description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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FIELD OF THE INVENTION
[0001] The present invention relates to the testing of atmospheric emissions and, in particular, to testing equipment for withdrawing samples from a flue gas stream or other atmospheric discharge, especially on a continuous testing basis.
BACKGROUND OF THE INVENTION
[0002] Owners and operators of certain combustion devices are required to comply with a variety of environmental regulations pertaining to the maximum allowable emissions of a particular substance. One example of such regulations is directed to the concentration of a substance suspended in a waste gas, such as the flue gas of a combustion device, that discharges a waste gas stream into the atmosphere. In addition to specifying maximum allowable amounts or concentrations, environmental regulations at times specify how a waste gas stream is to be tested in order to determine regulatory compliance. Taking into account the different technologies and characteristics of substances involved, different testing techniques are often required for different types of substances, and additionally for different timing of such testing. For example, testing can be periodic or continuous.
[0003] One example of continuous emission monitoring regulations is found in part 75 of Title 40 of the Code of Federal Regulations, which pertains to the protection of the environment by way of continuous emission monitoring. Subpart I of these regulations is concerned with the continuous emission monitoring of mercury mass emissions of certain coal-fired units. Included in the regulations is a requirement as to how certain aspects of the continuous emission monitoring are to be carried out.
[0004] Compliance may be audited by a site visit for testing purposes, or a continuous monitoring program may be required. In either event, testing can require a substantial investment in capital and man-hours. Improvements in testing equipment, especially for repetitive (e.g. continuous) testing are continually being sought.
SUMMARY OF THE INVENTION
[0005] The present invention provides a novel and improved arrangement for withdrawing carefully controlled samples from an active flue gas source. Equipment provided by the present invention allows easy withdrawal of the sample material, while leaving associated equipment, such as vacuum pumps and line heaters, undisturbed. The present invention minimizes the disadvantages associated with prior art devices and materials related thereto.
[0006] One embodiment comprises a testing assembly for connection to downstream processing equipment to obtain a sample from a gas stream. Included is a probe having a first end with a gas inlet and a second end, a flexible sample line and a coupler joining the second end of the probe and the flexible sample line. The flexible sample line includes at least one gas channel comprising a flexible gas line coupled to the probe to transmit a sample from the probe inlet to the downstream processing equipment. At least one externally controlled or self-regulating heating cable is put in heating communication with the flexible line. The flexible sample line further includes an outer sheath surrounding the flexible gas line and the heating cable, and a thermal insulator is disposed within the outer sheath and surrounds the flexible line and the heating cable.
[0007] In another embodiment, a system for controlled positioning of a probe with respect to a gas stream is provided wherein the probe has a first end with a gas inlet and a second end for connection to downstream processing equipment to deliver a sample from the gas stream. Included is a flexible interconnect for connecting the probe to the downstream processing equipment, and a coupler for joining the second end of the probe and the flexible interconnect. The flexible interconnect includes at least one gas channel comprising a flexible gas line coupled to the probe to transmit a sample from the probe inlet to the downstream processing equipment. At least one externally controlled or self-regulating heating cable is put in heating communication with the flexible line. The flexible interconnect further includes an outer sheath surrounding the flexible gas line and the heating cable. A thermal insulator is disposed within the outer sheath and surrounds the flexible line and the heating cable. A receptacle for receiving the probe and the coupler includes a lever operated cam spaced a predetermined distance from the gas stream and engaging the coupler so as to position the gas inlet of the probe with a preselected relationship to the gas stream.
[0008] In a further embodiment, a flexible interconnect is provided for connecting a probe having a first end with a gas inlet and a second end, to downstream processing equipment to obtain a sample from a gas stream. Included is a coupler for joining to the second end of the probe, at least one gas channel comprising a flexible gas line having an inlet end for coupling to the probe, to transmit a sample to downstream processing equipment, and at least one externally controlled or self-regulating heating cable in heating communication with the flexible line. An outer sheath surrounds the flexible gas line and the heating cable, and a thermal insulator is disposed within the outer sheath so as to surround the flexible gas line and the heating cable.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] In the drawings:
[0010] FIG. 1 is a schematic diagram of a testing system employing the present invention;
[0011] FIG. 2 is a schematic perspective view of a multi-channel probe shown installed in a flue gas stream;
[0012] FIG. 3 is an end view thereof;
[0013] FIG. 4 is an exploded perspective view thereof;
[0014] FIG. 5 is a side elevational view thereof;
[0015] FIG. 6 is a side elevational view thereof shown partly broken away;
[0016] FIG. 7 is a cross-sectional view taken along the line 7 - 7 of FIG. 1 ;
[0017] FIG. 8 is a cross-sectional view taken along the line 8 - 8 of FIG. 5 ; and
[0018] FIG. 9 is a schematic diagrammatic representation of a testing system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] The invention disclosed herein is, of course, susceptible of embodiment in many forms. Shown in the drawings, and described herein in detail, is a preferred embodiment of the invention. It is understood, however, that the present disclosure is an exemplification of the principles of the invention and does not limit the invention to the illustrated embodiment.
[0020] For ease of description, a system for testing a gas stream such as a combustion flue gas stream embodying the present invention is described herein in its usual assembled position as shown in the accompanying drawings and terms such as upstream, downstream, inner, outer, upper, lower, horizontal, longitudinal, etc., may be used herein with reference to this usual position. However, the system may be manufactured, transported, sold or used in orientations other than that described and shown herein.
[0021] Flue gas sampling is one example of many industrial applications where it is necessary to maintain the physical and chemical integrity of a gas sample extracted from a process stream. Frequently, the temperature of the sampled gas must be maintained above a critical lower temperature while it is being transported through sampling lines to downstream measuring devices and other equipment, in order to avoid condensation or otherwise altering important properties of the gas sample.
[0022] Conventional gas sample extraction systems are known to include a sample probe to be inserted directly into a process stream, such as the flue gas stream of a smokestack. A heated sample line is provided to transport the sample to downstream equipment. In many applications, gas sampling systems must be carefully constructed from non-reactive materials capable of sustaining elevated temperatures. However, certain problems have been noted in the use of conventional equipment. For example, the junction where the sample probe and sample transport line are connected must be maintained at an elevated temperature and must be free of leaks, either entering or leaving the gas sample system. The junction is typically embodied in a junction box, in order to meet demanding criteria, such as the criteria discussed herein.
[0023] Referring now to the drawings, and initially to FIG. 1 , a testing assembly is generally indicated at 100 . Included is a flexible sample line 102 and a generic probe 104 . If desired, probe 104 and sample line 102 could be made to carry only a single sampling channel. However, in the preferred embodiment, sample line 102 and probe 104 have the capacity to carry multiple separate, independent sampling channels, and are thus referred to herein as a multi-channel sample line and a multi-channel probe, respectively. As can be seen in FIG. 1 , the sample line 102 and probe 104 are joined, preferably permanently joined, so as to form a single unitary testing assembly.
