invention and the amides and salts thereof can be manufactured according to known synthetic methods elongating the peptide chain, i.e. by condensing amino acids stepwise or coupling the fragments consisting of two to several amino acids, or by combination of both processes, or by solid phase synthesis according to the method originally described by Merrifield, J. Am. Chem. Soc. 85:2149-2154 (1963). Alternatively, the peptides of the present invention may be synthesized using automated peptide synthesizing equipment.
The condensation between two amino acids, or an amino acid and a peptide, or a peptide and a peptide can be carried out according to the usual condensation methods such as azide method, mixed acid anhydride method, DCC (dicyclohexylcarbodiimide) method, active ester method (p-nitrophenyl ester method, N-hydroxysuccinic acid imido ester method, cyanomethyl ester method, etc), Woodward reagent K method, carbonyldiimidazol method, oxidation-reduction method. These condensation reactions may be done in either liquid phase or solid phase. In the case of elongating the peptide chain in the solid phase method, the peptide is attached to an insoluble carrier at the C-terminal amino acid. For insoluble carriers, those which react with the carboxy group of the C-terminal amino acid to form a bond which is readily cleaved later, for example, halomethyl resin such as chloromethyl resin and bromomethyl resin, hydroxymethyl resin, aminomethyl resin, benzhydrylamine resin, and t-alkyloxycarbonylhydrazide resin can be used.
As is usual in peptide synthesis, it is necessary to protect/deprotect the α- and ω- side chain amino groups and the carboxy group of the amino acid as occasion demands. The applicable protective groups to amino groups are exemplified such as benzyloxycarbonyl (hereinafter abbreviated as Z), o-chlorobenzyloxycarbonyl [Z(2-Cl)], p-nitrobenzyloxycarbonyl [Z(NO 2 )], p-methoxybenzyloxycarbonyl [Z(OMe)], t-butoxycarbonyl (Boc), t-amyloxycarbonyl (Aoc), isobornyloxycarbonyl, adamantyloxycarbonyl, 2-(4-biphenyl)-2-propyloxycarbonyl (Bpoc), 9-fluorenylmethoxycarbonyl (Fmoc), methylsulfonylethoxycarbonyl (Msc), trifluoroacetyl, phthalyl, formyl, 2-nitrophenylsulphenyl (NPS), diphenylphosphinothioyl (Ppt), dimethylphosphinothioyl (Mpt) and the like.
As protective groups for carboxy group there can be exemplified, for example, benzyl ester (OBzl), 4-nitrobenzyl ester (OBzl(NO 2 )], t-butyl ester (OBut), 4-pyridylmethyl ester (OPic), and the like. It is desirable that specific amino acids such as arginine, cysteine, and serine possessing a functional group other than amino and carboxyl groups are protected by a suitable protective group as occasion demands. For example, the guanidino group in arginine may be protected with nitro, p-toluenesulfonyl, benzyloxycarbonyl, adamantyloxycarbonyl, p-methoxybenzenesulfonyl, 4-methoxy-2,6-dimethylbenzenesulfonyl (Mds), 1,3,5-trimethylphenylsulfonyl (Mts), and the like. The thiol group in cysteine may be protected with benzyl, p-methoxybenzyl, triphenylmethyl, acetylaminomethyl, ethylcarbamoyl, 4-methylbenzyl, 2,4,6-trimethylbenzyl (Tmb) etc, and the hydroxyl group in serine can be protected with benzyl, t-butyl, acetyl, tetrahydropyranyl etc.
Conventional methods of peptide synthesis as described, for example, by Schroder et al., "The Peptides", Vol. I Academic Press, 1965, or Bodanszky et al., "Peptide Synthesis", Interscience Publishers, 1966 or McOmie (ed.), "Protective Groups in Organic Chemistry", Plenum Press, 1973, or "The Peptides: Analysis Synthesis, Biology", 2 Chapter 1, by Barany et al., Academic Press, 1980, the disclosures of which are hereby incorporated by reference.
EXAMPLE
Preparation of Herpes Simplex Virus Ribonucleotide Reductase
HSV RR was purified by Baby Hamster Kidney cells that were cultured with HSV2 Strain 186. After infection, cells were harvested and lysed. Crude HSV RR was prepared as described by Huszar et al., J. Virol 37: 580-588(1981), then subjected to further purification by hydroxyapatite column chromotography. The resultant enzyme preparation was about 80% pure HSV RR as judged by SDS polyacrylamide electrophoresis.
Assay of Inhibition of HSV RR
HSV RR activity was determined as the ability of the enzyme to catalyze the reduction of tritiated cytidine-diphosphate to deoxyribo-cytidinediphosphate in 30 minutes at 37° C. in the presence of dithiothreitol and MgCl 2 . Activity of oligopeptide inhibitors was determined by adding them to the reaction mix at the beginning of the incubation. Enzyme was not preincubated with inhibitor.
Synthesis, Purification, and Analysis of Oligopeptides
Oligopeptides were synthesized by either the solid phase method of Merrifield, op. cit., or by FMOC chemistry (John Morrow Stewart and Janis Dillaha Young, "Solid Phase Peptide Synthesis," 2nd ed., 1984, Pierce Chemical Co., Rockford, Il.) and purified to >98% homogeneity by reverse phase HPLC and recovered by lyophilization as trifluoroacetic acid salts. These were analyzed for amino acid composition and in some cases sequenced. Dry peptides were resuspended in 100 mM HEPES (pH 8.0) at about 2mM, relyophilized, and stored in aliquots at -80° C. Immediately prior to use they were rehydrated with distilled H 2 O and centrifuged to remove any undissolved peptide. The concentrations of these stock solutions were then determined by measuring A291 nm at basic pH (ε=2.55) for tyrosine-containing peptides and by quantitative amino acid composition for those peptides without tyrosine.
The following oligopeptides were tested for ability to inhibit herpesvirus ribonucleotide reductase according to the foregoing method and the extent of the inhibition (μM concentration of peptide producing 50% inhibition of enzyme activity) is shown in the following table.
______________________________________Peptide IC.sub.50 (μM)______________________________________A V V N dD L 520A V V dN D L 460A V dV N D L 600dA V V N D L 90dY V V N D L 30Y A G A V V dN D L >620Y A G dA V V N D L 72Y A dA A V V N D L 88Y dA G A V V N D L (210)dY A G A V V N D L 40______________________________________ | A series of oligopeptides each of which contains a D-amino acid has been found to inhibit the activity of the ribonucleotide reductase enzyme of herpes simplex virus in vitro thereby inhibiting viral replication. | 0 |
Background of the Invention
1. Field of the Invention
The present invention relates generally to hair nets and more particularly to a new and improved hair net to protect a coiffure or elaborate hairdo or arrangement while the person is active or asleep.
Women of today have steadily become more active than heretofore in their careers and in the business world and socially. Such activity requires a great deal of their time thereby leaving less time for them to personally maintain their coiffures. Since time must be devoted to their business or careers, there is a pressing need for women to maintain their coiffures for longer periods of time between visits to a beauty salon without additional cost or time. While the frequency of visits to a beauty salon may not be changed, the coiffure may be more easily maintained between visits with the hair net strip in accordance with the present invention.
2. Prior Art
In the past, conventional hair nets were used. Such hair nets generally comprise a simple net surrounded by an elastic band which kept the hairdo or coiffure in place. The problem with such hair nets is that the elastic band is uncomfortable and has a tendency to roll up and be displaced on a person's head and at times when it is being removed from a person's head, it may disturb the coiffure.
SUMMARY OF THE INVENTION
Briefly described, a hair net strip in accordance with the preferred embodiment of the invention for protecting a coiffure includes a longitudinal strip of netting material having a length and width sufficient to cover the coiffure and person's head along the forehead, nape and sides thereof. The strip is also of sufficient length to overlap at the ends thereof and an adhesive coating that is relatively non-irritating to the skin is fixed to the edge of the strip for adhering the hair net strip to the hair or skin along the forehead, nape and sides of a person's head so that the hair net strip protects the coiffure when placed about the coiffure and head. The adhesive firmly adheres the net to the head so that the person may be awake and active or asleep in bed without worry of the net rolling up or disturbing the coirffure and yet be easily removed without disturbing the coiffure.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood upon consideration of the following detailed description taken together with the accompanying drawings in which are like elements in various figures having like designations and in which:
FIG. 1 is a perspective view of a person wearing a hair net strip in accordance with a preferred embodiment of the invention;
FIG. 2 is a front view of the hair net strip illustrated in FIG. 1 being worn by the person;
FIG. 3 is a side view of the hair net strip in accordance with a preferred embodiment of the invention;
FIG. 4 is a front view of the hair net strip in accordance with a preferred embodiment of the invention;
FIG. 5 is a cross-sectional view of the hair net strip taken along lines 5--5 of FIG. 4;
FIG. 6 is a cross-sectional view of the hair net strip taken along lines 6-6 of FIG. 4;
FIG. 7 is a front view of another embodiment of another hair net strip showing another feature of the invention;
FIG. 8 is a cross-sectional view of the hair net strip of FIG. 7 taken along lines 8--8;
FIG. 9 is another embodiment of the invention in a hair net strip which is produced in series and separable by cutting or tearing along a perforated web section;
FIG. 10 is a cross-sectional view of the hair net strip of FIG. 9 taken along lines 10--10, and
FIG. 11 is a cross-sectional view of a hair net strip of FIG. 7 taken along lines 11--11.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The hair net strip of the present invention will be described with particular reference to the preferred embodiment illustrated in the drawing. It should be understood that the drawing illustrations and description are to be taken only as illustrative of the preferred embodiment of the hair net strip of the present invention and is to be understood in a general way and not in a restrictive way.
FIGS. 1-6 show a hair net strip 10 in accordance with a preferred embodiment of the invention for protecting a hairdo or coiffure 11 on the head 12 of a person 13.
The hair net strip 10 when in use is placed about the head 12 across the forehead 14, the nape 15 and the right and left sides 16 and 17. The forehead 14, the nape 15, right side 16 and left side 17 lie along a circumference 19 about the head 13.
The hair net strip 10 comprises a longitudinal strip 20 of a net material which is preferably a resilient, thin, porous tissue-like fabric. The longitudinal strip 20 has a relatively high tensile strength in both the dry and wet conditions. The longitudinal strip 20 is preferably made of inexpensive material so that the hair net strip 10 may be disposed of after the hair net strip 10 has been used. The longitudinal strip 20 in the flat position as shown in FIGS. 3 and 4 has a length which is greater than the circumference 19 and is of sufficient length so that left end 21 overlaps right end 22 of the longitudinal strip 20 when the hair net strip 10 is in use as illustrated in FIGS. 1 and 2. The longitudinal strip 20 is rectangular at end 22 while end 21 is triangular in shape to permit easy overlapping of the ends 21 and 22. In other words, alignment is not critical as long as the coiffure and head 12 are covered by the longitudinal strip 20. For that purpose, the width of the longitudinal strip 20 should be of a magnitude to cover the coiffure. Thus, the width of the longitudinal strip 20 is a function of the height of the coiffure and may come in various sizes to accommodate the coiffure. The longitudinal strip 20 has a hair and skin contacting inner surface 23 and an outer surface 24. The outer surface 24 of the longitudinal strip 20 may be smooth so that when the person 13 sleeps, the head 12 may easily move on a pillow or sheet (not shown).
The longitudinal strip 20 includes an upper edge 25 and a lower edge 26. The longitudinal strip 20 may be compacted along the upper and lower edges 25, 26 and end 21 so that the web material between the edges 25, 26 may be thinner than the upper and lower edges 25, 26. The upper and lower edges 25, 26 and end 21 are coated on the inner surface 24 with a thin, smooth visibly continuous hydrophobic transparent skin adhering pressure sensitive adhesive 27a to form a tape 27, similar to a tape described in U.S. Pat. No. 3,121,021. The adhesive coated tape 27 in the preferred embodiment essentially consists of a water-insoluble hydrophobic viscoelastic adhesive polymer which is also highly cohesive and pressure sensitive without being irritating to the human skin 9 and can be removed from the skin 9 after prolonged adhering contact. The tape 27 is sufficiently porous to permit perspiration and other liquids to evaporate through the tape 27 when it is adhered to the human skin 9. If desired, the tape 27 may be a separate tape not formed by the compacted edges 25, 26.
The longitudinal strip 20 also includes vertical tapes 28, 29, 30 similar to tape 27 on the outer surface 23 proximal to end 22. The vertical tapes 28, 29, 30 coact with end 21 for holding the longitudinal strip 20 in a cylindrical shape about the head 12 of the person 13. The vertical tapes 28, 29, 30 are spaced apart to accommodate various sizes of heads 12. The vertical tapes 28, 29, 30 and the triangular shaped end 21 of the strip 20 overlap in a "quick-to-find" adhering state. In effect, the vertical tapes 28, 29, 30 and triangular end 21 criss-cross each other to secure the hair net strip 10 as shown in FIGS. 1 and 2.
OPERATION
In the operation and use of the hair net strip 10, the hair net strip 10 is held at each end 21 and 22 in a straight stretched condition in back of the head 12. The lower edge 26 of the hair net strip 10 is then placed tightly in contact with the nape 15 of the head 12 and the hair net strip 10 is then wrapped about the right and left sides 16, 17 and across the forehead 14 in an overlapping state so that the ends 21, 22 are in adhering contact by tape 27 at end 21 and vertical tapes 28, 29, 30 at end 22 of the hair net strip 10. The tape 27 at the lower edge 26 should touch the skin 9 wherever possible especially the head 12 near the right and left ears 7, 8 and across the forehead 14. The upper edge 25 and tape 27 may, if desired, be patted down to fit the coiffure 11 or the hair net strip 10 may be left in a cylindrical shape about the head 12.
To remove the hair net strip 10, the ends 21, 22 of the hair net strip 10 are pulled apart without disturbing the coiffure 11 and the hair net strip 10 is removed from the head 12.
EMBODIMENTS OF THE INVENTION
Referring now to FIGS. 7 and 8, another embodiment of the invention is shown in a hair net strip 70 similar to the hair net strip 10, except that instead of a continuous adhesive 27a along tape 27 (FIG. 4), spots 71 of adhesive 27a are fixed to the inner surface 72 of a longitudinal strip 73 along a path 74 around the perimeter 78 of the longitudinal strip 73. This of course serves two purposes, first, there is a savings of adhesive 27a and secondly, there is spot contacting instead of continuous contacting between the adhesive 27a and the skin 9 of the head 12. A further difference between the hair net strip 10 and hair net strip 70 is that both ends 75, 76 are triangular in shape.
The longitudinal strip 73 has an outer surface 77 upon which adhesive 27a is coated at end 76. The longitudinal strip 73 may be made of various webbing material similar to the longitudinal strip 20 of FIG. 1.
Referring now to FIGS. 9-11, another embodiment of the invention is shown in a hair net strip 90 similar to the hair net strip 10 of FIG. 1.
The hair net strip 90 may be made in continuous hair net strips 90, 90a, 90b which may be sold in a roll form (not shown) if desired. Each of the hair net strips 90, 90a, 90b may be separated at a preferred web portion 91 at lines 92. The hair net strip 90 differs from the hair net strip 10 in that the ends 93, 94 are rectangular in shape for easy tearing or cutting of the longitudinal strip 95 of the netting material so as to separate the hair net strips 90, 90a, 90b.
The longitudinal strip 95 also has inner and outer surfaces 96, 97. The ends 93 and 94 of the longitudinal strip 95 are coated with adhesive 27a on both the inner surface 96 and outer surface 97 at ends 93 and 94. The hair net strip 90 includes a single row 101 of spots 98 of adhesive 27a on inner surface 96 of longitudinal strip 95. The spots 98 of adhesive 27a are employed for the same reason given for the hair net strip 70 except that a single row 101 is employed for a further savings of adhesive 27a.
Modifications and alterations may occur to those skilled in the art, for example, the tape 27 of FIG. 1 may be a two-sided tape, one side of which adheres to the longitudinal strip 20 and the other side adheres to the human skin 9.