[0024] Probe 104 and sample line 102 preferably have multiple separate and independent gas sampling channels. In the preferred embodiment, the gas sampling channels include tubing of flexible, non-reactive material such as TEFLON or other engineered fluoropolymeric material. The flexible lines are indicated in FIG. 1 at 110 , 112 . Also included are connectors for a variety of auxiliary equipment such as sensors and heaters. Included are connectors 114 , 116 associated with each flexible line and a connector 118 associated with instrumentation separate from the flexible lines.
[0025] Probe 104 can comprise virtually any type of probe known today, having either single or multiple channel capability. As mentioned, in a preferred embodiment, probe 104 has multi-channel gas sampling capability and includes a pair of gas sampling channels. Referring to FIG. 2 , the gas sampling channels have inputs 120 , 122 . A thermocouple 124 is also located adjacent gas inputs 120 , 122 . In the preferred embodiment, probe 104 is designed to have a specialized gas sampling capability, to withdraw gas samples using absorbent material. In a preferred embodiment, probe 104 utilizes sorbent trap technology.
[0026] Referring briefly to FIG. 4 , included in probe 104 is a sorbent trap 130 with an insert including sections 132 of sorbent trap material. Although not required, the sorbent trap insert 130 is received within an outer shell 136 of rugged stainless steel construction. A ferrule or frustoconical collar 138 is attached, preferably by welding or brazing, to the inlet end of shell 136 , and a nut or compression fitting 140 that threadingly engages a threaded nipple 142 which is fitted to an end cap 144 of a rugged stainless steel housing 146 of probe 104 . In a preferred embodiment, the compression fitting 140 can be removed for ready withdrawal of a sample cartridge 152 formed by the combination of sorbent trap insert 130 , outer shell 136 and, as an option, fitting 140 . The sorbent trap insert 130 may be easily withdrawn from shell 136 with the shell 136 either removed from housing 146 or left in place as shown, for example, in the adjacent gas sampling channel having input 122 . However, virtually any sample probe arrangement can be utilized with the present invention and removable inserts and/or removable cartridge assemblies are not required.
[0027] Referring to FIGS. 5 and 6 , the downstream ends 150 of the sorbent trap inserts 130 are coupled to flexible lines 110 , 112 (see FIG. 1 ) in a manner (not shown) to form a continuous gas sampling passageway. As will be seen herein, auxiliary equipment such as thermocouples and heaters are combined with the gas passageways to form a pair of gas sampling channels.
[0028] Referring now to FIG. 7 , a cross-sectional view of sample line 102 is shown. Included in the sample line 102 are two gas sampling channels generally indicated at 154 , 156 . Included in each channel are flexible hollow lines 110 , 112 which, as mentioned above, are preferably made of TEFLON material. Surrounding the flexible lines 110 , 112 is an outer covering 162 of thermal barrier material such as fiberglass cloth, which is coated, wrapped or otherwise disposed about each flexible line. As indicated in FIG. 7 , the channels 154 , 156 are spaced apart and disposed within a rugged outer weatherproof jacket 166 of polyurethane material. The outer jacket 166 is preferably formed with a shrink-wrap process. The interior of sample line 102 is filled with a thermal insulator material such as glass fiber insulation and most preferably non-hygroscopic glass fiber insulation material indicated at 168 .
[0029] Also included in each gas channel is a externally controlled or self-regulating heater preferably in the form of electrical cables schematically indicated at 172 . Preferably, each flexible line is wrapped with two independent externally controlled or self-regulating electric resistance cable heaters. The length of the first heater cable is equal to the length of the flexible line that is inserted into the process stream. The second heater cable is wrapped around the length of flexible line that remains outside of the process stream. As indicated in FIG. 7 , the heater cables are encapsulated in insulation material 168 . In the preferred embodiment, the two heaters for each gas channel provide an arrangement for maintaining two temperature zones. One zone is the section of the sample line that is covered by the probe sheath or outer probe housing 146 . This section is exposed to the process gas and must maintain the proper sample gas temperature while being exposed to the temperature of the process gases. The second heated zone is the section of the flexible line that transports the extracted sample to downstream equipment such as a gas conditioning and pumping system of the type generally indicated in FIG. 9 to be discussed below. The second heated zone maintains the proper gas temperature while being exposed to ambient air temperature.
[0030] The section of the sample line 102 that is inserted into the process stream is wrapped with a high temperature protective jacket of silicone material. This section is placed inside the rigid stainless steel tube forming the outer housing 146 , shown in FIG. 4 . As mentioned, the housing 146 at the free end of the probe is joined to an end wall 144 , preferably by welding, brazing, or other metallurgical joinder. That portion of sample line 102 that remains outside of the process gas is wrapped with the weatherproof protective jacket 166 (see FIG. 7 ).
[0031] In a preferred embodiment, sample line 102 contains instrumentation for the operation of the testing assembly. Included are a number of thermocouples measuring different operating parameters. The thermocouples are accessed by connectors 114 , 118 shown in FIG. 1 . Referring again to FIG. 7 , a line thermocouple 180 is provided to measure the internal temperature of sample line 102 . As mentioned with reference to FIG. 2 , a thermocouple 124 is provided for sensing the temperature of the process gas and is placed in-situ in the gas stream adjacent gas inlets 120 , 122 . The signal for this thermocouple is carried by electrical conductor 182 shown in FIG. 7 . Connection with the thermocouple is made with connector 118 in FIG. 1 . As mentioned, the sorbent trap inserts 130 are located in probe 104 . Preferably, the temperature of the sorbent traps are monitored by their own respective thermocouples, with signals being transmitted through electrical conductors 186 , 188 to a pair of connectors 114 as shown in FIG. 1 .
[0032] Referring now to FIG. 8 , a section of probe 104 is shown schematically in cross-section. Included are the sorbent trap inserts 130 , preferably in the form of hollow glass tubes receiving sections of sorbent trap material 132 , separated from one another by separator sections 134 as shown for example in FIG. 4 . Referring again to FIG. 8 , the outer shell 136 of the sorbent trap cartridge surrounds the sorbent trap inserts 130 . Electrical conductors 192 for thermocouple 124 are located in the upper portion of FIG. 8 and electrical conductors 194 are provided for additional instrumentation. The interior of the probe is filled with thermal insulation which, as mentioned, preferably comprises non-hygroscopic glass fiber insulation. As shown in FIGS. 7 and 8 , is the outer jacket 166 is preferably located immediately inside of the rigid, stainless steel housing 146 .
[0033] There are many applications involving the direct insertion of sorbent traps into an industrial gas stream to measure properties of the gas stream. One application, for example, requires the measurement of a trace component, such as mercury concentrations, using sorbent traps. Sorbent traps may include, for example, glass tubes packed with iodinated activated carbon. As mentioned in greater detail herein, one protocol for this measurement is contained in the alternative mercury monitoring approach detailed in 40 C.F.R. 75, Appendix K.
[0034] Usually, sorbent trap sampling requires forming and maintaining a gas-tight seal between the traps and the physical device used to hold them in place during sampling, herein referred to as a sorbent trap module or probe. This arrangement allows a vacuum to be placed on the apparatus during sampling and any leakage between the trap and the apparatus could lead to erroneous sampling results. For example, in Appendix K applications, the gas seal, such as that provided by the present invention must be able to maintain leak tightness at a minimum vacuum of 15 inches Hg absolute pressure. Additionally, the seal provided by the present invention is able to withstand chemical and physical conditions of the environment inside the gas stream which, as will be apparent to those skilled in the art, may often times be hot, corrosive and/or dust-laden.
[0035] Sorbent trap modules or probes according to principles of the present invention allow sorbent trap inserts to be quickly inserted and removed from the probe without the use of tools. The trap or insert is pushed by hand into a removable module inside the probe, preferably in the form of cartridge 152 shown for example in FIG. 6 . A leak-tight seal is made between the insert 130 and the shell 136 of cartridge 152 by a series of three o-rings 126 , preferably contained within interior grooved rings formed inside of cartridge shell 136 in the manner indicated in FIG. 1 . The probe 104 and cartridge 152 preferably include outer housings made of stainless steel or another type of corrosion-resistant ridged material. Preferably, the o-rings 126 are made of a pliable, chemically resistant and thermally stable polymer such as silicone or VITON. The cartridges 152 are held in place within the probe and sealed to the probe using a threaded compression fitting and nut assembly 142 , 138 and 140 , respectively.
[0036] Accordingly, the sorbent traps, i.e., sorbent trap inserts 130 can be inserted and removed without the need for tools such as wrenches or pliers. With the present invention, the sampling process is simplified and is made more time efficient. The sorbent trap module or cartridge 152 can be readily removed from probe 104 and replaced with a new one, as may be desired. The nut 140 used to hold the cartridge in place within probe 104 may be tightened and loosened with a wrench, but, according to a preferred embodiment, the cartridge 152 is not removed from the probe 104 except for periodic maintenance purposes, such as o-ring wear. In this regard, it is generally preferred in the present invention that three o-rings are provided to seal the sorbent trap insert 130 and to provide redundancy in case of failure of a particular o-ring. Further, as can be seen for example in FIG. 1 , it is generally preferred that two o-rings be placed close to each other at the downstream end 150 of the sorbent trap insert and that a single o-ring be located at the forward or free end of probe 104 , adjacent the gas inlet end 120 of the sorbent trap insert.
[0037] With reference to FIG. 6 , the test assembly 100 conveniently provides a multichannel, redundant testing capability which is often a condition for a regulatory body to allow self-testing programs implemented by the facility operator, rather than a designee or member of the responsible agency. In order to provide maximum benefits to an operator, the testing assembly should be relatively lightweight and for the most part reusable from one testing operation to another. This is particularly important where continuous or quasi-continuous monitoring is required. Several times a day, during continuous operation of the facility, examples are withdrawn from the gas stream, an operation often repeated during the life of the facility, especially since many large scale facilities are seldom completely shut down.
[0038] As mentioned above, the probe 104 is preferable made rigid and with locating fitting 218 , allows the accurate positioning of inlets for the gas sample channels within the gas stream flow to be tested. However, in light of the need for gas-tight seals to be continuously maintained during testing and the need for flexibility to allow the probe to be permanently joined to the sample line 102 , it is important that the sample line be made relatively flexible, without compromising leak-free integrity of the test assembly. The preferred construction described above with reference to FIG. 7 , for example, allows sample line 102 to meet these criteria while being relatively lightweight. The materials and dimensions of one example of a testing assembly have been given herein and afford a relatively lightweight construction, typically on the order of three pounds per linear foot.
[0039] With testing assemblies according to principles of the present invention, the exposed portions of the trap inserts, at the inlet to the gas channels, may be carefully controlled and protected by an operator from accidental contact and breakage, when contacting a nearby object. It should be remembered, in this regard, that often testing facilities are not typically provided for during design and construction of the facility but rather are added later, where space and other conditions allow. Further, testing operations are conducted, in many instances, continuously, year-round. In very cold weather when gloves and other protective apparel are required, the ability to control the free end of probe 104 and the exposed glass tubes projecting therefrom, becomes even more important. The flexible sample line 102 , the construction of the rigid probe 104 , the precision positioning fitting 218 and the receptacle construction 202 all contribute to ensure that continuous testing programs and other testing procedures can be successfully carried out, even during extreme atmospheric conditions.
[0040] The testing assembly according to the principles of the present invention provides a compact, relatively lightweight arrangement which aids in obtaining gas samples in difficult work areas of restricted accessibility such as may be provided about a smokestack of an operating combustion facility. For example, in one preferred embodiment according to the present invention, the outer housing 146 of probe 104 has a 2.5 inch outer diameter and sample line 102 has an outer diameter of similar dimensions. The sorbent trap inserts 130 are made of hollow glass tubing having an outer diameter of about 0.39 inches and an inside diameter of approximately 0.32 inches. The walls of outer shell 136 of the cartridge 152 preferably have a thickness of approximately 0.09 inches and a length of approximately 8.5 inches. The flexible lines 110 , 112 preferably have an approximate nominal external diameter of approximately one quarter inch.
[0041] Turning again to FIG. 1 , a fitting assembly generally indicated at 202 is provided for support and control of depth insertion of the probe in the process stream. Included in assembly 202 is a port 204 and flange 206 . Connected to flange 206 is a pipe nipple 208 which preferably has a nominal internal diameter of 2.5 inches. Also included is a quick lock fitting 210 with an internal bore of approximately 2.5 inches, dimensioned to receive probe 104 . A pair of cam locks (not shown) protrude into the inner bore of fitting 210 and are operated by lever arms 212 . The cam members seat against a grooved portion 216 of a fitting 218 mounted at one end of probe 104 and are preferably rigidly connected thereto by welding, brazing or other form of metallurgical joinder. A flexible, high-temperature o-ring 211 (e.g., Viton) sits in a groove within the fitting 210 and seals against fitting 218 when the cam locks are engaged.
[0042] Fitting 218 is in turn connected to sample line 102 and a strain relief system 222 is provided to transfer support load to assembly 202 . In operation, probe 104 is inserted into fitting 210 so as to project into the process flow in the manner indicated in FIG. 2 . Preferably, fitting 218 provides an approximate insertion limit by engagement with fitting 210 . The final insertion control is provided when the cam locks are operated by lever arms 212 with the cam locks received in groove 216 to provide a final, rigidly secure and accurately positioned engagement of the probe with respect to the process stream.
[0043] Although a particular probe construction has been described above, the testing assembly according to principles of the present invention can readily employ probes of different constructions and operating principles. Further, those skilled in the art will readily appreciate that the sample line can be readily modified to accommodate different numbers of gas channels to be monitored. For example, a single channel can be readily provided as can a system having three or more gas channels. Further, the present invention can be employed to test virtually any type of material.