Having thus described the invention, it will be evident that other modifications and improvements may be made by one skilled in the art which would come within the scope of the annexed claims. | A hair net strip for protecting a coiffure is disclosed wherein a longitudinal strip of netting material having a length and width sufficient to cover the coiffure and a person's head along the forehead, nape and sides thereof and a pressure sensitive adhesive which is non-irritating to the skin is fixed to the strip and adapted to contact said person's forehead, nape and sides to adhere thereto and to maintain said hair net strip in a coiffure protective position about the person's head. | 0 |
TECHNICAL FIELD
This invention relates to modular housing construction system of the type in which all basic components of the building are prefabricated at a factory or shop and simply erected at the site with a minimum of on-the-site construction.
BACKGROUND OF THE PRIOR ART
With the cost of labor, materials and financing in an upward spiral, conventional home construction has become out of reach of many people in the home buying market, such as families of limited income and basically little cash, and families on retirement income. Further, even where the high cost of conventional new home construction can be met, the waiting period for completion of conventional new home construction has often resulted in loss of purchasers to the mobile home market, which represented about 80% of new home sales in the State of Florida in 1980.
In the past, it has been the custom in manufacture of modular homes that the homes are built in, for example, two parts or sections, moved to the desired site or location in halves which are placed onto conventional foundation means and the two halves joined. It normally takes a crew four or five days to complete the construction on site.
It is also known to prefabricate housing components for erection at the site and representative of such prior art is found in U.S. Pat. No. 3,122,223 Chell et al. and U.S. Pat. No. 2,140,772 Slayter et al.
BRIEF SUMMARY OF THE INVENTION
It is a principle object of the present invention to construct in a controlled environment concrete footer/foundation components; modular floor panel elements; and interior/exterior module wall panel units where the quality and cost of both labor and materials can be closely controlled. The modular components can be manufactured at a much lower cost at a factory environment with the use of jigs, pneumatic clamps, nail guns, and other techniques of automation. It has also been found that relatively low cost labor can be used which labor can become proficient by the repititious building of similar components in an environment where weather is not a factor.
It is a further object to provide a housing system wherein a component inventory is established and from the component inventory it is possible to design and select components to a customer's requirements, only limited to the extent of four foot increments which form the basic size of the major modular units.
After selecting the desired components, they are delivered to a site where erection crews or the home owners themselves erect the house via an assembly sheet. It is projected that a home of medium size could be erected on site ready for occupancy in, for example, 150 man hours.
A further object of the present invention is to provide such a modular housing construction system that should the owners desire to move the assembled house, dissassembly thereof can be achieved without destruction of the components.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more fully described in reference to the accompanying drawings wherein:
FIG. 1 is a fragmentary partial perspective view of a modular housing unit constructed in accordance with the teachings of the present invention;
FIG. 2 is a perspective view of one precast concrete footer/foundation component;
FIG. 3 is a section on line 3--3 of FIG. 2;
FIG. 4 is a perspective view of a precast concrete footer/foundation corner component;
FIG. 4a is a perspective view of a wedge lock bracket for the foundation components;
FIG. 5 is a vertical sectional view of a pair of footer/foundation components and support means for a modular floor;
FIG. 6 is an exploded perspective view of preferred wedge lock type fastening means for the components;
FIG. 7 is a fragmentary view of the wedge lock system in operation;
FIG. 8 is a modular floor unit;
FIG. 9 is a section on line 9--9 of FIG. 8;
FIG. 10 is a partially exploded view of three modular wall panel units;
FIG. 11 is a fragmentary detailed view of one of the wedge lock assembling means for the wall panels of FIG. 10;
FIG. 12 is section on line 12--12 of FIG. 11;
FIG. 13 is a fragmentary top plan view of corner reinforcing means for the housing system;
FIG. 14 is an end view of the structures illustrated in FIG. 13;
FIG. 15 is a fragmentary sectional view of means for attaching the roof joist or trusses to the top plate of the housing unit;
FIG. 16 is a section on line 16--16 of FIG. 15; and
FIG. 17 is an enlarged fragmentary view of the truss or joist attaching means illustrated in FIGS. 15 and 16.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawing and in particular to FIG. 1 thereof, 10 generally designates a modular housing constructed in accordance with the teachings of the present invention. The modular housing is formed from a number of primary modulars including pre-cast concrete footer/foundation units 12, modular floor panel elements 14, interior/exterior modular wall panel units 16 and roof trusses 18. These various modular units will be described separately and in greater detail hereinafter.
Referring now particularly to FIGS. 2 through 4, the modular pre-cast concrete footer/foundation components 12 are of two forms. The first form, illustrated in FIG. 2, is for longitudinal side walls and is designated 20 and the other form is a longitudinal/corner wall forming member 22, illustrated in FIG. 4.
Each unit 20 consists of footers 24 and vertical wall sections 26. In forming these elements 20 and their counterpart units 22, conventional reinforced concrete casting procedures are followed.
At each end of unit 20 are a plurality of openings 28 which communicate with interior openings 30. The openings 28 and 30 receive wedge bars 32 as shown in FIG. 4 and wedge lock pins 34. In a preferred embodiment, each module 20 is 4 feet in length, 2 feet high, and 51/2 inches in thickness.
Along the inner wall is cast an inwardly projecting ledge 36, the top surface 38 of which is six inches below the top surface of the foundation components. The ledges are adapted to receive the floor panel modules as to be more fully described hereinafter. In the upper surface 40 of the foundation elements are cast wedge lock elements 42 more clearly illustrated in FIG. 3. The wedge lock elements 42 consist of a lazy U shaped metal element 44 having welded thereto an upright member 46 provided with an elongated slot 48 to receive one of the wedges 34. In a preferred embodiment two of the elements 42 are cast in each foundation unit 20 with the centers of the elements 42 positioned twelve inches from the closest side wall 50 of the foundation.
The corner foundation element 22 is pre-cast following reinforcing concrete casting procedures and each corner element is provided with openings such as openings 28 and 30, FIG. 2 and with wedge lock elements such as wedge lock elements 42, FIGS. 2 and 3 of the drawings. Each of the foundation units 20 and 22 may have cast in each of the openings 28 a bracket element as shown in FIG. 4a and at 28a in FIG. 4. The elements 28a help to stabilize the tie bars and the foundation from lateral displacement whereas the wedges 34 prevent longitudinal displacement of the foundation elements.
The bracket 28a in the bridge portion 29 is provided with elongated slot 31 adapted to receive one of the tie bars 32 or 32'. Each of the legs 33 of the bracket 28a is provided with a plurality of openings 35 which assist in anchoring the bracket in the concrete foundation either at the time of casting or subsequent thereto through the use of a suitable adhesive.
In initiating construction of the modular home, holes are dug in the soil to receive the footers 24 and the foundations with attached footers are erected and tied together with the wedge bars and wedges to form an interlocked foundation setting above the ground level. Thereafter, a plurality of block type footings designated 60, FIG. 1, are placed on 6' 8" intervals and support screw jacks 62 which screw jacks have top U shape members 64 which support 4"×4" timbers 68 with the top of the timbers mating with the top surface 38 of the ledges 36 in the foundation units. These 4"×4"'s support the ends of the modular floor panels as illustrated in FIGS. 1 and 5. With the 4"×4" beams 66 each end of a floor panel has support on either a ledge 38 or a 4×4 supported by the screw jacks 62. With the foundations 12 in place and with the 4×4's 66 in proper position, the structure is ready to receive the modular floor panel elements 14 to be described in reference to FIGS. 8 and 9 in conjunction with FIGS. 6 or 7.
Each floor panel 14 has finished dimensions of four feet by eight feet and the peripheral walls are preferably formed from 2"×6" wood boards 70 on the ends and 72 on the long edges. Further, each panel has a center element 76 also having a 2"×6" dimension and a cross beam 78 of similar stock. In addition longitudinal beams 72 and 76 are notched as at 80 to receive struts preferably cut from 11/2"×11/2" material and designated 82. Further, longitudinal beam 72 is provided with oblong openings 84 and 84' with openings 84 positioned 12 inches from the end members 70 and openings 84' twenty four inches on center. These openings 84 and 84' receive tie bars 32' having the oblong slots 90 in the ends thereof which oblong slots are shaped to receive the wedge lock pins 34.
The panel or module 14 is finish at the factory by nailing to its upper surface a cover sheet such as a 3/4 inch particle board.
In FIG. 6 the tie bar 32' is illustrated in two configurations, one where the entire bar is rectilinear and two wedge pins are used to lock the modular panels to one another and a form wherein end 92 is bent 90° so that only a single wedge pin 34 is needed. After placement of the panels on the support beams 66 and ledges 34 a locking bar 32 is inserted in each of the openings 84 and 84' in adjacent modules and then the panels are securely but releasably held together by the insertion of a locking pin 34 all as illustrated in the fragmentary view FIG. 7. The insertion of the locking bar 32' and the locking pins 34 is carried out beneath the floor in the "crawl space" created by the foundation walls, jacks 62, and beams 66.
Where desired the floor panels may receive conventional vapor barrier/insulation by stapling to the underside after the floor is installed at the building site.
Referring now to FIGS. 10, 11, and 12, a basic wall panel module 16 will now be described. Each wall panel module 16 is constructed of two inch by six inch boards with the panels having widths of 48" and heights of 7'11". The top and bottom boards 100 and 102 and the vertical side panels 104 and 106 are provided with oblong tie bar holes 108. In the illustrated form of the invention, there are two oblong tie bar holes at the bottom and three along the vertical edges and along the top. These oblong tie bar holes receive tie bars 32 or 32', previously described, and permit anchoring of the vertical members 104 and 106 to adjacent vertical members whereas the lower oblong holes 108 receive the upper ends 46 of the tie bars 42 anchored to the top surface 40 of the modular foundations as described in reference to FIGS. 2, 3, and 4. The top oblong holes 108 are employed to attach the top plate 110 to the structure, FIG. 1 of the drawing and to attach the roof trusses to be hereinafter described in reference to FIGS. 1, 15, 16 and 17.
As with the floor modules, the wall modules 16 include a center 2"×6" board 112 and a plurality such as four horizontal struts 114 which horizontal struts are received in slots cut in the vertical 2"×6"'s 104, 106 and 112. The struts 114 are, in the illustrated form of the invention, 11/2 inches square in cross dimension and 48" long.
The panels are also provided with an opening 116 in the top 2"×6" 102 so that electrical wiring may be run interiorly of the wall panels of those panels which are to be provided with electrical outlet boxes such as electrical outlet boxes 118, FIG. 1 of the drawing. The panels illustrated in FIGS. 10, 11 and 12 are designated the basic wall panels and such wall panels are modified during construction to receive door and door openings 120 and window and window openings 122, FIG. 1 of the paragraph.
After the wall panel modules have been framed out and wired, an exterior sheet 126 is applied to one face which exterior sheet may be exterior grade plywood or the like or wire lathing may be attached to the exterior face where the exterior finish is to be a simulated brick or stucco. The exterior plywood or finish sheet 126 laps as at 128 the bottom 2"×6" 100 so that when the panels are installed a weather seal is provided along the marginal top edge of the foundation modules. After applying the exterior sheet insulation as illustrated at 130 is placed in the panels and an interior finish sheet such as wall board 132 is affixed to the inner surface of each panel.
Adjacent each opening 108 in each of the vertical elements 104 and 106, and the bottom and top boards 100 and 102, the interior wall board 130 is provided with an oblong opening 132 so that the panels may be assembled and wedge locked together by the tie bars such as tie bars 32' and their cooperating wedges 34. For each of the oblong openings 132 there is provided a cover plate 134 which is attached by screws such as screws 136 to complete the finish of the panels.
After the side wall units are installed, attached to adjacent panels and to the top surface of the foundation, a top plate 110 is provided for attachment to the tops of the wall panel and for attachment of the roof trusses. The top plate 110 comprises 2×6 boards which are provided with oblong openings corresponding to oblong openings 108 in the top board 102 of each side wall panel and with bores 150 corresponding to bores 116 for wiring connections.
The top plates are sized to end in the center of top board 102 of a panel except at the ends to provide greater rigidity in the finished housing. The top plate 110 is attached by special wedge lock brackets 160 FIGS. 15, 16, and 17 of the application.
The brackets 160 comprise metal bars 162 having their lower ends provided with a locking wedge slot 164 and adjacent the upper end is welded a further plate 166, bored as at 168 to receive bolts 170 which bolts pass through the plates 166 and cooperating bores 172 in the trusses 118 as shown in FIGS. 1, 15 and 16. Thus each truss 18, the top plate 110 and each of the wall panel modules are integrally but releaseably joined via the brackets 160 and locking wedges 34.
In order to provide greater stability for the housing at the corners 180, special corner brackets are applied after erection of the side walls. Referring now to FIGS. 13 and 14, the special corner brackets, generally designated 182 comprise top and bottom space plates 184 and 186 which are welded to end plates 188. The end plates 188 are slotted as at 190 to receive tie bars 32' and locking wedges 34. It has been found that three of these corner brackets corresponding to the three oblong slots provided in the basic wall panel modules provides the desired corner support. Where desired, trim strips may then be added to render the corners square.
After the trusses 18 are in place conventional roof finishing materials are added thereto such as external grade plywood and roofing shingles. Interiorly, wall board is added to the undersurface of the trusses.
From the foregoing description it will be seen that a modular housing construction is disclosed which will provide the low and medium priced purchaser a substantially completely finished home having the advantages of factory constructed durable modules at a minimum expense.
It will be evident to those skilled in the art that various modifications may be made in the modular house without departing from the spirit and the scope of the present invention as defined in the appended claims.
It will be further appreciated by those skilled in the art that while the housing is of very sturdy construction, if it becomes necessary to relocate the housing, substantially the entire house but for the roof and ceiling may be disassembled by removing the wedge lock pins and reassembled at another site at minimum expense. | A modular housing construciton consists of pre-cast concrete footer/foundation components; modular floor panel elements; interior/exterior modular wall panel units; and a roof. The floor panel elements, wall panel units, and foundation components have preformed wedge/lock receiving openings and the pre-cast concrete footer/foundation components and the wall panel units have preformed wedge-lock operating openings provided therein. Certain of the wall panel units are provided with windows and certain of the wall panel units are provided with doors. Electrical receptacle and wiring are fabricated in selected wall panel units. The wall panel units, the floor panel units and footer/foundation components are preferably preformed in four foot sections whereby the size of the housing is determined by the selected number of such units. With the modular form of construction on the site erection and diassembly of the footer/foundation components, floor panel elements, wall panel units and roofing is minimized and quality control is standardized. | 4 |
TECHNICAL FIELD
The present invention relates generally to a method and apparatus for imaging the internal structure of biological tissue through the technique of electrical impedance tomography (“EIT”), and this invention specifically relates to a method and apparatus for remotely imaging the internal structure of biological tissue by acquiring raw data, transmitting same to a remote computer through a communications network, processing the raw EIT data at the remote computer and displaying an image of the internal structure of the biological tissue at said remote computer, at the location of data acquisition or at any other location.
BACKGROUND OF THE INVENTION
In the fields of medical diagnosis and research it is often necessary to visualize the internal tissue structures of biological subjects or patients which cannot be otherwise observed without invasive procedures. An example of an area where such visualization is helpful is in the detection, monitoring and analysis of tumors and other malignancies hidden inside the soft tissue of a subject or patient. When dealing with live subjects or patients it is usually not medically advisable or preferable to conduct an invasive procedure for diagnostic purposes unless there exists some prior indication that a particular feature, such as a tumor, is present in the tissue to be examined. In addition, even where there is knowledge or suspicion that a target feature exists, such a feature is sometimes located in an area which either cannot be reached through invasive procedures or would expose the subject or patient to undue medical risk should an invasive procedure be attempted. Moreover, invasive procedures expose subjects and patients to more generalized risks such as infection, bleeding, and other complications, which are not present with non-invasive visualization techniques. Finally, invasive procedures are almost invariably significantly more expensive and time-consuming than non invasive procedures.
Several non-invasive procedures have been developed to aid in the monitoring and visualization of internal structures found in biological tissue. Examples of such techniques are x-rays, ultrasound imaging, magnetic resonance imaging (“MRI”), computerized tomography (“CT”), and positron emission tomography (“PET.”) Another such imaging technique, the technique to which the subject invention is directed to, is electrical impedance tomography (“EIT.”) EIT relies on differences in bio-electrical properties within the target tissue to characterize different regions within it and subsequently output an image correlating to such characterization. Generally, an EIT scan is performed by placing a series of electrodes in a predetermined configuration in electrical contact with the tissue to be imaged. A low level electrical sinusoidal current is injected through one or more of the electrodes and a resulting voltage is measured at the remaining electrodes. This process may be repeated using different input electrodes, and electrical currents of different frequencies. By comparing the various input currents with their corresponding resulting voltages, a map of the electrical impedance characteristics of the interior regions of the tissue being studied can be imaged. It is also possible to map the impedance characteristics of the tissue by imposing a voltage and measuring a resulting current or by injecting and measuring combinations of voltages and currents. By correlating the impedance map obtained through an EIT scan with known impedance values for different types of tissues and structures, discrete regions in the resulting image can be identified as particular types of tissue (i.e., malignant tumors, muscle, fat, etc.)
Each of the above-mentioned imaging techniques has relative advantages and disadvantages, including varying abilities to image different types of tissue and structures at differing resolutions and different speeds. All modem imaging implementations, however, share one basic characteristic: they require equipment which is large, expensive and largely non-mobile, making it necessary for the subject or patient to be transported to a facility which houses the imaging equipment in order to have access to it.
For many reasons, some of which are herein detailed, it is desirable to be able to perform an EIT scan of a patient at a remote location, generate an image at a different location, and transmit the image back to the patient's location or to a physician or technician who may be located at yet a third site. In almost all situations, it is impractical from both an economic and logistical standpoint to transport current imaging equipment to a remote site where it is more convenient for the subject or patient for the imaging to be performed. Also, on occasion, it is impossible, due to health of the patient or subject and for other reasons, to transport the subject or patient to the facility housing the imaging equipment making it altogether impossible to perform imaging using currently available equipment and techniques. In addition, in some regions of the world there is very limited access, if any, to advanced imaging equipment, such as EIT, and to qualified physicians and/or technicians who can interpret the results of a diagnostic scan. For patients located in such regions it is impossible to receive the benefits of this type of diagnostic tool using existing equipment. Finally, the ability to perform EIT scans remotely, process images locally, and transmit resulting images to patients, technicians and/or physicians, carries the additional benefit of permitting a single server to operate as a central processing location for multiple scanning locations scattered anywhere within range of the communications network used to transmit data and images between the server and remote locations. Because the scanning equipment used for EIT imaging is relatively inexpensive in comparison with the image processing and generation equipment, the ability to service multiple scanners using one server has the potential to generate tremendous cost savings and efficiency gains.
Previous attempts have been made to provide remote capabilities to equipment used for imaging of biological tissue and structures such as described in U.S. Pat. No. 6,044,131 to McEvoy et al. ('131 patent); U.S. Pat. No. 6,006,191 to DiRienzo ('191 patent) and U.S. Pat. No. 5,851,186 to Wood et al. ('186 patent); all of which are incorporated herein by reference.
The '131 patent describes a security system for capture of x-ray images to a digital cassette which can download the images to a computer and assign them electronic signatures. The computer, in turn, can be directly connected to other computers via a modem or to a digital network of computers via a private communications link. Images on this system are accessible from remote locations by those who have proper authentication codes and have computers which have access to the private communications link. Although this system allows for electronic distribution of images to remote locations, x-ray systems such as this one inherently rely on large, expensive and non-mobile equipment to scan the subject or patient and to process the scanned data once it is digitized. As a result, this invention does not solve the problems associated with requiring a subject or patient to travel to a fixed location to be scanned. Moreover, because this system does not separate the data acquisition and processing functions, it is not possible to achieve the economic benefits of using a centralized data processing component to service multiple data acquisition components. Finally, the invention described by the '131 patent is limited to x-ray imaging which is not as effective as EIT in visualizing muscle and other soft tissues. Accordingly, the invention described in the '131 patent does not address or overcome the above-listed problems with existing imaging techniques.
The '191 patent describes a system for transmitting, storing, retransmitting and receiving electronic medical images and permits more efficient diagnostic readings by physicians during periods of down time. The system described by this patent is used to decentralize storage and distribution of electronic medical images and to direct images, such as x-rays, MRI, CT Scans, etc., which need interpretation, to medical professionals who read the images and diagnose conditions based on their readings. To accomplish this, the invention outlines methods for storage of medical images in digital format as well as a system that allows qualified physicians to bid on the opportunity to read and interpret stored images. The '191 patent, however, is directed only at remote access and distribution of medical images and not at remote creation of medical images. In order to input images into the system, the patient must rely on traditional imaging techniques which require them to travel to a facility that houses imaging equipment. Accordingly, the invention described in the '191 patent does not address or overcome the above-listed problems with existing imaging techniques.
The '186 patent describes a medical ultrasonic diagnostic imaging system which is capable of being accessed over data communication networks such as the Internet. The system described by the '186 patent allows a person to control an ultrasound imaging machine remotely over the Internet and to retrieve images from the ultrasound imaging machine. However, the remote capabilities of this invention are limited to controlling the ultrasound equipment and downloading of images. As with all other traditional imaging techniques previously described, the data acquisition (i.e., scanning) and processing of data both occur at the same location. Consequently, the equipment needed to perform these functions is bulky and expensive foreclosing the possibility of home use or use at locations where economic conditions make owning such equipment prohibitive. Moreover, although the '186 patent describes a networked embodiment of the invention in which multiple ultrasound imaging machines are linked and are remotely accessible, because the data acquisition and data processing functions are both performed locally, the equipment needed for such functions must be duplicated at every node of the network thus eliminating any cost savings. Accordingly, the invention described in the '186 patent does not address or overcome the above-listed problems with existing imaging techniques.
None of the inventions mentioned above describe a method or apparatus for remotely imaging the internal structure of biological tissue by acquiring raw data, transmitting same to a remote computer through a communications network, processing the raw EIT data at the remote computer and displaying an image of the internal structure of the biological tissue at said remote computer, at the location of data acquisition or at any other location.
Consequently, there is a need in the art for a method and apparatus which makes it possible to perform EIT imaging of biological tissue at a remote site without requiring the patient or subject to travel to a fixed location.
There is a further need in the art for a method and apparatus which allows patients to perform EIT imaging on themselves, in the privacy of their homes, without necessity of the services of a doctor or specialized medical technician.
There is a further need in the art for a method and apparatus which permits a doctor or medical technician to review and interpret EIT images of a patient located in one remote location, from a second remote location.
There is a further need in the art for a method and apparatus which makes it possible for a single image processing and generation server to centrally service multiple scanning locations within range of the communications network used to transmit data and images between the server and the remote scanning locations.
There is a further need in the art for a method and apparatus which for broadcasting to multiple locations, images generated locally from remote EIT scans of patients or subjects.
Finally, there is yet a further need in the art for a method of selling to patients, insurers, employers and other entities, remote EIT images and interpretation services thereof by qualified physicians and technicians.
SUMMARY OF THE INVENTION
The present invention overcomes significant deficiencies in the art by providing a method and apparatus for remotely imaging the internal structure of biological tissue from a remote location using electrical impedance tomography. The method and apparatus which is the subject of this invention accomplishes this by separating the functions of data acquisition from those of processing and imaging, and by connecting the data acquisition, processing and imaging components through a communications network, thus permitting the data acquisition, processing and imaging functions to be carried out at disparate locations within said network.
Generally described, the present invention describes an apparatus for remotely imaging the internal structure of biological tissue using the technique of electrical impedance tomography (EIT), comprising at least two electrodes arranged in a predetermined configuration electrically connected to the tissue, a power source for applying electrical input currents, voltages, or combinations thereof, of predetermined values to at least one of the electrodes, electrical measuring hardware for measuring the values of resulting output currents, voltages, or combinations thereof, at one or more of the electrodes, optionally, computer programming for converting the values of the electrical input currents, voltages, or combinations thereof and the values of the resulting output currents, voltages, or combinations thereof, into a format suitable for transmission over a communications network, communications hardware and software for transmitting the values of the electrical input currents, voltages, or combinations thereof, and the values of the resulting output currents, voltages, or combinations thereof, to a remote computer through a communications network, computer programming for calculating at the remote computer an electrical impedance value at one or more points on the tissue by analyzing the values of the electrical input currents, voltages, or combinations thereof, and the values of the resulting output currents, voltages, or combinations thereof using a front tracking or a hybrid algorithm, computer programming for generating an image of the internal structures of the tissue corresponding to the calculated impedance value or values, computer programming for transmitting from the remote computer through the communications network the image of the internal structures of the tissue to the location of the remote computer or to a location other than that of the remote computer; and computer programming and a monitor for displaying the image at the location of the remote computer or at the other location.
The present invention also describes, in general terms, a method for remotely imaging the internal structure of biological tissue using the technique of electrical impedance tomography (EIT), comprising the steps of electrically connecting at least two electrodes to the tissue, applying electrical input currents, voltages, or combinations thereof, of predetermined values to at least one of the electrodes, measuring the values of resulting output currents, voltages, or combinations thereof, at one or more of the electrodes, optionally converting the values of the electrical input currents, voltages, or combinations thereof and the values of the resulting output currents, voltages, or combinations thereof, into a format suitable for transmission over a communications network, transmitting the values of the electrical input currents, voltages, or combinations thereof, and the values of the resulting output currents, voltages, or combinations thereof, to a remote computer through the communications network, calculating at the remote computer an electrical impedance value at one or more points on the tissue by analyzing said values of the electrical input currents, voltages, or combinations thereof, and the values of the resulting output currents, voltages, or combinations thereof using a front tracking or a hybrid algorithm, generating an image of the internal structures of the tissue corresponding to the calculated impedance value or values, transmitting through the communications network the image of the internal structures of the tissue to the remote compute or to a location other than that of the remote computer; and displaying the image at the remote computer or other location.
In the preferred embodiment, the connecting step includes placing in direct proximity to the tissue to be examined, a probe of known dimensions, with at least two electrodes incorporated therein, so as to cause the electrodes to come in electrical contact with the tissue. The probe can be formed from rigid or flexible materials such that it is shaped to fit the particular geometrical features of the tissue to be studied.
In the preferred embodiment, the electrical input application step includes the designation of one of the electrodes on the probe as the source, or positive, electrode and a second electrode as the sink, or negative, electrode. The remaining electrodes are designated as differential electrodes. An input current, voltage, or combination thereof, of known value is applied by connecting a power source across the source and sink electrode pair, causing an electrical current to flow between the source and sink electrodes. Alternatively, if the probe incorporates only two electrodes, the second electrode would be designated as a differential electrode and the tissue would be directly connected to an electrical ground to complete the circuit. In addition to this, a number of different electrode injection and measurement configurations not mentioned here but well known in the art may be employed in the preferred embodiment.
In the preferred embodiment, the output measurement step includes using electrical measuring hardware to measure the output electrical current voltage or combination thereof which results from the electrical input at each of the differential electrodes.
In the preferred embodiment, the conversion step includes reducing, through techniques known in the relevant art, raw waveform values of measured output current, voltage, or combination thereof at each of the differential electrodes and input current voltage, or combination thereof, at the source and sink electrodes, into amplitude ratio and phase shift data which is more easily transmitted over a communications network. In an alternate embodiment of the present invention, the conversion step may be omitted and the measured raw waveforms may be transmitted without conversion.
In the preferred embodiment, the input application, output measurement and conversion steps are repeated several times using successive combinations of pairs of electrodes on the probe as the source and sink. The digital data resulting from each iteration of this process is stored until all data necessary for the desired imaging is acquired.
In the preferred embodiment, the transmitting step includes initially establishing communication with a remote computer containing software and hardware specifically programmed to receive the data generated in the previous steps. Once communication has been established, the data is transmitted to the remote computer where it is stored for processing. Communication with the remote computer is usually accomplished through the Internet. However, any type of communications network is acceptable to accomplish this step.
In the preferred embodiment, the calculation step includes initially accessing the data stored in the remote computer and demodulating the converted input and output values to recover the phase and amplitude information from the waveform data. Once the data is demodulated, it is processed using a reconstruction algorithm which calculates electrical impedance values at different points on the tissue and assigns a representative color to each point on the tissue depending on its impedance value. The output of this step is a three-dimensional numerical mapping of the subject tissue which designates an impedance value and corresponding color for different points in the tissue.
In the preferred embodiment, the display step includes creating a computer-readable graphical representation of the internal structures of the tissue in question from the numerical impedance mapping generated through the EIT scanning operation. The graphical representation can be stored, displayed on a monitor or printed at the location of the remote computer, or transmitted back to the location of the user or a third party, such as a physician or technician, for viewing, printing and/or storage.
Accordingly, it is an object of the present invention to provide a method and apparatus which makes it possible to perform EIT imaging of biological tissue at a remote site without requiring the patient or subject to travel to a fixed location.
Another object of the present invention is to allow patients to perform EIT imaging on themselves, in the privacy of their homes, without necessity of the services of a doctor or specialized medical technician.
Another object of the present invention is to permit a doctor or medical technician to review and interpret EIT images of a patient located in one remote location, from a second remote location.
Another object of the present invention is to provide a method and apparatus which makes it possible for a single image processing and generation server to centrally service multiple scanning locations within range of the communications network used to transmit data and images between the server and the remote scanning locations.
Another object of the present invention is to provide a method and apparatus for broadcasting to multiple locations, images generated locally from remote EIT scans of patients or subjects.
Another object of the present invention is to provide a method of selling to patients, insurers, employers and other entities, remote EIT images and interpretation services thereof by qualified physicians and technicians.
These and other objects, features and advantages of the present invention may be more clearly understood and appreciated from a review of the following detailed description of the disclosed embodiments and by reference to the appended drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram illustrating the computer environment for practicing a preferred embodiment of the present invention.
FIGS. 2A through 2D are a flowchart illustrating the steps in a system implementing a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to FIG. 1 of the drawings, in which like numerals indicate like elements throughout the several views, the computer environment in a preferred embodiment of the present invention includes a server site 200 which is connected through the Internet 202 to one or more patient sites 206 and one or more physician sites 204 . The communications link between the server site 200 and each of the patient sites 206 and physician sites 204 is bidirectional. The server site is equipped with a computer server 100 , an electronic storage system 102 and a modem 104 or other communication device capable of connecting to the Internet. Each physician site is equipped with a personal computer 106 capable of connecting to the Internet through a modem 108 or other communication device. The patient sites are also equipped with a personal computer 110 capable of connecting to the Internet through a modem 112 or other communication device. In addition, each patient site is equipped with an electrode probe 114 which is connected to the site's personal computer 110 and is installed on the patient 116 at the location in the body where the imaging is to take place. The electrode probe 114 may be made of pliable material capable of conforming to different parts of the body or may be made of a rigid material depending on the part of the body which is to be imaged. The electrode probe 114 may also take the shape of a wearable garment, such as a woman's brassiere in a mammography application, in order to make it easier and more accurate to don and use.
A flowchart depicting the steps involved in the typical application of a preferred embodiment of the present invention begins at FIG. 2 A. The sequence begins at step 10 and advances to step 12 where the user, who may also be the patient, located at the patient site, attaches the electrode probe, which is connected to the personal computer at the site, to the part of the patient's body which is to be imaged. Next, in step 14 the user establishes an Internet connection to the server site and in step 16 logs on to the server by providing information such as a user name and password. If the correct log-on information is entered by the user, the sequence proceeds to step 20 where a patient profile record is located in a patient database accessible by the server. In step 22 , the method then extracts from the patient profile record information regarding the electrode configuration and geometry for the probe attached to the patient in step 12 . Alternatively, the information to be extracted from the patient profile record may be interactively input by the patient after log-on is accomplished. In step 24 , using the electrode configuration and geometry, the server determines the electrode pairing sequence which is to be employed by the probe to acquire data from the patient. The electrode pairing sequence determines which of the probe's electrodes will act as the source, sink, reference and differential electrodes for each iteration in the data acquisition cycle. Based on the electrode geometry and the electrode pairing sequence, the server, in step 26 , generates a series of switching commands which will be issued to current transmission hardware contained within the probe at the patient site. The switching commands are then transmitted in step 28 to the patient site.