[0044] Referring now to FIG. 9 , a sample system suitable for use with the aforementioned probe, sample line and related equipment is generally indicated at 10 . Included is a duct wall 12 confining a gas stream which flows in the direction of arrow 14 . An entrance 16 formed in duct wall 12 is provided for probe 20 . In one example, probe 20 includes a sorbent trap 22 which is placed in the gas stream. A pump 26 draws flue gas through trap 22 and probe 20 . That portion of the gas stream passing through trap 22 is drawn through a chiller 30 and desiccant unit 32 before entering subsystem 34 which includes pump 26 . An isolation valve 40 and flow control valve 42 are provided along with a flow controller/data logger 44 which outputs data on port 46 . Gas stream leaving pump 26 passes through dry gas meter 50 and a rotating meter device 52 before being discharged at 54 .
[0045] The foregoing descriptions and the accompanying drawings are illustrative of the present invention. Still other variations and arrangements of parts are possible without departing from the spirit and scope of this invention. | Arrangements for withdrawing carefully controlled samples from an active flue gas source are disclosed. A testing assembly is provided for connection to downstream processing equipment to obtain a sample from a gas stream. Included is a probe, a flexible sample line and a coupler joining the probe and the flexible sample line. At least one externally controlled or self-regulating heating cable is put in heating communication with the flexible line. A receptacle engaging the coupler is also provided for positioning the probe with respect to the flue gas source. | 6 |
BACKGROUND OF THE INVENTION
In a scroll device one scroll member orbits with respect to a second scroll member which is typically fixed. Each scroll member has a flat plate or floor portion and an axially extending wrap of a spiral configuration. Ideally, the tips of the wraps of each scroll coact with the floor of the other scroll and the flanks of the wraps of the scrolls coact with each other to define a plurality of trapped volumes or chambers in the shape of lunettes. The lunettes are each approximately 360° in extent and are generally symmetrical but are asymmetrical with respect to the axis of the fixed scroll. The ends of the lunettes, which are defined by the points of tangency or contact between the flanks, are transient in that they are continuously moving towards the center of the wraps as the trapped volumes or chambers continue to reduce in size until they are exposed to the outlet port.
During the compression process, a number of forces come into effect. The gas being compressed acts against the scroll members tending to separate them both radially and axially but because one scroll member is fixed, any movement is limited to the orbiting scroll. Since the axis of the orbiting scroll is located eccentrically with respect to the axis of rotation of the crankshaft, the trapped volumes or chambers are located eccentrically with respect to the axis of the fixed scroll as are the forces associated therewith. Also, there are inertia and friction forces inherent in the driving of the orbiting scroll. To offset these forces a fluid pressure bias has been applied to the back side of the orbiting scroll to offset the axial component of the gas forces, with the net force being the clamping or reaction force, and the bearing supporting the hub of the orbiting scroll has been located so as to minimize the turning moment of the tangential component of the gas forces.
Because leakage must be minimized to have an acceptable device, the fluid pressure bias applied to the back side of the orbiting scroll must exceed the opposing forces so that the plate of the orbiting scroll is held in engagement with the opposing structure of the fixed scroll by a positive clamping force. The excess clamping or reaction force needed to maintain the desired sealing over the entire operating envelope and the friction forces resulting therefrom puts an extra load on the motor and accelerates wear.
SUMMARY OF THE INVENTION
Because the trapped volumes or chambers are eccentrically located with respect to the axis of the crankshaft and fixed scroll, their gas forces vary cyclically with the crank angle. This cyclic variation means that the radial location of the reaction force also changes with the crank angle. So, rather than requiring a uniform radial extent as exemplified by a circular scroll plate, there are localized requirements for greater and lesser radial extents. By reducing the radial extent of the scroll in one location, there is a removal of material, a reduction in friction due to the reduced contact area and an increase in the available space. Where the radial extent is increased the reverse is true but there is a resultant greater stability of the orbiting scroll.
It is an object of this invention to provide an orbiting scroll having increased stability and reduced overall/average clamping or reaction force.
It is another object of this invention to reduce part contact wear and friction in scroll compressors by reducing the overall clamping or reaction force.
It is a further object of this invention to optimize the scroll floor of an axially compliant orbiting scroll for spatial reasons. These objects, and others as will become apparent hereinafter, are accomplished by the present invention.
Basically, the axial forces acting upon the orbiting scroll of a scroll compressor during operation produce a resultant or clamping force. The resultant force requires a radius in order to attain dynamic equilibrium and this radius varies with the crank angle. The flat plate or floor portion of the orbiting scroll is configured to be acted on by the resultant force by having the radius of the scroll plate vary in the same manner as the variation in the radius of the location of the resultant force for the entire operating envelope considered.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the present invention, reference should now be made to the following detailed description thereof taken in conjunction with the accompanying drawings wherein:
FIGS. 1-4 are schematic views sequentially illustrating the relative positions of the wraps at 90° crank angle intervals of orbit;
FIG. 5 is a top view of an orbiting scroll made according to the teachings of the present invention;
FIG. 6 is a vertical sectional view through the scrolls of a scroll compressor employing the present invention;
FIG. 7 is a horizontal view of the forces acting on the orbiting scroll;
FIG. 8 is a vertical sectional view of the orbiting scroll of the present invention showing the forces acting thereon;
FIG. 9 is an exemplary plot of moment vs. crank angle;
FIG. 10 is an exemplary plot of reaction force vs. crank angle;
FIG. 11 is an exemplary plot of chamber pressure vs. crank angle for three different operating envelope points or conditions;
FIG. 12 is an exemplary plot of radius, r, vs. crank angle;
FIG. 13 is a superposition of FIG. 7 on FIG. 5; and
FIG. 14 is similar to FIG. 5 except that it only has an area of increased radius.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIGS. 1-4, the numeral 20 generally indicates the fixed scroll having a wrap 22 and the numeral 21 generally indicates the orbiting scroll having a wrap 23. The chambers labeled A-M and 1-12 each serially show the suction, compression and discharge steps with chamber M being the common chamber formed at discharge or outlet 25 when the device is operated as a compressor. It will be noted that chambers 4-11 and D-K are each in the form of a helical crescent or lunette approximately 360° in extent with the two ends being points of line contact or minimum clearance between the scroll wraps. If, for example, point X in FIG. 1 represents the point of line contact or of minimum clearance separating chambers 5 and 9 it is obvious that there is a tendency for leakage at this point from the high pressure chamber 9 to the lower pressure chamber 5 and that any leakage represents a loss or inefficiency. To minimize the losses from leakage, it is conventionally necessary to maintain close tolerances, use a positive mechanical tip seal and to run at high speed and/or to provide a fluid pressure axial bias. Again referring to FIGS. 1-4, it will be noted that there is a symmetry in that chambers 1-12 correspond to chambers A-L with the difference being that they are on opposite sides of the wraps 22 and 23. However, it will be noted that the chambers 1-12 and A-L are not symmetrically located with respect to the axes of the fixed scroll represented by the intersection of the vertical and horizontal dashed lines in the outlet 25. Further, it should be noted that chambers A-C and 1-3 are at suction pressure so they do not contain pressurized gas acting against the scrolls 20 and 21 and tending to separate them. Chambers 4 and D are just at the start of the compression process so they are nominally at suction pressure and so do not contain pressurized gas tending to separate scrolls 20 and 21. So, chambers E-M and 5-12 are the only ones containing significantly pressurized gas tending to separate scrolls 20 and 21. Again referring to FIGS. 1-4 and noting that the chambers 1-12 and A-L are not symmetrically located with respect to the axes, it can be further noted that the centroids of these chambers will be eccentric to the axes, along with the gas forces associated therewith.