Turning to FIG. 2B, in step 30 , at the patient site, the switching commands generated by the server are acquired by the current transmission hardware in the probe which in turn, in step 32 , assigns the source, sink, differential and reference electrodes within the probe for the first iteration of the data acquisition cycle. In step 34 , the current transmission hardware generates an input current or voltage based on the switching commands which is then applied to the source electrode in step 36 . In step 38 , a resulting output current or voltage is measured at each of the differential electrodes and is filtered to remove electrical noise. The output signal measured and filtered in step 38 and the input signal generated in step 34 are digitally sampled in step 40 . The sampling process entails observing the analog current and voltage signals at each electrode over a prescribed period of time and recording a numerical value in digital format which corresponds to the voltage level at each electrode at fractional increments in time over said prescribed period of time. Next, in step 42 , the digital input signal value and its corresponding digital output signal values are stored in memory. The sequence then advances to step 44 where a query is made to determine if all of the switching commands transmitted to the patient site have been processed. If the answer to this query is “No,” then steps 32 through 42 are repeated for the next switching command in the sequence. This process is repeated until all switching commands have been processed and multiple sets of digital input signal values and digital output signal values are stored in memory. Once the last switching command has been processed, the answer to the query in step 44 will be “Yes” and the method continues to step 46 where the stored digital input signal values and digital output signal values are transmitted to the server site for processing.
Turning next to FIG. 2C, in step 48 the digital input signal values and digital output signal values are received by the server which, in turn, in step 50 demodulates the values to recover amplitude and phase information from the digital sampling process of step 40 . In step 52 , using the phase and amplitude data from step 50 , the electrode geometry determined in step 22 and the electrode pairing sequence determined in step 24 , the server generates a raw image which corresponds to a three dimensional color mapping of impedance values for multiple adjacent points located in the part of the patient's body to which the electrode probe is attached. In order to generate the raw image, the server uses a specialized reconstruction algorithm which is based on a front tracking technique developed especially for use with the present invention. Use of the front tracking technique allows generation of a high-resolution image using significantly fewer independent voltage measurements and electrodes resulting in substantial time and resource savings. Details of the front tracking reconstruction algorithm are discussed in detail below.
Continuing with step 54 , the raw image is filtered by post-processing software to remove noise and to sharpen details and a final image is generated. Then, in step 56 , the final image is stored at the server and linked to the patient's profile in the patient database. In step 58 , the method queries to determine whether a copy of the final image should be transmitted to a physician site for interpretation. If the answer to the query is “Yes”, the final image is transmitted to the physician site before continuing to step 60 . The Internet address for the physician site to which the image is transmitted is obtained from the patient's profile. If the answer is “No,” the method continues to step 60 without transmitting the final image to the physician site. In step 60 , another query is made to determine whether a copy of the final image should be sent to the patient site. If the answer is “No,” the method terminates at the server site at step 62 . If the answer is “Yes,” a copy of the final image is transmitted to the patient site.
Turning finally to FIG. 2D, once an image has been transmitted to a patient site, in step 64 , the image is stored and displayed at the personal computer in the patient site. Execution then terminates at the patient site in step 66 . Similarly, once an image has been transmitted to a physician site, in step 68 , the image is stored and displayed at the personal computer in the physician site. Execution then terminates at the physician site in step 70 .
It will be evident from the foregoing that modifications of the EIT method and apparatus herein described can be effected without departing from the principles of the invention. For example, in addition to physician interpretation of images generated using the present invention, it is also possible for the server to automatically compare multiple images of the same patient taken over time and to alert the patient or a designated physician to a particular course of action based on changes in the images.
Front Tracking Reconstruction Algorithm
The central role of an EIT image reconstruction algorithm is to determine the impedance distribution within a region of interest given a set of current-induced voltage measurements taken at the region's surface (either internal or external). One of the most reliable reconstruction techniques is known as the Newton-Raphson method, a general description of which follows. First, a region of interest within the body is identified and geometrically defined. A pattern of electrode placements suitable to this region is then determined, and the absolute electrode positions are measured. Accompanying this electrode arrangement is the data collection algorithm which defines the ordering of the current source/sink and voltage measurement electrode pairs during an image scan. Decisions involving the electrode geometry and data collection algorithm are based upon the imaging region geometry and the specific application, and will ultimately determine the overall attainable image quality.
These pre-procedure definitions are then used to create a mathematical model representing the real imaging region of interest. The model is designed to reflect all relevant bio-electrical physical behavior expected of the real imaging region. That is to say, if the exact impedance distribution of the real region were known, it could be entered into the model and be expected to produce the same voltage measurements as the real system given identical electrode placement and data collection algorithms. This model may then be used as a testing tool for possible impedance distribution candidates by comparing the measured voltages from the real and model regions. The smaller the overall difference in voltage measurements between real and modeled systems, the more closely the modeled impedance distribution represents the real distribution.
Reconstructing an image then become an iterative process involving an initial distribution guess, a testing of that guess via comparison of modeled and real voltage measurements, and a refining of the initial guess based on the comparison results. This process is repeated until the real and modeled measurements are suitably close.
There are two major components of the Newton-Raphson technique: the modeling method, and guess refining algorithm. Most existing modeling methods take a finite element approach which will hereinafter be referred to as an impedance mapping technique. Briefly, this approach approximates a bioelectrical continuum as a set of connected electrically homogeneous elements with enforced boundary continuity. Each element represents an impedance “pixel”. The more elements, the better the image resolution.
The modeling approach which is the subject of this invention differs fundamentally from this impedance mapping method, and will hereinafter be referred to interchangeably as the front tracking technique or front tracking method. The front tracking technique breaks the region of interest into a number of electrically homogeneous zones defined by a finite number of simply connected boundary segments. The placement of the segment endpoints then define the shape of each zone, with more segments allowing a finer shape resolution. The mathematical method of solution for this model description is known as the boundary element method.
The two things that characterize the type of guess refining algorithm used in the Newton-Raphson method are the parameters which are being refined, and the method of that refinement. Impedance mapping techniques adjust the impedance of each element, whereas the front tracking method adjusts the location of boundary segment endpoints, and therefore the shape of the electrically homogeneous zones. The method of refinement in each case is based on a differential matrix, or Jacobian calculation. This matrix represents the unit change in each measured voltage given a unit change in each element impedance (impedance mapping) or segment end position (front tracking).
One of the major advantages of front tracking over impedance mapping techniques is a drastic decrease in the necessary number of electrodes needed to produce comparable images. Inverse problems of this type are mathematically constrained in that they require at least as many independent voltage measurements as there are adjusting parameters (i.e. elemental impedances or segment end positions). Many imaging applications, such as localized cancers, have fairly simple geometries which can be described well by a small number of shape segments using front tracking. In contrast, impedance mapping would require a comparatively large number of elements, and therefore electrodes, to achieve similar morphological distinction. Front tracking also naturally enforces the expected step changes in impedance across tumor or organ boundaries. Impedance mapping algorithms tend to smooth these boundaries, degrading important morphology features.
One challenging aspect of the front tracking method not present in impedance mapping, is the need to “seed” electrically homogeneous zones. That is, before the front tracking algorithm can begin refining a given shape, it needs to know where, how many, and how big the initial zone guesses should be. A solution to this problem is achieved by combining aspects of the two reconstruction algorithms. A typical sequence demonstrating this would begin by using impedance mapping to roughly identify probable homogeneous zones within the region of interest. These areas would be seeded and the front tracking algorithm would take over in further refinement of each zone's shape until the overall difference between modeled and physical surface voltages was acceptable. Thus, by exploiting the specific strengths of each algorithm, a technique more effective than either the front tracking or impedance mapping technique alone is realized. This combined technique is hereinafter referred to as a hybrid technique.
It will be understood by those skilled in the relevant art that while the preferred embodiment is directed towards a system based on application of EIT technology, alternative imaging technologies could be utilized in carrying out the present invention, including, without limitation, x-rays, ultrasound imaging, magnetic resonance imaging (“MRI”), computerized tomography (“CT”), and positron emission tomography (“PET.”)
Accordingly, it will be understood that the preferred embodiment of the present invention has been disclosed by way of example and that other modifications and alterations may occur to those skilled in the art without departing from the scope and spirit of the appended claims. | A method and apparatus for imaging the internal structure of biological tissue from a remote location using electrical impedance tomography. The method and apparatus accomplish this by separating the functions of data acquisition from those of processing and imaging, and by connecting the data acquisition, processing and imaging components through a communications network, thus permitting the data acquisition, processing and imaging functions to be carried out at disparate locations within said network. | 8 |
FIELD OF INVENTION
This invention relates to Cabinetry Drawer Construction, involving the use of an integrated drawer side and drawer roller combination. The drawer roller assembly also forms the drawer side. To attach the combination drawer side and drawer roller assembly to a drawer front, requires the precise location of pilot holes for screws or dowel ribbed fasteners. The placement of the pilot hole locations must be adjustable to the requirements of the user.
DISCUSSION OF PRIOR ART
Current methods of assembling integrated drawer slides, involves large clamping fixtures. These fixtures temporally hold the drawer components together while providing drilling locations for the fasteners. These machines are very expensive and require expensive floor space to set up and use. These disadvantages put the purchase of these machines beyond the financial capabilities of most potential users of integrated drawer slides. Tile present invention is developed to produce an effective system that is adjustable for hole locations to accurately drill material to receive the integrated drawer slide hardware fasteners.
SUMMARY OF THE INVENTION
The present invention is a machine accessory to be used with boring or drilling devices, such as a drill press or hand held electric drill motor.
An object of the invention is two parallel channel guide rail members, having connecting fastener holes at each end.
A further object of the invention is the channel guide rail members face each others open side.
A still further object of the invention is attachment of the guide rail members through the provided holes with fasteners. The rail members spaced apart by a spacer on one end and a fixed positioning stop on the other end, forming a closed raceway guide.
Another object of the invention is washers captured between the rail members, of a size to move freely in the closed raceway guide.
A further object of the invention is the fixed positioning stop acts as a positioning reference point, to position a workpiece.
A still further object of the invention is a scale provided on one side of the rail member, in such a manner as to be used with a reference line on the template assembly, adjacent to the fixed positioning stop.
Another object of the invention is a sliding stop operating between the rail member spacer and a second template assembly, to capture a workpiece between the fixed positioning stop, the sliding stop and the guide rail member.
A further object of the invention is an intermittent clamping means provided on the sliding stop to position the stop at a desired location along the rail members. A still further object of the invention is a guiding slot provided on each template.
Another object of the invention is a drill guide assembly, comprising two components so that when placed together in the provided slot, the slot becomes a guide to the two components.
A further object of the invention is the provision of fasteners to hold the drill guide assembly components together and act as an intermittent clamping means to affix the assembly at a desired location within the parameters of the slotted guide.
Another object of the invention are drill guide bushings in the drill guide assembly, to guide a drill bit into contact with a workpiece. A further object of the invention is an indexing scale on each template.
A still further object of the invention is a reference line on each drill guide assembly, to use in conjunction with the indexing scale. By loosening the intermittent clamping screws, the elevation of the drill guide assembly can be adjusted to a desired setting on the indexing scale, while maintaining the spacing between drill guide bushings.
Another object of the invention are notches on one corner of each template. By first setting the location of the template adjacent the fixed stop, using the index scale on the guide rail and reference line on the template, then placing the drawer back between the notches of the templates, the second template is automatically positioned.
A further object of the invention is an auxiliary locator, comprising a T shaped member, complete with a fixed stop and drill guide means to locate and drill the fastener position of the drawer back. Another object of the invention is that the tool is portable. A further object of the invention is the tools efficiency. A still further object to the invention is that the tool is inexpensive.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become more apparent from the specification taken in conjunction with the accompanying drawings in which:
FIG. 1 is an exploded perspective view of the drawer front drilling assembly and the drawer back drilling assembly, together forming the integrated drawer slide tool.
FIG. 2 is a perspective view of the drawer front drilling assembly showing the drawer back being used to set template 2 of the drawer front assembly. FIG. 3 is a perspective view of the drawer front drilling assembly placed on the drawer front for the fastener drilling operation.
FIG. 4 is a perspective view of the drawer back drilling assembly placed on a drawer back for the fastener drilling operation.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, numeral 1 are channel members facing one another to form a race way to capture washers 7 & 8. Channel members 1 spaced apart by fixed foot 4 and spacer 10 at one end and by spacer 9 at the opposite end. The channel members being attached together by fasteners 12 and 13 passing thru holes in channel numbers 1 and holes in spacer 10, fixed foot 4 and spacer 9, forming a closed raceway assembly.
Adjustable foot 3 is intermittently located along the raceway assembly by means of a hand knob 14 with a threaded stud passing thru washer 21. Washer 21 in combination with washer 8 captures a wall side of a channel members 1 when the stud portion of hand nob 14 is threaded into a threaded hole in adjustable foot 3, thereby intermittently affixing the adjustable foot at a desired location along channel members 1. Templates 2 are provided with a threaded hole to accept the stud portion of hand knob 14, passing thru washer 15 and washer 7 thereby capturing a wall side of channel number 1, to intermittently clamp template 2 at desired locations along the raceway assembly.
Templates 2 constructed with a slotted raceway to accept a T shaped drill guide locator 5, complete with drill guide bushings is retained by clamping plate 6 and clamping screws 16, to capture template 2 when screws 16 are tightened. Clamping plate 6 having a reference line for setting the elevation of guide locator 5 using the indexing scale 17 provided on templates 2.
Clamping plate 6 having reference line 18, to set the distance from the face of fixed foot 4, by use of indexing scale 23.
Drawer back drilling fixture 19 constructed of T shaped material, so as to form a stop when placed on a work piece, complete with a locating pin 20 and drill guide bushing 11.
Referring to FIG. 2, template 2 is automatically being positioned by employing the drawer back in the notches of the templates.
Referring to FIG. 3, the drawer front drilling assembly is positioned on a drawer front after being set up by use of the indexing scale on channel member 1, the indexing scales on templates 2 and following the procedure in FIG. 2. The drawer front is captured between fixed foot 4 and adjustable foot 3, to prevent movement during the drill operation.
Referring to FIG. 4, the drawer back drilling assembly is position on a corner of drawer back 22 using the T shaped edge of base 19 and stop pin 20 to correctly locate drill guide bushing 11 to guide drill bit 30 into contact with back 22. | The present invention is a device for locating fastener positions and is more particularly concerned with the aspect of precise location for removal of material by boring or drilling by means of a hand held electric drill motor or drill press. | 8 |
REFERENCE TO RELATED APPLICATIONS
[0001] This application is a national stage application under 35 USC 371 of International Application No. PCT/EP2014/062864, filed Jun. 18, 2014, which claims priority to German Application No. 20 2013 005 959.1, filed Jul. 3, 2013, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a method for installing tower fittings by introducing at least two separate supply modules into a wind turbine tower, wherein a separate supply module structurally comprises one segment each of at least two system components of the wind turbine tower, and wherein an upper segment end is arranged on an upper edge, and a lower segment end on a lower edge, of the supply module.
BACKGROUND OF THE INVENTION
[0003] Powerful wind turbines require large rotors and high wind speeds. High wind speeds are found far above the ground. The towers of the wind turbines therefore have a very high construction. In addition, high wind turbine towers permit larger rotors. For this purpose, the towers require a sufficiently high degree of stability in order to act as a support structure for the large and therefore also heavy rotors. Said towers are constructed locally at the construction site of the wind turbine since said towers are much too large for premanufacturing. It has proven successful to erect the towers from a plurality of concrete tower segments arranged one above another. The tower segments here can be completely or partially produced from semi-finished elements. High towers can thereby be efficiently erected even in remote areas. However, there is the problem of producing and installing the tower fittings which comprise, for example, conduction means for transmitting the electrical energy generated in the nacelle or for transmitting control signals for operating the wind turbine, or a climbing device for the operating personnel for climbing up the tower. The installation of the tower fittings in the erected tower is complicated and hazardous since work at a great height is partly also required.