Referring now to FIG. 5, it will be noted that the outer configuration of orbiting scroll 21 is at a varying distance from the axis represented by the intersection of the horizontal and vertical axes. Where the outline of a conventional circular orbiting scroll plate differs from the scroll plate 110 of the present invention, it is shown in dashed lines in FIG. 5 and the difference between the dashed and solid lines represents the material added or removed. To maintain the center of gravity of the orbiting scroll 21, a counterweight 90 and/or drilled holes (not illustrated) may be provided to offset the addition and loss of material necessary to configure the floor or plate 110 of the orbiting scroll 21.
In FIG. 6, the numeral 100 generally designates a hermetic scroll compressor. Pressurized fluid, typically a blend of discharge and intermediate pressure, is supplied via bleed holes 28 and 29 to annular chamber 40 which is defined by the back of orbiting scroll 21, annular seals 32 and 34 and crankcase 36. The pressurized fluid in chamber 40 acts to keep orbiting scroll 21 in engagement with the fixed scroll 20, as illustrated. The area of chamber 40 engaging the back of orbiting scroll 21 and the pressure in chamber 40 determines the compliant force applied to orbiting scroll 21. Specifically the tips of wraps 22 and 23 will engage the floor of scrolls 21 and 20, respectively, and the outer portion of the floor or plate portion 110 of orbiting scroll 21 engages the outer surface 27 of the fixed scroll 20 due to the biasing effects of the pressure in chamber 40. As is conventional, orbiting scroll 21 is held to orbiting motion by Oldham coupling 50. Orbiting scroll 21 has a hub 26 which is received in bearing 52 and driven by crankshaft 60, as is conventional. Crankshaft 60 rotates about its axis Y--Y, which is also the axis of fixed scroll 20, and orbiting scroll 21, having axis Z--Z, orbits about axis Y--Y.
In FIG. 7, Y is the point representation of axis Y--Y of crankshaft 60 and fixed scroll 20 and Z is the point representation of axis Z--Z of the orbiting scroll 21. The distance between Y and Z is the throw of crankshaft 60 as well as the radius of orbit of orbiting scroll 21. The angle θ is the crank angle and is arbitrarily shown as measured from a horizontal reference line. The tangential gas force, F gt , acts at a point mid-way between Y and Z and in a direction opposite to the direction of orbit. The axial gas force, F ga , also acts at a point mid-way between Y and Z but in a direction parallel to axes Y--Y and Z--Z (into the paper). The reaction or clamping force, F r , acts in a direction parallel to axes Y--Y and Z--Z (into the paper) and at a crank angle dependent radius, r, from point Z and the plane defined by Y--Y and Z--Z. The reaction force, F r , results from the outer portion of the floor or plate portion 110 engaging the outer surface 27 of the fixed scroll 20 due to the biasing effects of the pressure in chamber 40. Referring now to FIG. 8, as noted, the reaction force, F r , acts at a crank angle dependent radius, r. The gas forces have a tangential, F gt , and an axial, F ga , component. Pocket 40 is annular so that the axial compliant force, F p , is axial generally along the vertical axis Z--Z of the orbiting scroll 21. The tangential gas force, F gt , is assumed to be located at the center of the wrap height and is opposed by a bearing reaction force, F' gt , supplied by the bearing 52 at an axial distance, l, from the location of force F gt . The radius of the plate or floor 110 of orbiting scroll 21 is R and varies as illustrated in FIG. 5. Radius r also varies and is always less than or equal to R in a stable device.
For a scroll operating at any point in the operating envelope, a moment exists on the orbiting scroll. The moment is equal to F gt l and varies with the crank angle as illustrated in FIG. 9. F gt is an instantaneous value and l is minimized to the extent possible. Thus, the curve can be shifted vertically without changing its shape. The bearing reaction force, F' gt , is assumed to be approximately equal to F gt , but adding friction forces makes it greater and requires more motor watts. However, this moment must be counteracted at all times or the orbiting scroll will vibrate. The moment is counteracted by supplying an upward axial pressure (compliant) force, F p , which holds the scrolls together plus leaves a net reaction force, F r , which acts at radius r, creating the counteracting moment at all times. Referring now to FIG. 10, F p and therefore F r depend upon the area of and pressure in chamber 40. The pressure is dependent upon the location of the bleed holes 28 and 29 in orbiting scroll 21, as illustrated in FIG. 5, which supply pressure to chamber 40. The plots of the chamber pressure vs. crank angle in FIG. 11 for three operating envelope points show the pressures available during the entire compression process, which requires approximately 950° of crankshaft revolution. Thus, in FIG. 10, the curve for F r , (F p -F ga ), can be shifted up or down depending upon whether more or less force is desired. Increased F r also means more friction wattage.
Referring now to FIG. 12, we first assume a uniform radius, R, of the orbiting scroll 21 equal to 3.5 inches, the selected design radius of the plate 110 of orbiting scroll 21. Plotting r, the radius required to locate the necessary reaction force, F r , we see that between a crank angle of 240° and 300° there is insufficient radius to multiply by F r values to counteract the moment since r>3.5 inches. This is also illustrated in FIG. 13, where at a crank angle θ of approximately 260°, the radius r required to located F r falls outside the uniform radius of 3.5 inches indicated by the dashed lines; and Y, Z, θ, and F r are as defined in FIG. 7. So, in the interval between a crank angle of 240° and 300° there will be a deficit moment which is illustrated by the dashed line in FIG. 9. The orbiting scroll 21 will vibrate under these conditions. Again referring to FIG. 12, it will be noted that between 0° and 220° and between 320° and 360° the required r is consistently less than the 3.5 inches provided.
As noted above, the location of bleed holes 28 and 29 and the area of chamber 40 can be changed to shift the curve of FIG. 10 to increased values of F r which would require smaller r values. However, this adds friction and motor wattage. Alternatively, we can add radius to the plate or floor 110 of orbiting scroll 21, as shown in FIGS. 5 and 13, to meet the increased radius requirements between crank angles of 240° to 300°. Also, as illustrated in FIGS. 5 and 13, the radius can be reduced at places where the larger radius is not required such as between 0° and 220° and between 320° and 360°, or, more typically, for balancing simplification, in places approximately 180° opposed to where radius was added.
It is necessary to consider all of the extreme points of the compressor's intended operating envelope, as exemplified by the plots of FIG. 11, plus several rating points within the envelope. Then, a "best fit" of the orbiting scroll shape for a particular design can be obtained. The benefits are: (1) a lower F r curve (FIG. 10) for all design points; (2) reduced friction watts; and (3) additional space for other components where the material is removed.
Referring again to FIG. 8, all of the variables except 1 are time (crank angle) dependent. Inertia and friction forces are neglected and the following assumptions are made: (1) F gt and F' gt are essentially equal; (2) F p >F ga at all times or the scroll 20 and 21 will separate; and (3) F p and F ga mostly act in a plane defined by axes Y--Y and Z--Z and generally parallel to the vertical axis/centerline of orbiting scroll 21 (axis Z--Z).