[0004] DE 10 2010 015 075 A1 discloses segmenting at least two system components of the tower fittings and structurally combining said segments to form separate supply modules. The supply modules are preassembled at the construction site or ex works and, for installation, are introduced into the tower interior. A supply module is fastened here to the tower inner wall at the designated location. The segments of the system components of supply modules adjacent to one another are coupled to one another, for example via series connection devices. Manufacturing-induced tolerances in the tower segments are compensated for here either during the connection of supply modules adjacent to one another or at the supply module which is fastened at the upper end of the wind turbine tower.
[0005] It is known from DE 20 2011 106 727 U1 to introduce tubular segments successively through the door into the tower where the respective system components are then connected to one another. The supply system is thus constructed from the bottom upward and only mounted at the top of the tower in the final step.
[0006] Furthermore, it is known from DE 20 2010 007 565 U1 to suspend preassembled interior fittings on the tower flange in each case, as a result of which only a construction from the bottom upward is possible. The installation of the interior fittings is preferably carried out in this case while the tower is still in a horizontal position.
SUMMARY OF THE INVENTION
[0007] An object on which the invention is based is the provision of a method which further simplifies the installation of the tower fittings and increases the safety of the installation personnel during the installation of the tower fittings.
[0008] The object is achieved by the features as broadly described below. Advantageous developments are described in the detailed embodiments below.
[0009] In a method for installing tower fittings by introducing at least two separate supply modules into a wind turbine tower, wherein a separate supply module structurally comprises one segment each of at least two system components of the wind turbine tower, and wherein an upper segment end is arranged on an upper edge, and a lower segment end on a lower edge, of the supply module, provision is made according to the invention for the method to comprise the following steps: arranging the upper edge of a first separate supply module at an upper end of the wind turbine tower; connecting an upper segment end of the first separate supply module to a lower segment end of the corresponding system component of a second separate supply module; and arranging the upper edge of the second separate supply module at the upper end of the wind turbine tower.
[0010] First of all, a few terms will be explained in more detail below:
[0011] A system component is understood as meaning components of the wind turbine that are installed in the tower of the wind turbine in order to enable the maintenance and operation thereof. Said components can be, for example, power conduction means, signal conduction means, illuminating means or a climbing device for operating personnel.
[0012] An upper edge is understood as meaning that edge of a supply module which, in the fitted position, is aligned with the nacelle of the wind turbine. A lower edge is understood as meaning that edge of the supply module which is directed toward the tower base.
[0013] An upper end of the wind turbine tower is understood as meaning a region at the upper end of the tower. Said region does not necessarily have to be arranged directly at the highest point of the wind turbine tower. It may also be arranged a few meters below the highest point. In the case of towers composed of a different material in sections, for example a concrete tower at the bottom and a tubular steel tower placed on at the top, each upper end of a portion is an “upper end” within the meaning of the invention.
[0014] The invention is based on the finding that the separate supply modules can be connected to one another as they are being introduced into the wind turbine tower, before said supply modules are fastened, optionally in their entirety, to the tower inner wall. During the introduction into the tower interior, the supply modules are inserted from above, that is to say said supply modules are guided past the upper end of the wind turbine tower. The upper edge of the first separate supply module introduced first is arranged there on the lower edge of the second separate supply module to be introduced next. The segments of the system components of the two separate supply modules are connected to each other via the segment ends arranged on the edges. The separate supply modules which are now connected to each other are then lowered downward until the upper edge of the second supply module is arranged at the upper end of the wind turbine tower. The operation is repeated until all of the supply modules which are to be installed have been introduced into the tower interior. The separate supply modules which are connected to each other are finally then fastened to the inner wall of the wind turbine tower after the final separate supply module has been arranged at the upper end of the wind turbine tower and the completely assembled supply module has been brought into the final installation position.
[0015] The supply modules are therefore connected successively to one another and lowered into the tower. The connecting work for joining together the supply modules can therefore be carried out at a central, stationary work site. The installation personnel no longer needs to handle the connecting points between the supply modules along the tower inner wall, but instead the supply modules which are to be installed migrate, as it were, past the stationary work site. Since a stationary working platform for the installation personnel is customarily provided in any case at the upper end of the wind turbine tower, no additional outlay is required. In addition, said working platform provides greater safety than mobile working devices which would have to be arranged in a vertically movable manner on the tower inner wall. Furthermore, by connecting the supply modules prior to fastening same to the wind turbine tower, manufacturing-induced tower tolerances are circumvented. The connections of the segments of the system components to the upper end of the wind turbine tower are always arranged in a defined position relative to the tip of the tower. The position of the lower end of the supply modules which are connected to one another is no longer of importance. Compensating work needs only to be carried out—if at all—at the tower base. Since the work is not carried out there at a great height, the safety of the installation personnel should be ensured in a simple manner. It is now no longer necessary to carry out compensating work on the basis of the tower tolerances at each connecting point between the separate supply modules. This considerably simplifies the installation of the tower fittings.
[0016] Furthermore, the fastening to the tower inner wall in particular prevents the supply module from being displaced in a horizontal plane. The main load in terms of weight of the supply module continues to be supported by the suspension at the upper tower end.
[0017] It is expedient to provide a working platform at the upper end of the wind turbine tower prior to the introduction of the separate supply modules. The safety of the installation personnel is therefore increased and the connecting work between the supply modules is facilitated further.
[0018] In order further to increase the safety during the connecting work, provision is advantageously made, prior to the introduction of the separate supply modules into the wind turbine tower, to provide a holding apparatus at the upper end of the wind turbine tower for the at least temporary suspension of a separate supply module. The holding apparatus advantageously comprises at least one connecting device for the connection to a separate supply module. Furthermore, the holding apparatus expediently has at least one load ring which is fastened to the tower wall or tower upper edge, wherein the connecting device comprises at least one shackle or a lifting sling. The first separate supply module can advantageously therefore be suspended at the upper end of the wind turbine tower before the segments of the system components are connected to those of the second separate supply module. The suspended supply module is secured by the holding device at the upper end of the wind turbine tower, and therefore the connection of the system component segments to a supply module arranged above the suspended supply module is further simplified. The design of the holding device, comprising a load ring and a shackle or a lifting sling, permits a simple connection of the upper edge of the suspended supply module to the holding apparatus. For this purpose, the supply module can have a support plate to which the connecting devices are fastened.
[0019] After the introduction of the final separate supply module, the latter can be fastened to the tower wall or tower upper edge by means of the load ring.
[0020] In an alternative embodiment, the support plate can be designed as an angled support plate for fastening the final separate supply module to the tower wall or tower upper edge. With the aid of the angled support plate, the final separate supply module can be hung over the tower upper edge and fastened to the tower wall or tower upper edge. The fastening outlay for the final separate supply module to the tower wall or tower upper edge is therefore reduced.
[0021] The holding apparatus can furthermore advantageously comprise at least one support element which is fastened to the tower wall or to the tower upper edge and to which a support module comprising a mounting portion is releasably fastened, wherein the supply module has a mounting element with which the separate supply module, after the arrangement of the upper edge at an upper end of the wind turbine tower, is mounted on the mounting portion of the support module. For this purpose, the support module has a mounting portion in which the mounting element can be arranged. The mounting element is supported by the mounting portion. A simple mounting of the separate supply modules on the support element is made possible with the support module. The separate supply modules can therefore be suspended in an uncomplicated manner on the upper edge of the wind turbine tower. Given a suitable design of the tower upper edge, the support module can be fastened to the tower upper edge even without the use of a support element. For the temporary suspension on the upper edge of the wind turbine tower, the supply modules do not require any fastening to the holding apparatus by means of the shackles. The shackles can optionally be used for fastening the separate supply modules after the final separate supply module has been introduced into the tower interior.
[0022] The wind turbine tower is advantageously formed from at least two tower segments. Furthermore, it is expedient that the separate supply modules span a plurality of tower segments. A smaller number of separate supply modules than the number of tower segments is therefore required for fitting into the tower interior. This reduces the amount of required connecting work between the supply modules, and further simplifies and accelerates the installation of the tower fittings. To reduce the diversity of variants of the separate supply modules, it is expedient to design both the lowermost supply module in each case and the supply modules in each case lying in between to be identical. A rough adaptation to the respective tower height is achieved via the number of supply modules lying in between and to be mounted. The precise coordination with the ultimately required length of the complete supply module is achieved by adaptation of the uppermost separate supply module.
[0023] The system components expediently comprise power conduction means, signal conduction means, illuminating means and/or a climbing device for operating personnel, wherein the illuminating means comprise lamps arranged discretely or continuously.
[0024] A tubular steel tower can advantageously be installed as an upper part of the wind turbine tower, wherein the lower part is a concrete tower. The supply modules are advantageously introduced into the concrete tower prior to the placing-on of a tubular steel tower. The system components can be installed in the tubular steel tower ex works, on the construction site or after the tubular steel tower has been erected. By fitting the supply modules as per the method according to the invention before the tubular steel tower is erected, it is ensured that the upper edge of the supply module fitted last in the concrete tower bears against a defined point relative to the upper end of the wind turbine tower. The coupling between the system components installed in the tubular steel tower and the system components of the concrete tower can therefore take place without special compensating work. Furthermore, a support plate, which is of angled design, of a supply module introduced last can be connected to the tubular steel tower in order to prevent the support plate from slipping off a tower upper edge of a concrete tower.
[0025] It is furthermore advantageous, prior to the introduction of the separate supply modules into the wind turbine tower, to fasten at least one fastening apparatus to at least one of the separate supply modules, said fastening apparatus having a clamping element which is connected to the supply module and a guide element, comprising a fastening piece projecting laterally on the supply module, which is arranged between the clamping element and the supply module. Projecting laterally on the supply module is understood as meaning that, when a supply module hangs on the tower inner wall, the fastening piece runs along the wall and the supply module does not cover the fastening piece.
[0026] The fastening apparatuses can therefore be introduced together with the supply modules into the tower interior, which further simplifies the fitting of the separate supply modules. The guide element is movable here in a vertical direction along the separate supply module, and therefore the guide element can be arranged flexibly along the separate supply module.
[0027] It is furthermore advantageously provided here, after the introduction of a final separate supply module, to fasten the fastening apparatus to the tower wall of the wind turbine tower by means of the fastening piece, and to clamp the guide element to the supply module by means of the clamping element. Alternatively to the clamping element, a locking element may also be provided, the locking element releasably fastening and at the same time locking the guide element to the supply module.
[0028] The fastening pieces can be reached directly from the front because of the lateral projection thereof from the supply modules. The installation personnel can therefore easily reach the fastening pieces and in an uncomplicated manner carry out the fastening of the supply modules introduced into the tower interior. By means of the fastening of the fastening pieces to the tower wall, the supply modules are secured in the horizontal direction. A vertical displacement for aligning the supply modules is furthermore permitted until the guide element of the fastening apparatus is clamped by means of the clamping element. In order to secure the separate supply modules in the vertical direction, the guide element is clamped between the clamping element and the separate supply module. The clamping can be brought about by fastening elements which press the clamping element onto the supply module. The fastening elements can be actuated here from the front side of the supply module. The supply module therefore cannot be moved further along the guide element.
[0029] The invention furthermore relates to a wind turbine tower, comprising a holding device for the suspension of a separate supply module at the upper end of a wind turbine tower for carrying out the abovementioned method. Reference is made to the above description for explanation purposes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The invention is explained in more detail below with reference to the attached drawing in which an advantageous embodiment is illustrated. In the drawing:
[0031] FIG. 1 shows a schematic illustration of a wind turbine with tower fittings;
[0032] FIGS. 2 a - d show a schematic illustration of individual method steps;
[0033] FIGS. 3 a, b show a schematic illustration of the supply modules suspended in the tower interior on a holding apparatus, with (a) shackles and (b) lifting slings;
[0034] FIG. 4 shows a schematic illustration of a hybrid tower;
[0035] FIGS. 5 a, b show a schematic illustration of a supply module, a support module and a support element in the separate state (a) and mounted state (b);
[0036] FIG. 6 shows a schematic illustration of a fastening apparatus arranged on a supply module;
[0037] FIG. 7 shows a schematic cross-sectional view of a fastening apparatus arranged on a supply module; and
[0038] FIG. 8 shows a schematic illustration of the final supply module fastened to an angled support plate.
DETAILED DESCRIPTION OF THE INVENTION
[0039] The method is carried out for the erection of a wind turbine, denoted in the entirety thereof by the reference number 100 . The wind turbine 100 comprises a wind turbine tower 1 which is erected from a plurality of tower segments 10 , 11 , 12 , 13 , 14 , 15 , 16 and is designed as a hybrid tower. The lower part of the hybrid tower is a concrete tower 19 and the upper part is a tubular steel tower 18 . Furthermore, the wind turbine 100 comprises a nacelle 101 , which is connected to an upper end 17 of the wind turbine tower 1 , and a rotor 102 , which is mounted rotatably on one side of the nacelle 101 . The rotor 102 is connected to an electric generator 104 via a shaft 103 . Furthermore, the wind turbine 100 comprises an operation controller 105 which is connected to the generator 104 and to the rotor 102 via signal lines. The operation controller 105 and the generator 104 are arranged in the nacelle 101 . Furthermore, at the base of the wind turbine tower 1 , the wind turbine 100 comprises a transformer 106 for connection to the electrical grid. The generator 104 and the transformer 106 are connected via power conduction means 33 for transmitting the power generated by the generator 104 to the grid.
[0040] Furthermore, a climbing device 36 , which includes illuminating means 35 , for operating personnel is fastened in the interior of the wind turbine tower 1 to the tower inner wall, wherein the illuminating means comprise lamps arranged discretely or continuously. In order to activate the operation controller 105 , signal conduction means 34 are provided in the tower interior. The power conduction means 33 , signal conduction means 34 , illuminating means 35 and the climbing device 36 for operating personnel are referred to in summary as system components 33 , 34 , 35 , 36 .
[0041] The system components 33 , 34 , 35 , 36 are divided in each case into individual segments. The segments of at least two different system components 33 , 34 , 35 , 36 are structurally combined to form a separate supply module 3 , 4 . The structural combining simplifies the fitting of the supply modules 3 , 4 after the wind turbine tower 1 has been erected. The supply modules 3 , 4 each have an upper edge 37 , 47 and a lower edge 38 , 48 . The upper segment end 30 , 40 of the system components 33 , 34 , 35 , 36 is arranged on the upper edge 37 , 47 . Accordingly, the lower segment end 31 , 41 of the system components 33 , 34 , 35 , 36 is arranged on the lower edge 38 , 48 of the separate supply module 3 , 4 .
[0042] In a first preferred embodiment, the separate supply modules 3 , 4 can be preassembled at the works. Alternatively, in a second preferred embodiment, the separate supply modules 3 , 4 can be assembled at the construction site. The preassembly of the supply modules can take place in the horizontal position.
[0043] The wind turbine tower 1 is erected from the tower segments 10 to 16 . A working platform 6 is installed at the upper end 17 of the wind turbine tower 1 after erection. The working platform 6 is used for the installation personnel to be on during the erection and installation work on the wind turbine tower 1 . Furthermore, the working platform can be used for subsequent maintenance work, in particular at the transition piece to the hybrid tower. The working platform 6 can have rails and eyes for safety ropes.
[0044] The working platform 6 can extend over the entire tower inside diameter and can have a suitable cutout for the system components. The separate supply modules are then guided downward through the cutout in the working platform 6 . Individual supply modules can be provided with additional components (for example feed boxes), as a result of which the cross section of the supply modules is increased. In order also to permit the fitting of said separate supply modules, the working platform 6 can be equipped with a floor flap, as a result of which the cutout in the working platform can be temporarily enlarged for the passage of said additional components.
[0045] Furthermore, for the preparation of the fitting of the separate supply modules 3 , 4 , a holding device 5 is fastened to the upper end 17 of the wind turbine tower 1 . In a first embodiment, the holding device 5 comprises two connecting devices 51 , 52 for the connection to a separate supply module 3 , 4 . A connecting device 51 , 52 is formed from two shackles, which are coupled to each other and are fastened to a load ring 53 , which is fastened to the tower wall. A supply module 3 , 4 can be suspended on the shackles by means of a support plate 54 which has eyes 39 for this purpose. The holding device 5 is designed here in such a manner that it can be loaded with the entire weight of all of the separate supply modules 3 , 4 to be fitted.
[0046] However, in a second alternative embodiment, the support plate 54 can also be designed as an elbow and, for the temporary suspension of a separate supply module 3 , 4 , can be hung directly over the tower upper edge. The support plate 54 is then fastened to the tower upper edge, for example by means of bolts. In addition, precision bolts may be provided as security against slipping off.
[0047] Furthermore, in a third embodiment, a support element 55 , on which a support module 8 can be mounted, is provided on the holding apparatus 5 . For this purpose, the support module 8 has a resting portion 82 which is formed in a complementary manner with respect to the support element 55 and is bordered by a flange 83 . The resting portion 82 is arranged on the support element 55 . The support module 8 is secured against displacement from the support element 55 by means of the flange 83 . The support module 8 furthermore has a mounting portion 81 . A mounting element 49 fastened to the separate supply module 3 , 4 can be arranged in the mounting portion 81 . It is thus possible to suspend the separate supply modules 3 , 4 on the support module 8 in an uncomplicated manner after introduction into the wind turbine tower 1 . Given a suitable design of the tower upper edge, the support module 8 can be fastened to the tower upper edge even without the use of a support element 55 .
[0048] By means of the use of lifting slings, the suspension of the supply modules 3 , 4 on the support module 8 can be further simplified. For the fastening to the holding apparatus 5 after removal of the support module 8 , the final separate supply module 4 introduced into the wind turbine tower 1 can be fastened to the shackles or to the tower upper edge directly via an angled support plate 54 . A fastening apparatus 9 is provided for the final fastening of the separate supply modules 3 , 4 to the tower inner wall 7 . The fastening apparatus 9 comprises a clamping element 92 which is fastened to the support module 3 , 4 by means of fastening elements 93 . The fastening elements 93 are reachable from the front side of the separate supply modules 3 , 4 and can be actuated from there. A guide element 94 is provided between the clamping element 92 and the supply module 3 , 4 . The guide element 94 furthermore has spacers 95 , 96 and a fastening piece 91 . The fastening piece 91 projects laterally from the supply module. It can easily be reached by the installation personnel for connection to the tower wall. The spacer 96 spaces the separate supply module 3 , 4 and the wall. The spacer 95 furthermore acts as a resting element and guide element for the clamping element 92 .
[0049] By actuation of the fastening elements 93 , the clamping element 92 is pressed against the separate supply module 3 , 4 . The clamping element 92 presses here onto the guide element 94 via the spacer 95 . As a result, the guide element 94 is clamped between the clamping element 92 and the separate supply module 3 , 4 .
[0050] FIG. 2 a illustrates a wind turbine tower 1 with a working platform 6 at the upper end 17 thereof, said wind turbine tower having been erected from the tower segments 10 to 16 . The tower segments 10 to 16 form a concrete tower 19 which, in this preferred embodiment, acts as a lower part of a hybrid tower.
[0051] In order to introduce the supply modules into the wind turbine tower 1 , the holding device 5 is installed at the upper end of the wind turbine tower 1 . A support module 8 is placed onto the holding device 5 .
[0052] For the fitting of the system components, a first separate supply module 3 , which in the completely constructed state of the wind turbine 100 is arranged at the base of the wind turbine tower 1 , is disposed onto the upper end 17 of the wind turbine tower 1 with a crane (not illustrated). The guide elements 94 of the fastening apparatuses 9 fastened to the separate supply module 3 are still free here and can be moved along the supply module 3 in the vertical direction.
[0053] The installation personnel on the working platform 6 guide the first separate supply module 3 during the subsequent lowering thereof into the interior of the wind turbine tower 1 .
[0054] For better clarity, the wall portions concealing the tower interior have been omitted in FIGS. 2 b , 2 c , 2 d , 3 a , 3 d and 8 such that the tower inner wall 7 is visible.
[0055] The first separate supply module 3 is lowered into the tower interior until the upper edge 37 of the supply module 3 is arranged at the upper end 17 of the wind turbine tower 1 . At the same time, the upper edge is arranged on the working platform 6 in such a manner that the installation personnel can carry out work on the upper edge 37 from the working platform. The first separate supply module 3 is hung onto the holding device 5 at the mounting portion 81 of the support module 8 by means of the mounting element 49 . The first separate supply module 3 is then released by the crane and hangs with its full weight on the holding device 5 . Furthermore, the upper segment ends 30 of the system components 33 , 34 , 35 , 36 are likewise arranged at the upper end 17 of the wind turbine tower 1 . The first separate supply module 3 spans a plurality of the tower segments 10 to 16 . That is to say the upper edge 37 of the first separate supply module 3 is arranged on a different tower segment 10 to 16 than the lower edge 38 of the first separate supply module 3 .
[0056] In a further step, the second separate supply module 4 is raised with the crane and arranged with its lower edge 48 on the upper edge 37 of the first separate supply module 3 . The lower segment ends 41 of the system components 33 , 34 , 35 , 36 of the second separate supply module 4 are aligned with the upper segment ends 30 of the system components 33 , 34 , 35 , 36 of the first separate supply module 3 . After the alignment, the upper segment ends 30 are connected to the lower segment ends 41 by the installation personnel. The installation personnel can carry this out from the working platform 6 . After the connection of the upper segment ends 30 and the lower segment ends 41 , the first separate supply module 3 and the second separate supply module 4 are connected to each other.
[0057] After the connection of the first and second separate supply module 3 , 4 , the holding device 5 is released from the first separate supply module 3 . The supply module 3 is unhooked from the support module 8 . The separate supply modules 3 , 4 which are connected to each other are lowered further into the tower interior by the crane until the upper edge 47 of the second separate supply module 4 is arranged at the upper end of the wind turbine tower 1 . The second separate supply module 4 is then hung on the holding device 5 by means of the mounting element 49 , which is fastened to the separate supply module 4 , and the support module 8 , and released from the crane. In an alternative embodiment, the supply module is hung by means of lifting slings of the holding device 5 . The above-mentioned steps are repeated for all of the separate supply modules to be fitted, except for the final one. In a first embodiment, the final separate supply module is fastened to the holding device 5 via the connecting devices 52 . For this purpose, the connecting devices 52 are guided through the holding eyes 39 of the support plate 54 of the final separate supply module and locked.
[0058] In an alternative embodiment, the support plate of the final separate supply module is of angled design. The final separate supply module can be hung over the tower upper edge with the aid of the angled support plate 54 and fastened there with bolts. Furthermore, the angled support plate 54 can be fastened to a tubular steel tower 18 to be placed onto the concrete tower 19 .
[0059] After the introduction of all of the further separate supply modules 4 into the tower interior, the first separate supply module 3 is arranged at the tower base and forms the lowermost separate supply module. After the connection and lowering of the seperate supply modules 3 , 4 , the complete supply module hangs on the holding device 5 . In a further step, the separate supply modules 3 , 4 are connected to the tower inner wall 7 by the fastening pieces 91 being fastened to the tower inner wall 7 . Furthermore, the fastening elements 93 are actuated such that the supply modules 3 , 4 can be pulled onto the tower inner wall 7 via the clamping elements 92 and the guide elements 94 . By means of the connection to the tower inner wall via the fastening device 9 , in particular a displacement of the supply module in a horizontal plane is prevented. The main load of the supply module hangs on the holding device 5 .
[0060] After the fitting of the supply modules into the concrete tower 19 , a tubular steel tower 18 is placed onto the concrete tower 19 . The system components 33 , 34 , 35 , 36 installed in the tubular steel tower 18 are connected to the upper segment ends 40 . The lower segment ends 31 of the first separate supply module 3 are optionally likewise connected to the system components 33 , 34 , 35 , 36 installed in the tower base. | A method for installing tower fittings by introducing at least two separate supply modules into a wind turbine tower, wherein a separate supply module structurally includes one segment each of at least two system components of the wind turbine tower, and wherein an upper segment end is arranged on an upper edge, and a lower segment end on a lower edge, of the supply module, including: arranging the upper edge of a first separate supply module at an upper end of the wind turbine tower; connecting an upper segment end of the first separate supply module to a lower segment end of a corresponding system component of a second separate supply module; and arranging the upper edge of the second separate supply module at the upper end of the wind turbine tower. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to provisional application No. 60/982,175, filed on Oct. 24, 2007, which application is incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX
Not Applicable.
BACKGROUND OF THE INVENTION
Nonvolatile memory systems, subsystems and integrated circuits are used in multiple consumer, computer and communications applications. They can be a NAND flash memory IC or NOR flash memory. Part of the memory system may contain volatile memory like static random access memory (SRAM) or dynamic random access memory (DRAM). They can be many IC's mounted on a memory card or module. A subsystem may contain at least one such module and a memory controller. A system may contain several subsystems as well as multi core CPU's (Central Processing Unit). The memory integrated circuits used in such a system may be SLC (single level) or MLC (multi level) storage. The read/write access ports to the system may be single ported or multi ported.
Today's dominant memory is flash. In flash, the dominant architecture is NAND flash. In spite of the fact that the internal IC architecture of NAND (or for that matter other flash architectures like NOR, OneNAND™) has “page” architecture for read and write access, the performance (read time, program/write time) is slow compared to volatile memory systems built with SRAMs and DRAMs. The “page” architecture in NAND indeed has “static latches” that can temporarily store data as a buffer (one page per block), and sometimes have an additional “write cache buffer” for the whole IC. The page is 1 KB (1,024 bytes) to 2 KB (2,048 bytes). Each nonvolatile memory block of NAND flash memory cells, may have 64 to 128 pages (or, 128 KB to 256 KB). Still, the performance is relatively poor to mediocre at best from a randomly and independently accessible perspective per each byte of data. The “page buffered architecture” of today's NAND flash memory does not lend itself to true, fast, read and write memory access for SSD (solid state disk) and similar commercial applications in PCs and servers for data computation, storage and multimedia execution.
The invention described in this utility patent application focuses on ways to modify the already existing “buffers” in an optimal manner to enhance the random access performance of nonvolatile IC, subsystem and system. The volatile random access memory (RAM) in a preferred embodiment is a 6-transistor SRAM memory cell at the core, and complete peripheral address decoding circuitry for independent accessible access (read, write etc) at a fine grain level of a bit, or byte. In another embodiment, the volatile RAM in each block can be an 8-transistor dual-ported SRAM. In another embodiment, the nonvolatile memory can be a DRAM. The invention is applicable to other nonvolatile or pseudo non volatile memories like PCM (phase change memory), nano crystalline memory, charge trapped memory, ferroelectric memory, magnetic memory, plastic memory and similar embodiments.
BRIEF SUMMARY OF THE INVENTION
The preferred embodiment adds new commands to be executed in the Command Register of the NVM (nonvolatile memory). In other embodiments, these commands can be shared between the NVM IC and memory controller. Prior art NVM IC's have limited commands like (1) read page in flash; (2) erase block in flash; (3) program page in flash, etc. With this invention, new additional commands are executed: (4) read page in the SRAM of the block only; (5) read new page from the nonvolatile memory (NVM) block; (6) write page into SRAM of the block, but, not program into the NVM block until such a command is additionally given. This invention provides every page of each NVM block as an independently accessible random access memory to perform load/store applications, as well as a coupled memory to the assigned NVM block. Each NVM NAND flash may have 1,024 such blocks. Each block is typically 64 kilobytes in density. Page for each block is typically 1 to 2 kilobytes and each bit is independently addressable in a random manner, as well as accessed in a random manner. Error correction and detection to the memory on a page basis can be implemented as well either on the NVM IC or in the memory controller.
Another preferred embodiment selects any of the currently unused blocks and uses the SRAM pages in those blocks to perform other operations as necessary. Such data manipulating operations can be arithmetic and/or logic operations. In another preferred embodiment, the “volatile memory of a page” is a DRAM. That DRAM, again, is independently accessible and addressable in a random manner.
BRIEF DESCRIPTIONS OF THE DRAWINGS
FIG. 1 is a diagram showing a nonvolatile memory system with features as described for the present invention.
FIG. 2 shows an exemplary NAND memory integrated circuit as one element of the NVMS (nonvolatile memory system).
FIG. 3 shows various components of a controller for the nonvolatile memory system (NVMS) of this invention.
FIG. 4 shows a novel implementation of block erase per this invention.
FIG. 5 shows a flash memory controller with block erase feature.
FIG. 6 shows a current NAND flash chip architecture by Samsung.
FIG. 7 shows a pin out for a 1 Gb Samsung flash memory.
FIG. 8 shows some operational features of the above Samsung flash memory.
FIG. 9 shows how the invention of this patent distinguishes itself from today's nonvolatile memory.
FIG. 10 shows improved features of this invention compared to currently available (commercial) multichip NVMS solutions.
FIG. 11 shows how the “random access memory” of this invention can be implemented in dual port access for enhanced performance.
FIG. 12 shows a high level architecture of the NVMS of this invention which comprises both nonvolatile and volatile memory.
DETAILED DESCRIPTION OF THE INVENTION
Each NAND flash memory commercially available (in various pin outs/densities) today has a 512 B-1 KB-2 KByte page in a 64Kb to 128K Byte block (a block contains at least one sector), 64 rows worth of data, 1 page/sector. To write one page takes about 200 μs. There are about 1,024 sectors in a 1 Gbit flash (NAND). So each NAND flash chip has 1 Mb SRAM (1 k pages). The invention requires each page to have “bit-to-bit” NVM back up (nonvolatile SRAM). So a page can be copied directly to the NVM as needed. This additional row can be in the sector itself. Address/control logic to accommodate this page can be easily done in the sector, if needed.
Page invention—Modify page as shown in Samsung K9F1G08R0A (1 Gbit NANDflash). In the Samsung device, Page is approximately 2 KByte+64 bits (for some kind of Ecc) in each 128 KByte block. There are 1 K blocks, each of 128 KBytes (inclusive of Page). The Page has no direct identity (namely, it is not a register or RAM with independent random address and command executions)—it is temporary storage buffer to help execute read/write to nonvolatile array. Since each block (sector) is addressable, one can have a “Tag address bit”—if enabled it can activate “page addressing.”
Control Page—Nonvolatile array communication with a ‘Switch’ where volatile and nonvolatile memory can be accessed (unlike current art)—then page 2 Kbytes can be used as independent RAM for other useful purposes. One preferred embodiment—Select any of the currently unused blocks and use that/those pages as a modified SRAM; access that SRAM by currently used NC pins and rename them. Even with “concurrent Read/Write”, “write cache buffering” and other features, most blocks among the (1,024 or more) many in a NAND flash chip are unused while one or two blocks are being accessed (read, write, erase). The associated “page buffers” are also unused and wasted. In this preferred embodiment, a page of the currently unused block's page (2 K Bytes×1 Kblocks is 2 MBytes of SRAM per chip—with a little overhead circuitry it can be 2 MBytes of SRAM with multiple port access as well) can be read and written (random page access, random access within a page, serial access from a page etc.). There are plenty of NC pins available in commercially available NAND flash ICs (one example is provided in FIG. 7 )—we can configure NC pins to be used as Address, DATA, Command, Control in a combination. In parallel, the NAND flash can concurrently operate.
The concepts of SRAM mode by using available pages can also be implemented in Samsung's one NAND™ flash (for example), NOR flash or even Serial EEPROM flash—The exact implementation, page/latch size, command set may vary. The concepts of SRAM mode by using available pages can also be implemented in traditional NOR flash, as well, with slight modifications (e.g., one row equivalent page in every block or sector, on chip cache, boot code, data buffers). The concepts of SRAM mode can also be implemented in other nonvolatile memory devices (and their controllers) e.g., FeRAM, MRAM, Phase change RAM/memory, CNT RAM, NROM (Saifun) and similar ones. All these concepts can configure the multiple functions of the device or combination there of by (1) control/command signals, (2) programmable registers, (3) mode registers, (4) command register, etc—they can reside in part or in whole in controller, memory, special control, command, interface chip or even CPU.
It should be made clear that the “pages” and “buffers” mentioned in these pages titled “NVMS” do not necessarily have to be (1) static latches (6 transistor latches) or (2) traditional SRAM's. They can be DRAM's as is known widely in the industry. They can be MRAM, FeRAM (ferroelectric) or other similar concepts (molecular RAM etc). The implementation of a nonvolatile memory system may contain these configurable NVMS chips as described here (one or more). Configurable NVMS can be combined with commodity NOR/NAND/One NAND, flash chips, controllers, PSRAM's, DRAM's, or other similar functions to offer a total “system-in-package” (SIP) or “system-on-chip” (SOC).