Since F.sub.gt ≈F'.sub.gt, ΣF.sub.x =0
For ΣF.sub.Z to equal 0, F.sub.p =F.sub.r +F.sub.ga or F.sub.r =F.sub.p -F.sub.ga
For ΣMoments to equal 0, F.sub.gt l=F.sub.r r
r=(F.sub.gt l)/F.sub.r =(F.sub.gt l)/(F.sub.p -F.sub.ga)
Because F gt , F p and F ga are each crank angle (time) dependent, the value of R necessary to locate the reaction force F r at radius r is also crank angle dependent. Stated, otherwise, R must be greater than r in order to properly locate the reaction force F r but beyond a safety factor, any excess of R over r: (1) produces undesirable friction forces and wear as described above; (2) wastes space; and (3) means that F p -F ga , or F r , is too large therefore causing excessive friction. However, the final distribution of R depends upon analyzing all envelope points at which the device is intended to operate.
Starting with the design and/or calculated values of F gt , F ga and F p at all crank angles for each intended operating condition of any axially-compliant scroll device, the shape of the orbiting scroll floor 110 can be optimized by first designing in a constant reference radius R such as the 3.5 inch radius indicated in FIG. 12. Considering all crank angles for each intended operating condition, material will be added or removed (i.e. R will be increased or decreased) accordingly as prescribed by the relationship
r=(F.sub.gt l)/(F.sub.p -F.sub.ga)
Additionally, a safety factor or distance, δ, is included so that R-r≧δ at all crank angles for each intended operating condition. The final configuration is, preferably, a smoothed curve. However, as noted in FIG. 12, r is generally constant except for the 220°-340° crank angles and only the 240°-300° range is greater than 3.5 inches so the resultant shape will be essentially constant for over 240° and of an increased radius over a range of 60° to 120°. Thus the final shape can be of a distorted circle having a small section of increased radius and the rest being of a generally uniform radius as illustrated in FIG. 14 and labelled 121. Because the increased radius takes away room that might otherwise be used for locating wires, sensors, etc., as best illustrated in FIG. 5, orbiting scroll 21 is provided with the nominal 3.5 inch radius and with an area of increased radius over a nominal 90°. Additionally, in the diagonally opposite section material is removed to reduce friction and provide more room as noted above. The diagonally opposite location is preferred for ease of balancing but the reduced radius portion may be located elsewhere, if required.
Although a preferred embodiment of the present invention has been illustrated and described, other modifications will occur to those skilled in the art. It is therefore intended that the present invention is to be limited only by the scope of the appended claims. | The axial forces acting upon the orbiting scroll of a scroll compressor during operation produce a resultant force which requires a varying, crank angle dependent radius for dynamic equilibrium. The flat plate or floor portion of the orbiting scroll is provided with a varying radius to provide sufficient radius to be acted on by the resultant force. In a preferred embodiment, the radius is only increased beyond the nominal radius for the angular extent necessary and a diametrically located angular extent of reduced radius is provided to make room for other components and/or to reduce friction. | 5 |
TECHNICAL FIELD
The invention relates generally to implantable medical devices, and, in particular, to a method and apparatus for electrically isolating leads coupled to an implantable medical device from circuitry in the implantable medical device.
BACKGROUND
Numerous types of implantable medical devices (IMDs), such as cardiac pacemakers, implantable cardiovertor defibrillators (ICDs), neurostimulators, operate to deliver electrical stimulation therapies to excitable body tissue via associated electrodes. The electrodes are disposed at a targeted therapy delivery site and are commonly coupled to the IMD via conductors extending through elongated leads. Patients implanted with such IMDs are generally contraindicated for undergoing MRI procedures. The gradient magnetic fields that may be applied during an MRI procedure can induce current on the elongated lead conductors, which can be large enough to cause undesired stimulation of the excitable tissue in contact with the electrode(s) carried by the lead. As the number of patients having IMDs continues to grow, it is desirable to provide IMD systems that allow patients to safely undergo MRI procedures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of an IMD coupled to a patient's heart via a cardiac lead.
FIG. 2 is a functional block diagram of an IMD including isolation circuitry.
FIG. 3 is a timing diagram illustrating IMD function during a gradient field operating mode.
FIG. 4 is a flow chart summarizing one method for controlling isolation circuitry included in an IMD.
DETAILED DESCRIPTION
In the following description, references are made to illustrative embodiments for carrying out the invention. It is understood that other embodiments may be utilized without departing from the scope of the invention. The invention is generally directed toward providing an IMD and an associated method for protecting a patient from unwanted tissue stimulation due to current induced on implanted leads in the presence of time-varying magnetic or electrical fields, such as during MRI procedures involving gradient magnetic fields or in the presence of time-varying electrical fields associated with electronic article surveillance systems (EAS). As used herein, the term “gradient field” refers to any time varying magnetic or electrical field that is strong enough to induce current on an implanted lead and potentially cause tissue stimulation. As used herein, the term “module” refers to an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that execute one or more software or firmware programs, a combinational logic circuit, or other suitable components that provide the described functionality.
FIG. 1 is a schematic diagram of an IMD coupled to a patient's heart via a cardiac lead. IMD 10 is shown as a single chamber cardiac device, however it is recognized that various embodiments of the present invention may be implemented in single, dual, or multi-chamber cardiac devices or single or multi-channel neurostimulators. Embodiments of the present invention include IMDs provided as monitoring devices without therapy delivery capabilities. IMDs provided with therapy delivery capabilities may include, for example, cardiac pacemakers, cardioverter/defibrillators, drug delivery devices, and neurostimulators.
IMD 10 is embodied as an implantable cardioverter defibrillator (ICD) and is coupled to lead 30 for sensing cardiac signals and delivering electrical stimulation pulses to the heart in the form of cardiac pacing pulses and cardioversion/defibrillation shock pulses. Lead 30 is provided with a tip electrode 42 and ring electrode 44 which are generally used together for bipolar sensing and/or pacing functions or in combination with IMD housing 12 for unipolar sensing and/or pacing functions. Lead 30 also includes a right ventricular coil electrode 46 and a superior vena cava coil electrode 48 used in delivering high-voltage cardioversion and defibrillation shocks.
Each of the electrodes 42 , 44 , 46 and 48 are coupled to individual connectors 34 , 36 , 38 and 40 included in a proximal lead connector assembly 32 via conductors extending through elongated lead body 31 . The lead connector assembly 32 is adapted for insertion into a connector bore provided in connector header 14 of IMD 10 . Electrode terminals 50 , 52 , 54 and 56 included in connector header 14 are electrically coupled to lead connectors 34 , 36 , 38 and 40 when lead connector assembly 32 is fully inserted in the connector header bore.