In order to conserve operating power, the unselected, yet available pages can be in a “stand by” mode—namely, reduced Vcc (power supply voltage), until the access to that page is required. Such a, ‘cycle look ahead’, can be built into the memory chip, or provided by controller (on chip or off chip). A battery back up for the SRAM part of the device can be a very attractive option for a very large density total nonvolatile static random access memory (NVSRAM) that can go into a broad range of applications in computer, consumer, communications etc. Maxim supplies NVSRAM's—no flash IC in NVSRAM. A “power triggered switch-off/on” (Similar to what Simtek's NVSRAM's do) is also possible, thus eliminating the “battery option”.
Commands/Instructions are given as follows, in a preferred embodiment, which vary between NAND, One NAND, NOR, serial flash etc. Traditional flash: Read page in flash, Erase block in flash, Program page in flash, Etc. New commands with these inventions: Read page as SRAM/RAM, Write page as SRAM/RAM, Read/Modify/W Write page as SRAM/RAM, Read byte out of a page, etc; Write byte out of a page etc. Nibble mode/Serial access/double data rate are all possible.
The “address boundary” for a commercial NAND flash (especially in burst mode access e.g., burst READ) is different than a “2 K byte” NAND flash page. The address boundary does/should not deter by using the inventions mentioned here for a superior READ (intelligent caching) or WRITE performance. Most flash systems are weighted to MOSTLY READ and FEW ERASE/PROGRAM (WRITE) due to the obvious endurance limitations (write/erase cycles limit). Hence, any performance in READ—Speed, and available Storage space—is always beneficial to a stand alone die and/or card, module, subsystem, system. To write to a page or pseudo page, WRITE command and immediately PROGRAM SUSPEND to invalidate writing into NVM. The data should be in page/pseudo page. This is one example.
As described in earlier pages, the page latches are available for reading. The pages can be read a byte (8 bits) or 2 bytes (16 bits) at a time. The whole page 2K bytes, can be sequentially accessed in 20-25 ns/byte. The subject invention uses the pages as a content addressable memory (CAM) and the NVM core as the stored data. The match lines (as used in CAM's—refer to U.S. Pat. Nos. 6,310,880 and 6,597,596 which use a DRAM storage) can be connected to the pages. The addresses in each block can be sequentially read, until the MATCH is found. | A nonvolatile memory system is described with novel architecture coupling nonvolatile storage memory with random access volatile memory. New commands are included to enhance the read and write performance of the memory system. | 6 |
CROSS REFERENCE TO PRIOR APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 12/876,508, filed Sep. 7, 2010, which is a continuation of International Patent Application No. PCT/EP2009/051764, filed Feb. 16, 2009, which claims priority to Swiss Patent Application No. CH 00350/08, filed Mar. 7, 2008. The entire disclosure of both applications is incorporated by reference herein.
FIELD
[0002] The present invention relates to the field of combustion technology. It refers to a method for combusting H 2 -rich fuels. It also refers to a burner arrangement for implementing the method and for its use.
BACKGROUND
[0003] From WO-A1-2006/069861, a premix burner with subsequent mixing section or mixer tube (a so-called AEV burner) has been known, in which in the premix burner, which is formed according to EP-A1-704 657, a first fuel can be centrally injected and between the air inlet slots or passages which are formed by the shells in the swirler (shown clearly especially in EP-A1 321 809) at least one second fuel can be introduced into the air which flows into the inner space there. In the subsequent mixer tube, provision is made for a further device for injecting a third fuel. All printed publications which are referred to here or later, and their further developments, form an integrating element of this application.
[0004] For combusting H 2 -rich fuels, as created for example in the form of syngas during coal gasification, it has already been proposed to inject at least some of the H 2 -rich fuel via the mixer tube of such a premix burner. Also, such a premix burner has already been tested with natural gas in lean premix operation, during which under high pressure H 2 -rich fuels with H 2 -to-N 2 ratios of 70/30 and 60/40 have been injected in an axially staged manner in the premix burner and in the mixer tube.
[0005] During these tests, it has been shown that if a changeover is made from natural gas entirely to the H 2 -rich fuel, the flame migrates upstream into the mixer tube. Although the burner was able to be operated in this way without damage and with sufficiently low NOx emission, numerous disadvantages arose, however, specifically:
The pressure losses in the premix burner are increased by the factor of 3. This is undesirable in the case of gas turbines with regard to an associated gas turbine cycle. The available mixing length, i.e. the distance between the location of the injection of the fuel and the flame front, is reduced, which leads to increased NOx-emission. High-frequency pulsations gain in importance. In this context, it may be mentioned that the thermoacoustic vibrations represent a hazard for each type of combustion application. They lead to high-amplitude pressure vibrations, to limitation of the operating range, and they can increase pollutant emissions. This applies especially to combustion systems with low acoustic damping, as is the case for example in annular combustion chambers with reverberant walls. In order to ensure a high performance conversion over a wide operating range with regard to pulsations and pollutant emissions, provisions against these pulsations must be made.
SUMMARY OF THE INVENTION
[0009] In an aspect of the invention, a method for combusting H 2 -rich fuels is provided which reliably prevents migrating of the flame back into the burner and also pulsations, even during a changeover from natural gas to H 2 -rich fuels.
[0010] In an embodiment of the invention, in addition to the H 2 -rich fuel, a small amount of natural gas is introduced into the burner arrangement during premix operation and combusted together with the H 2 -rich fuel.
[0011] One development of the method according to the invention is characterized in that first of all an air/fuel mixture is created from the air and the natural gas, and in that the H 2 -rich fuel is then injected into the air/fuel mixture. In particular, a burner arrangement, which comprises a premix burner and a mixer tube which is connected to it, is used for this purpose, wherein the fuel/air mixture is created in the premix burner. The H 2 -rich fuel can be injected into the mixer tube and/or into the swirler. A swirler can be advantageously used as the head stage of the premix burner, as is described for example in EP-A1-321 809.
[0012] Another development of the method according to the invention is characterized in that first of all the natural gas and the H 2 -rich fuel are intermixed, and in that the resulting fuel mixture is mixed and combusted with air in the burner arrangement. As a result of this, the system of fuel feed and fuel distribution can especially be simplified. Also in this case, a burner arrangement can preferably be used which comprises a premix burner and a mixer tube which is connected to it, wherein in the premix burner the air/fuel mixture is created from the air and the fuel mixture.
[0013] A burner arrangement can also be used, however, as is disclosed for example in WO-A1-2007/113074, in which within the scope of a sequential combustion a fuel lance projects into a hot gas flow, and wherein the fuel mixture is injected via the fuel lance, if necessary with additional air, into the hot gas flow. The fuel lances which are shown in this printed publication (FIGS. 2-6) are designed for use in the low-pressure combustion chamber (Pos. 14). Also, this last-named printed publication forms an integrating element of this application. The operation of such a low-pressure combustion chamber with the use of a fuel lance which is described above in a sequentially fired gas turbine, results for example from EP 620 362 A1, which printed publication also represents an integrating element of this description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The invention shall subsequently be explained in more detail based on exemplary embodiments in conjunction with the drawing. All elements which are not necessary for the direct understanding of the invention have been omitted. Like elements are provided with the same designations in the various figures. The flow direction of the media is indicated by arrows.
[0015] In the drawings:
[0016] FIG. 1 shows a simplified schematized view of a burner arrangement of the AEV type, in which according to one exemplary embodiment of the method according to the invention the additional natural gas and the H 2 -rich fuel are injected one after the other in the flow direction, wherein the H 2 -rich fuel can also be selectively injected into the swirler;
[0017] FIG. 2 shows a view which is comparable to FIG. 1 of a burner arrangement of the AEV type, in which according to another exemplary embodiment of the method according to the invention the additional natural gas and the H 2 -rich fuel are first of all mixed and the resulting mixture is then injected;
[0018] FIG. 3 shows a simplified schematized view of a burner arrangement with a fuel lance, which is provided for sequential combustion, in which according to another exemplary embodiment of the method according to the invention the additional natural gas and the H 2 -rich fuel are first of all mixed and the resulting mixture is then injected into a hot gas flow; and
[0019] FIG. 4 shows use of the fuel lance according to FIG. 3 in a combustion chamber of a gas turbine with sequential combustion.
DETAILED DESCRIPTION
[0020] Reproduced in FIG. 1 , in a simplified schematized view, is a burner arrangement with a head stage, which is formed as a swirler, and an adjoining mixer tube, in which according to one exemplary embodiment of the method according to the invention the additional natural gas and the H 2 -rich fuel are injected one after the other in the flow direction. The burner arrangement 10 comprises a swirler 11 , which at times can also be used as a stand-alone premix burner, wherein this is formed in a known manner per se in the shape of a cone, as is described for example in EP-A1-321 809. In this case, it is important that the swirl intensity in the swirler is selected via its geometry so that the bursting of the vortex, or vortices, does not take place in the mixer tube but further downstream at the combustion chamber inlet, wherein the length of the mixer tube 13 is to be dimensioned so that a satisfactory mixture quality is established for all fuels which are in use. If such a swirler is taken as a basis, then the swirl intensity results from the design of the corresponding cone angle, of the air inlet slots or passages, and their number. Combustion air flows into the interior of the premix burner 11 through said air inlet slots or passages, wherein in the region of these air inlet slots or passages provision is made for means for injecting a fuel in such a way that an air/fuel mixture 12 is formed in the inner space which is formed by the partial cone shells. The air/fuel mixture 12 is given a swirl around the axis 15 of the burner arrangement 10 and enters a mixer tube 13 downstream, where the complete mixing-through of air and fuel takes place. The mixer tube 13 opens into a combustion chamber 14 in which a flame front is formed, with which the air/fuel mixture is combusted. On the mixer tube 13 , provision is made for an injection device 16 of preferably annular design, through which fuel can be additionally injected into the mixer tube 13 and incorporated into the combustion. When required, transfer passages, which are not shown in more detail in this figure, are provided in a transition region between swirler 11 and mixer tube 13 and undertake the transfer of air or air/fuel flow, which is formed in the swirler 11 , into the mixer tube 13 . Such a configuration results from EP-A1-704 657, wherein its disclosure content forms an integrating element of this application. Furthermore, the swirler can be designed so that this comprises at least two hollow partial shells which are nested one inside the other in the flow direction, making up a body, the cross section of which in the flow direction, in contrast to the swirler 11 above, does not extend conically but cylindrically or virtually cylindrically, wherein in the inner space, preferably on the symmetry axis of the body, an inner body is provided, the cross section of which in the flow direction reduces conically or virtually conically. Such a configuration has been known for example from EP-A1-777 081, wherein this printed publication also forms an integrating element of this application.
[0021] According to the exemplary embodiment which is shown in FIG. 1 , a small quantity of natural gas F 1 is injected into the premix burner 11 during premix operation and mixed with air. The natural gas F 1 is fed via a first fuel feed line 17 and can be adjusted to the required mass flow for example by means of a valve 19 . The main part of the output of the burner arrangement 10 is contested, however, by an H 2 -rich fuel F 2 which is directed to the injection device 16 via a second fuel feed line 18 and injected there into the air/fuel mixture 12 from the swirler 11 acting upstream. A portion of this H 2 -rich fuel 18 ′ can also be selectively injected into the swirler 11 , as results from FIG. 1 , wherein its portion typically constitutes up to 30%. This type of burner operation has the following advantages:
The pressure loss coefficient Zeta is reduced from 2.8 to 1.5, which corresponds to a sharp reduction of the pressure loss in the burner. The high-frequency pulsations (of 2 to 4 kHz) are practically eliminated. NOx-emissions are minimized, this based on the fact that the flame is maintained by a maximized premixed air/fuel mixture. The fuel feed lines 17 in the region of the swirler 11 are constantly purged for the natural gas so that changing over to natural gas operation is possible within an extremely short time. If the flame front actually migrates upstream into the burner, it is anchored relatively far downstream in the mixer tube and burns in a stable and reliable manner. If in a multi-burner arrangement, as is customary in gas turbines, a flashback occurs in a burner, this leads more easily to a stable state in the burner and not to an operation-relevant negative development in which the flame front migrates still further upstream until destruction of the burner commences, as is immanently the case in normal burners. If this state occurs, then the reason to be looked for is that the burner in question is blocked and the throughflow of air is reduced. This then also means that an individual burner can be temporarily shut down and reignited. The operation of the other burners in the gas turbine is consequently not affected. The reason that the flame front in this case cannot flash back to the premixed burner 11 which is used according to the invention, and destruction cannot correspondingly occur, is to be seen as that of the very same flame front assuming a fixed local anchoring inside the mixer tube 13 in such a way that it also cannot creep upstream either, the air flow hardly being impaired in the process.
[0028] Whereas in the exemplary embodiment of FIG. 1 the natural gas F 1 and the H 2 -rich fuel F 2 are injected separately and in axial staging in the burner arrangement 10 , it is also conceivable to premix the two fuels before injection according to FIG. 2 . For this purpose, the two fuel feed lines 17 and 18 for the fuels F 1 and F 2 are brought together and the resulting fuel mixture is then injected on the one hand into the swirler 11 and on the other hand into the injection device 16 on the mixer tube 13 .
[0029] Stabilizing the flame position and limiting NOx-emissions which is associated therewith, and avoiding pulsations by means of a small addition of natural gas, can also be applied in a gas turbine with sequential combustion, specifically in the second or subsequent combustion stage. In FIG. 3 , a fuel lance 20 is reproduced, as is disclosed in WO-A1-2007/113074 which is referred to in the introduction, wherein this printed publication also forms an integrating element of this application. The fuel lance 20 projects into the hot gas flow 26 from a previous combustion stage which can comprise for example the burner arrangement which is shown in FIG. 1 . In the fuel lance 20 , an outer tube 21 and an inner tube 22 are arranged one inside the other. The outer tube has injection orifices 23 . Air 25 is fed into the gap between inner tube 22 and outer tube 21 , while through the inner tube 22 a mixture consisting of the H 2 -rich fuel F 2 and the small portion of natural gas F 1 is introduced. The air/fuel mixture which is formed discharges into the hot gas flow 26 and ignites there, forming a flame.
[0030] FIG. 4 shows in schematic view a low-pressure combustion chamber 27 in a gas turbine which is operated by means of sequential combustion. Such a gas turbine results for example from an article by Joos, F. et al., “Field Experience of the Sequential Combustion System for the ABB GT24/GT26 Gas Turbine Family”, IGTI/ASME 98-GT-220, 1998 Stockholm, wherein FIG. 1 shows the construction of such a gas turbine. Furthermore, reference is made to a publication in ABB Review February 1997 (pages 4-14), especially to FIG. 15 (page 13), in which the main components of such a gas turbine are also shown. The low-pressure combustion chamber is referred to here as a “SEV combustor”. The operation of this low-pressure combustion chamber 27 is designed for self-ignition, i.e. the hot gas flow 26 which flows into the combustion chamber 27 has a very high operating temperature in such a way that combustion of the fuels F 1 or F 1 +F 2 or F 2 , which are injected via at least one fuel lance 20 , is carried out by means of self-ignition. With this type of combustion, it is important that the flame front in the combustion chamber 14 which is arranged downstream remains stable as regards location. Also, for achieving this aim, provision is made in this self-ignition combustion chamber 27 , preferably arranged on the inner or outer wall in the circumferential direction, for a row of elements 28 , so-called vortex generators, which are positioned in the axial direction preferably upstream of the fuel lance 20 which basically comprises a vertical outer tube 21 and a horizontal outer tube 21 ′. The purpose of these elements 28 is to generate vortices which induce a backflow zone. The design of these vortex generators 28 and also the arrangement in the combustion chamber 27 results from DE-44 46 611 A1, wherein this printed publication also forms an integrating element of this description. With regard to the different injection possibilities 29 of the fuels F 1 or F 1 +F 2 of F 2 into the combustion chamber 27 , reference is made essentially to WO 2007/113074 A1. A further possibility is apparent in FIG. 4 itself, in which the symbolized fuel jets 29 flow from one or more injection orifices which are arranged on the circumference of the axial outer tube 21 ′ of the fuel lance 20 and inject the fuel, or fuels, into the flowing 26 of the combustion chamber 27 at a specific injection angle α. This injection angle a preferably varies between 20° and 120° in relation to the surface of the horizontal outer tube section 21 ′ of the fuel lance 20 , wherein injection angles of less than 20° and more than 120° are also possible, however. A further injection of the fuels F 1 or F 1 +F 2 or F 2 is provided downstream of the fuel lance 20 via the injection device 16 which also has one or more injection orifices, wherein the direction of the fuel jets 30 can assume a broad spectrum, as results from FIG. 4 , the injection preferably having an angle α′ of between 20° and 120° in relation to the surface of the inner wall of the combustion chamber 27 , wherein injection angles of less than 20° and more than 120° are also possible. The type of operation of this combustion chamber 27 concerning the fuels which are introduced there and with regard to the injection angle of the fuel jets or of the fuel orifices 29 , 30 , depends upon factors which are related to the sequential combustion. Naturally, the introduction of the fuels according to FIG. 4 can also be provided in the same or similar manner in the case of the previously described combustion chambers according to FIGS. 1 and 2 . An additional introduction of a quantity of air, as results from FIG. 3 , is likewise possible and also provided, when required, also during operation of the combustion chamber 27 from FIG. 4 .
[0031] The subject according to the invention can be used with particular advantage in a gas turbine with at least one combustion chamber stage, wherein the hot gas which is produced is expanded in the gas turbine, performing work.
LIST OF DESIGNATIONS
[0000]
10 Burner arrangement
11 Swirler
12 Air/fuel mixture
13 Mixer tube
14 Combustion chamber
15 Axis
16 Injection device
17 , 18 Fuel feed line
19 Valve
20 Fuel lance
21 Vertical outer tube of the fuel lance
21 ′ Horizontal outer tube of the fuel lance
22 Inner tube
23 Injection orifice
24 Fuel
25 Air
26 Hot gas flow
27 Low-pressure combustion chamber operated by means of self-ignition
28 Vortex generators
29 Fuel injection
30 Fuel injection
F 1 Fuel (natural gas)
F 2 Fuel (H 2 -rich, for example syngas)
α Injection angle
α′ Injection angle | A method for producing hot gas for operating a turbomachine fired with at least one combustion chamber includes premixing a fuel with a plurality of operating gases by introducing fuel into the plurality of operating gases in a mixing chamber disposed upstream of the combustion chamber using a burner arrangement, wherein the fuel includes at least one of a combustible gas and a H 2 -rich fuel; and introducing the premixed fuel into the combustion chamber. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application claims the benefit of U.S. Provisional Application No. 61/975,421 filed Apr. 4, 2014. The above application is incorporated by reference herein in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
The invention described herein was made by an employee of the United States Government and may be manufactured and used by the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefore.
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to the field of hydraulic engineering and more specifically to a vertically sliding adjustable fluid control system.
2. Description of Related Art
Weir stacks and water control gates are permanent structures known in the art used to maintain desired water levels and to control the stage, discharge, distribution, delivery or direction of water flow.
A weir stack is a barrier that operates like a small adjustable dam, pooling water behind the stack while also maintaining a maximum water level by allowing it to flow steadily over the top of the stack. Common uses of weir stacks include altering the discharge flow of rivers to prevent downstream flooding, regulating fluid discharge and rendering rivers navigable. Typically, weir stacks consist of a stack of “stop logs” fabricated out of timber or aluminum and held into place with vertical channels. One of problems known in the art is that buoyant stop logs can float, compromising the stack. Additionally, water level control is typically achieved by removing logs from or adding logs to the stack. Adjusting the weir stack places personnel at risk in situations where the flow of water is powerful.
Water control gates are used as an alternative to weir stacks. A control gate is a single, solid structure held into place with vertical channels, or hinged and employing water pressure to seat the gate. Water is drained from a reservoir by lifting a mechanically actuated gate. Constructing a water control gate is an expensive undertaking, because the structure requires a substantial foundation and complex engineering. Once installed, it is difficult to modify the structure as environmental conditions change. Another problem known in the art is that water released from the reservoir bottom may contain undesired sediment or be under unacceptably high pressure.
Traditional water control structures in the art offer limited options for adjusting and controlling the flow of water, are difficult to modify and are not capable of achieving incremental release or multiple flow paths.
BRIEF SUMMARY OF THE INVENTION
In one embodiment, an incrementally adjustable fluid control system includes two guide channels, a plurality of stack beams and a picker mechanism. The two guide channels are located in opposition. Each guide channel includes a plurality of guide channel flanges connected by a guide channel web. The plurality of stack beams are constrained between the two guide channels. Each stack beam includes a stack beam channel and a plurality of stack beam flanges operatively connected by a stack beam web. Each stack beam is made of a non-porous, non-buoyant material. The picker mechanism includes a picker beam operatively connected to a picker rod by a picker connector.
In another embodiment, a method for opening an incrementally adjustable fluid control system includes the step of determining a desired gate opening height within a plurality of stack beams constrained between two guide channels. Each guide channel includes a plurality of guide channel flanges connected by a guide channel web. Each stack beam includes a stack beam channel and a plurality of stack beam flanges operatively connected by a stack beam web. Each stack beam is made of a non-porous, non-buoyant material. Next, the method lowers a picker mechanism including a picker beam operatively connected to a picker rod by a picker connector, until the picker beam reaches a stack beam corresponding to the desired gate opening height. The method then inserts at least one of the picker beam flanges between at least two of the plurality of stack beam flanges and applies a lifting force to the picker beam through the picker rod. Next, the method raises at least one of the plurality of stack beams along the two guide channels.
In another embodiment, a method for installing an incrementally adjustable fluid control system includes the step of fixing two guide channels in opposition. Each guide channel includes a plurality of guide channel flanges connected by a guide channel web. The method then inserts a plurality of stack beams into the guide channels such that the plurality of stack beams are constrained between the two guide channels and substantially block movement of a fluid through an area located between the guide channels. Each stack beam includes a stack beam channel and a plurality of stack beam flanges operatively connected by a stack beam web. Each stack beam is made of a non-porous, non-buoyant material. Next, the method supplies a picker mechanism including a picker beam operatively connected to a picker rod by a picker connector.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWING(S)
FIGS. 1 a -1 c are top, back and side views, respectively, illustrating an exemplary embodiment of an incrementally adjustable fluid control system.
FIG. 2 is a flowchart illustrating an exemplary embodiment of a method for opening an incrementally adjustable fluid control system.
FIG. 3 is a flowchart illustrating an exemplary embodiment of a method for installing an incrementally adjustable fluid control system.
TERMS OF ART
As used herein, the term “horizontal tolerance” means a physical, horizontal distance between two parts.
As used herein, the term “non-buoyant material” means a material having an average density greater than that of a fluid in which the material is immersed.
As used herein, the term “non-porous material” means a material that does not gain more than 5% weight when immersed in fluid for a period of time of at least one week.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 a -1 c are top, back and side views, respectively, illustrating an exemplary embodiment of an incrementally adjustable fluid control system 100 . Incrementally adjustable fluid control system 100 includes two guide channels 10 , a plurality of stack beams 20 and a picker mechanism 30 .
Guide channels 10 are substantially vertically oriented channels located opposite each other. Each guide channel 10 includes two guide channel flanges 11 a and 11 b connected by a guide channel web 12 . In the exemplary embodiment, guide channels 10 are spaced apart according to the width of the fluid channel bracketed. In other embodiments, multiple guide channels 10 may be attached along their respective guide channel webs 12 to connect multiple incrementally adjustable fluid control systems 100 . In still other embodiments, guide channels 10 may be attached along their respective guide channel webs 12 to posts or other structures within a fluid channel or reservoir to enable fluid guidance. Guide channels 10 may be attached along their respective guide channel webs 12 using means including, but not limited to, an adhesive, at least one mechanical fastener or a combination thereof.
Guide channels 10 partially enclose first and second ends of the plurality of stack beams 20 . Guide channel flanges 11 a and 11 b have a width greater than twice the horizontal tolerance of stack beams 20 . This width ensures guide channel flanges 11 a and 11 b are wide enough to securely hold stack beams 20 , while not so wide as to impede fluid flow. Guide channel flange 11 b provides a smooth mating surface with stack beams 20 . A length of guide channel web 12 is approximately 5% to approximately 15% longer than a length of stack beams 20 . This tolerance allows for substantially frictionless raising of stack beams 20 but is not enough to allow stack beams 20 to become slanted and/or wedged
The plurality of stack beams 20 are vertically stacked atop each other between guide channels 10 to lie in a substantially horizontal orientation. Stack beam flanges 22 a and 22 b and stack beam web 23 surround stack beam channel 21 . In the exemplary embodiment, each of the plurality of stack beams 20 has a C-shape formed by connecting stack beam flanges 22 a and 22 b with stack beam web 23 . In the exemplary embodiment, stack beam channel 21 faces upstream while stack beam web 23 faces downstream. In an alternate embodiment, stack beam channel 21 faces downstream while stack beam web 23 faces upstream. In this embodiment, the ends of stack beams 20 are sealed.
In the exemplary embodiment, the plurality of stack beams 20 with stack beam channels 21 facing upstream provides a large flat sealing surface between beam web 23 and guide channel flange 11 b , forming a wall spanning the horizontal distance between guide channel flanges 11 a and 11 b . Another embodiment of stack beam 20 closes stack beam channel 21 with an additional stack beam web 23 to create a hollow core stack beam 20 . In another embodiment, the plurality of stack beams 20 is a combination of C-shaped stack beams 20 and hollow core stack beams 20 . In one embodiment, certain individual stack beams 20 may be attached to other stack beams 20 to limit potential openings. Stacks beams 20 may attach to each other through adhesive or welding, or may be integrally formed.
Each of the plurality of stack beams 20 is a non-porous, non-buoyant material. This material may be, but is not limited to, composite material, stainless steel and marine grade aluminum. In one embodiment, the stack beams are fiberglass reinforced, UV resistant polymer resin. Calculation of the density and resultant buoyancy of the material takes into account the specific gravity of the surrounding fluid and any air pockets contained within stack beam 20 in embodiments using hollow core stack beams 20 .
In the exemplary embodiment, the easily accessible stack beam flanges 22 a and 22 b allow for insertion of a lifting mechanism such as, but not limited to, picker mechanism 30 into stack beam channel 21 to lift the plurality of stack beams 20 . In another embodiment, part of picker mechanism 30 inserts between two stack beams 20 . Because lifting the plurality of stack beams 20 can occur at any point along the plurality of stack beams 20 , system 100 may create a window anywhere in the plurality of stack beams 20 and function interchangeably as a sluice, a weir or a suspended orifice. This can allow for the bypassing of sediment to maintain reservoir capacity or controlled drainage of a reservoir to a given level.
Picker mechanism 30 includes picker beam 31 , picker rod 37 and picker connector 38 . Picker beam 31 has a width of approximately 50% to less than 100% of the width of stack beam 20 . This width prevents stack beam 20 from rising in a non-level manner when raising the plurality of stack beams 20 if uneven weighting occurs in stack beam channel 21 due to settled sediment or unequal fluid or slurry drainage. This also reduces the likelihood of stack beam 20 tilting and becoming wedged in guide channel 10 .
In the exemplary embodiment, picker beam 31 includes picker beam channel 32 , picker beam flanges 33 a and 33 b , picker beam web 34 , optional picker beam apertures 35 and optional picker beam spacer pads 36 . In the exemplary embodiment, picker beam channel 32 faces downstream, allowing picker beam flanges 33 a and 33 b to slide between stack beam flanges 22 a and 22 b . Because picker beam web 34 is located upstream of picker beam flanges 33 a and 33 b , hydraulic pressure more firmly seats picker beam flanges 33 a and 33 b between stack beam flanges 22 a and 22 b and reduces the likelihood of accidental disengagement. In one embodiment, picker beam flanges 22 a and 22 b are spaced at a height less than or equal to a height of stack beam web 23 . In another embodiment, picker beam flanges 22 a and 22 b are spaced at a height greater than a height of stack beam web 23 . This configuration allows picker beam flanges 33 a and 33 b to surround at least one stack beam 20 .
Optional picker beam apertures 35 in picker beam flanges 33 a and 33 b allow picker beam 31 to sink through fluids and allow for improved drainage when picker beam 31 rises above the fluid surface. Optional picker beam spacer pads 36 attach to picker beam flanges 33 a and 33 b . Picker beam spacer pads 36 can provide increased friction between picker beam flanges 33 a and 33 b and stack beam flanges 22 a and 22 b , making stack beam 20 less likely to dislodge from picker beam 31 . In the exemplary embodiment, picker beam spacer pads 36 are a high-friction material, such as a rubberized material attached to picker beam flanges 33 a and 33 b with an adhesive or fastened with mechanical fasteners. In other embodiments, picker beam spacer pads 36 may be texturized regions of picker beam flanges 33 a and 33 b.
A proximal end of picker rod 37 connects to picker beam 31 via picker connector 38 . Because a downstream side of picker beam 31 engages an upstream side or sides of stack beams 20 , picker rod 37 must connect to an upstream side of picker beam 31 . Picker rod 37 may connect through picker beam flanges 33 a and/or 33 b , or along picker beam web 34 . A distal end of picker rod 37 extends above the maximum height of the plurality of stacker beams 20 , allowing application of a lifting force to picker mechanism 30 . In one embodiment, a mechanical device operatively attached to the distal end of picker rod 37 provides the lifting force when actuated. In another embodiment, the lifting force is manual.
FIG. 2 is a flowchart illustrating an exemplary embodiment of a method 200 for opening an incrementally adjustable fluid control system 100 .
In step 202 , method 200 determines a desired gate opening height within stack beams 20 constrained by two guide channels 10 in opposition.
In step 204 , method 200 lowers picker mechanism 30 until picker beam 31 reaches a stack beam 20 corresponding to the desired gate opening height.
In step 206 , method 200 inserts a portion of picker beam 31 between stack beam flanges 22 a and 22 b of at least one of the plurality of stack beams 20 . In one embodiment, method 200 inserts at least one of picker beam flanges 33 a and 33 b between stack beam flanges 22 a and 22 b.
In step 208 , method 200 applies a lifting force to picker beam 31 through picker rod 37 . In one embodiment, application of the lifting force includes actuating a mechanical device providing the lifting force.
In step 210 , method 200 raises at least one of the plurality of stack beams 20 along guide channels 10 .
FIG. 3 is a flowchart illustrating an exemplary embodiment of a method 300 for installing an incrementally adjustable fluid control system 100 .
In step 302 , method 300 fixes two guide channels 10 in opposition. In certain embodiments, guide channels 10 bracket a fluid channel. In other embodiments, multiple guide channels 10 may be attached along their respective guide channel webs 12 to connect multiple incrementally adjustable fluid control systems 100 . In still other embodiments, guide channels 10 may be attached along their respective guide channel webs 12 to posts or other structures within a fluid channel or reservoir to enable fluid guidance.
In step 304 , method 200 inserts a plurality of stack beams 20 into and between guide channels 10 . In such a configuration, the plurality of stack beams 20 are constrained between guide channels 10 and substantially block movement of a fluid through an area located between guide channels 10 .
In step 306 , method 200 supplies picker mechanism 30 .
It will be understood that many additional changes in the details, materials, procedures and arrangement of parts, which have been herein described and illustrated to explain the nature of the invention, may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims.
It should be further understood that the drawings are not necessarily to scale; instead, emphasis has been placed upon illustrating the principles of the invention. Moreover, the terms “substantially” or “approximately” as used herein may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. | The present invention provides a water control system with the reservoir level versatility of a weir stack and the relatively easy drainage of a water control gate. Multiple stack beams constrained between two opposed guide channels create a fluid reservoir having an incrementally adjustable fluid level. Increasing or decreasing the reservoir level is a matter of adding or removing one or more stack beams. To create an opening for draining fluid from any level of the reservoir, a picker mechanism captures at least one of the stack beams. By lifting the captured stack beam, and any stack beams atop the captured stack beam, the picker mechanism opens a gate at any level of the reservoir through which fluid may flow. | 4 |
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.