Electrode terminals 50 , 52 , 54 and 56 are electrically coupled to internal IMD circuitry 16 , enclosed in hermetically sealed IMD housing 12 . Electrode terminals 50 , 52 , 54 and 56 are coupled to internal circuitry 16 via isolation circuitry 60 and protection circuitry 18 , shown schematically in FIG. 1 . The actual physical location of isolation circuitry 60 and protection circuitry 18 may be anywhere between electrode terminals 50 , 52 , 54 , and 56 and any portion of the internal circuitry 16 . The functionality of isolation circuitry 60 may be implemented using dedicated components or providing dual functionality of existing switching devices included in IMD 10 .
Isolation circuitry 60 provides protection to the patient against unwanted tissue stimulation due to current induced on conductors carried by lead body 31 . For example, in an MRI environment involving gradient magnetic fields, current induced on lead conductors can be carried along a circuit path that includes lead 30 , the IMD housing 12 , and body tissue. Isolation circuitry 60 interrupts this circuit path by introducing a high-impedance element as will be described in greater detail herein. Protection circuitry 18 is generally grounded to IMD housing 12 thereby providing a path from electrode terminals 50 , 52 , 54 , and 56 to the IMD housing 12 , completing the circuit pathway through the patient's body along which induced currents may be conducted. Isolation circuitry 60 is provided to open that circuit pathway to prevent unwanted tissue stimulation in an MRI or other gradient field environment.
Protection circuitry 18 is provided for eliminating or minimizing electromagnetic interference (EMI) that may be encountered in normal operating environments. EMI can produce a potential between any of electrodes 42 , 44 , 46 and 48 and housing 12 . Circuit elements and parasitic effects provide paths for current to flow as a result of these potentials. Protection circuitry 18 prevents EMI from being coupled to the internal circuitry 16 , which may otherwise cause inappropriate IMD function. Protection circuitry 18 typically includes electrically insulated, filtered feedthroughs such that electrical connections made between electrode terminals 50 , 52 , 54 , and 56 and internal circuitry 16 are electrically isolated from IMD housing 12 . The filtered feedthroughs typically include capacitive elements for filtering EMI. Examples of protection circuitry included in IMDs are generally disclosed in U.S. Pat. No. 5,759,197 (Sawchuk, et al.) and U.S. Pat. No. 6,414,835 (Wolf et al.), both of which patents are hereby incorporated in their entirety. Protection circuitry 18 may include other noise-reduction and protection networks for static discharge and other transient voltages that may arise due to EMI.
FIG. 2 is a functional block diagram of an IMD including isolation circuitry. IMD 10 generally includes timing and control circuitry 152 and an operating system that may employ microprocessor 154 or a digital state machine for timing sensing and therapy delivery functions in accordance with a programmed operating mode. Microprocessor 154 and associated memory 156 are coupled to the various components of IMD 10 via a data/address bus 155 . IMD 10 includes therapy delivery unit 150 for delivering an electrical stimulation therapy, such as cardiac pacing therapies, under the control of timing and control 152 . Therapy delivery unit 150 is typically coupled to two or more electrode terminals 168 via switch/multiplexer 158 . Switch/MUX 158 is used for selecting which electrodes and corresponding polarities are used for delivering electrical stimulation pulses.
Electrode terminals 168 may also be used for receiving electrical signals from the body, such as cardiac signals or other electromyogram (EGM) signals, or for measuring impedance. In the case of cardiac stimulation devices, cardiac electrical signals are sensed for determining when an electrical stimulation therapy is needed and in controlling the timing of stimulation pulses.
Electrode terminals 168 are typically included in a connector header as described in conjunction with FIG. 1 . Electrode terminals 168 may be electrically coupled to switch/MUX 158 via the isolation circuit 180 and any EMI protection circuitry 182 . The remaining functional blocks shown in FIG. 2 are typically implemented on a hybrid circuit board having contact pads for making electrical connections to protection circuitry 182 . Isolation circuitry 180 may be implemented anywhere between electrode terminals 168 and the connections to the various components included on a hybrid circuit board.
Isolation circuitry 180 , shown as a functional block in FIG. 2 , may include switching elements physically located at separate locations relative to the hybrid circuit board and IMD housing. If isolation of an associated lead from all IMD circuitry is desired, isolation circuitry 180 could be located outside the IMD housing or contained within a separate Faraday shield within the IMD housing. In other embodiments, isolation circuitry 180 may include switches used to isolate only portions of the hybrid circuitry from an associated lead and might include switching elements incorporated on the hybrid circuit board.
Switching elements already present in the IMD circuitry may be utilized to provide the isolation circuit functionality as well as other functions. For example, IMD 10 may be provided with switches used for protecting IMD circuitry from voltages produced by external defibrillation. Switches 185 a through 185 d may include such switches. In other words, any of switches 185 a through 185 d serving functionally as a part of isolation circuit 180 for protecting the patient from induced current in the presence of time-varying EM fields may be embodied as a switch already provided in IMD 10 for protecting the IMD circuitry from voltages produced by external defibrillation.
Electrodes used for sensing and electrodes used for stimulation may be selected via switch matrix 158 . When used for sensing, electrode terminals 168 are coupled to signal processing circuitry 160 via switch matrix 158 . Signal processor 160 includes sense amplifiers and may include other signal conditioning circuitry and an analog to digital converter. Electrical signals may then be used by microprocessor 154 for detecting physiological events, such as detecting and discriminating cardiac arrhythmias.
In some embodiments, microprocessor 154 uses signals received at electrode terminals 168 for automatically detecting induced signals associated with a gradient field, such as a time-varying magnetic field associated with MRI. Alternatively, a gradient field sensor circuit 186 may be provided for sensing external signals corresponding to a time-varying MRI or other gradient field environment. Gradient field sensor circuit 186 may be embodied according to the sensor circuit generally disclosed in U.S. Pat. No. 6,198,972 (Hartlaub et al.), hereby incorporated herein by reference in its entirety. Gradient field sensor circuit 186 may be located anywhere in a patient's body and may therefore alternatively be coupled to IMD circuitry via a sensor terminal 170 . In response to a gradient field detection signal generated by gradient field sensor circuit 186 , microprocessor 154 causes timing and control circuitry 152 to generate a signal on signal line 184 that opens switches 185 a through 185 d included in isolation circuitry 180 . The circuit path through the IMD housing and the patient's body is effectively opened thereby preventing unwanted tissue stimulation due to induced currents on implanted leads coupled to IMD 10 . During MRI, a sensor that detects the very strong static magnetic field may be used alone or in conjunction with other sensors to activate isolation circuitry 180
IMD 10 may additionally or alternatively be coupled to one or more physiological sensors. As such, physiological sensor terminals 170 are provided and are electrically coupled to a sensor interface 160 via protection circuitry 182 . Sensor terminals 170 may also be electrically coupled to IMD circuitry, or portions of IMD circuitry, through isolation circuitry 180 when terminals 170 are coupled to elongated leads that could carry induced currents to body tissue. Physiological sensors may include pressure sensors, accelerometers, flow sensors, blood chemistry sensors, activity sensors or other physiological sensors known for use with IMDs.
Signals received at sensor terminals 170 are received by a sensor interface 162 which provides sensor signals to signal processing circuitry 160 . Sensor signals are used by microprocessor 154 for detecting physiological events or conditions. For example, IMD 10 may monitor heart wall motion, blood pressure, blood chemistry, respiration, or patient activity. Monitored signals may be used for sensing the need for delivering a therapy under control of the operating system.
The operating system includes associated memory 156 for storing a variety of programmed-in operating mode and parameter values that are used by microprocessor 154 . The memory 156 may also be used for storing data compiled from sensed physiological signals and/or relating to device operating history for telemetry out on receipt of a retrieval or interrogation instruction. All of these functions and operations are known in the art, and many are generally employed to store operating commands and data for controlling device operation and for later retrieval to diagnose device function or patient condition.
IMD 10 further includes telemetry circuitry 164 and antenna 128 . Programming commands or data are transmitted during uplink or downlink telemetry between IMD telemetry circuitry 164 and external telemetry circuitry included in a programmer or monitoring unit. Telemetry circuitry 164 and antenna 128 may correspond to telemetry systems known in the art. In one embodiment of the invention, a gradient field mode command is transmitted to IMD telemetry circuitry 164 by a clinician or other user using an external programmer. In response to the gradient field mode command, microprocessor 154 causes timing and control circuitry 152 to generate a signal on signal line 184 to open switches included in isolation circuitry 180 .
During a gradient field operating mode, electrode terminals 168 (and/or sensor terminals 170 ) are electrically disconnected from IMD circuitry by introducing a high-impedance element included in isolation circuitry 180 . Isolation circuitry 180 generally includes switches 185 a through 185 d which may be embodied as electro-mechanical relays, semiconductor devices, or MEMS relays. Switches 185 included in isolation circuitry 180 may be implemented as generally described in the above-incorporated Hartlaub patent. It is recognized that each of switches 185 a through 185 d may include one or more electronic switches coupled in series to form a high-impedance element through isolation circuitry 180 . The number of switches 185 included in isolation circuitry 180 will vary between applications and will correspond to the number of electrode terminals 168 and sensor terminals 170 that need to be electrically disconnected from the IMD ground path to prevent conduction of currents induced on elongated lead conductors during MRI procedures or in the presence of other gradient EM fields.
When microprocessor 156 determines that an electrical stimulation therapy is needed, or if an electrical stimulation therapy is in process upon initiation of the gradient field operating mode, timing and control circuitry 152 generates a transient “close” signal on signal line 184 . The “close” signal is generated just prior to or contemporaneously with the generation of an electrical stimulation pulse by therapy delivery unit 150 . A stimulation pulse generated by therapy delivery unit 150 is delivered to electrode terminals 168 across isolation circuitry 180 . The “close” signal causes at least one switch included in isolation circuitry 180 that corresponds to a selected stimulation electrode to briefly close so that the stimulation pulse can be delivered. Other switches included in isolation circuitry 180 may remain open during stimulation pulse delivery. Accordingly, it is understood that signal line 184 may carry a multiplexed signal for operating multiple switches included in isolation circuitry 180 individually. With regard to the embodiment shown in FIG. 1 , a switch coupled to electrode terminal 56 corresponding to tip electrode 42 may be controlled separately from a switch coupled to electrode terminal 54 , corresponding to ring electrode 44 to allow unipolar stimulation using tip electrode 42 during a gradient field operating mode.
IMD 10 may optionally be equipped with patient alarm circuitry 166 for generating audible tones, a perceptible vibration, muscle stimulation or other sensory stimulation for notifying the patient that a patient alert condition has been detected by IMD 10 . In some embodiments, an alarm signal may be generated upon detection of a gradient field or upon initiating a gradient field mode of operation.
FIG. 3 is a timing diagram illustrating IMD function during a gradient field operating mode. At a time 202 , a gradient field mode is initiated in response to a gradient field operating mode command or the automatic detection of gradient field signals, corresponding to a time-varying MRI field or other gradient EM field, by a gradient field sensor circuit. Two biasing signals 205 and 215 are provided to individual switches, for example MOSFETs, included in isolation circuitry. Initially, prior to the initiation of gradient field operating mode at time 202 , the MOSFET switches are biased with high signals 208 and 214 that maintain the switches in a closed or ON operative state. For example, a MOSFET may be biased to 5.0 volts relative to circuit common to hold the transistor in the ON state to allow normal sensing and therapy delivery functions.
Upon initiation of the gradient field operating mode at time 202 , biasing signals 205 and 215 are switched to low signals 210 and 216 to open the corresponding MOSFETs to an OFF operative state. For example, the MOSFETs may be biased to 0.0 volts relative to circuit common to hold the transistor in the OFF state to prevent conduction of induced currents to excitable body tissue. A feedback or bootstrap network could be used to maintain the correct state of the MOSFET.
Pacing pulses 206 a , 206 b , 206 c through 206 n are delivered after the initiation of gradient field mode at time 202 . Pacing therapy may have been in progress at the time of initiating the gradient field mode or a need for pacing therapy may be detected during the gradient field mode using other sensors or circuits that are not opened by isolation circuitry. In pacing dependent patients, initiation of the gradient field mode may include maintaining a predetermined pacing rate. Reference is made to U.S. Pat. App. Pub. No. 2003/0144705 (Funke), hereby incorporated herein by reference in its entirety. Intrinsic cardiac signals may be sensed during the gradient field operating mode through high impedance signal path sensing channels or utilize a gradient energy cancellation sensing method.
In order to deliver pacing pulses 206 a through 206 n , at least one switch (for unipolar pacing) included in isolation circuitry is transiently closed by generating a high biasing signal 212 a , 212 b , 212 c , 212 n at appropriate times relative to pacing pulses 206 a through 206 n . In order to deliver bipolar pacing pulses, two switches may be transiently closed during pacing pulse delivery. Timing and control module 152 ( FIG. 2 ) controls the alternation between high and low bias signal levels applied to isolation circuit switches to control the operative state of the switches. A switch is closed to close a pacing or electrical stimulation circuit at appropriate times during the gradient field mode to allow therapeutic stimulation to be performed, for example during MRI procedures. The switch(es) included in a pacing or electrical stimulation circuit are briefly closed for an interval of time starting just prior to or approximately the same time as a stimulation pulse and extending for a time at least equal to the stimulation pulse width. While the timing diagram shown in FIG. 3 illustrates the delivery of cardiac pacing pulses, it is recognized that any type of electrical stimulation pulses may be delivered during a gradient field mode by controlling the opening and closing of switches included in isolation circuitry. For example the need for high-voltage cardioversion/defibrillation shocks may be detected based on sensing intrinsic signals using a gradient energy cancellation method and high energy therapies may be delivered based on determining a reliable sensing signal for arrhythmia detection.
FIG. 4 is a flow chart summarizing one method for controlling isolation circuitry included in an IMD. Flow chart 300 is intended to illustrate the functional operation of the device, and should not be construed as reflective of a specific form of software or hardware necessary to practice the invention. It is believed that the particular form of software will be determined primarily by the particular system architecture employed in the device and by the particular detection and therapy delivery methodologies employed by the device. Providing software and/or hardware to accomplish the present invention in the context of any modern IMD, given the disclosure herein, is within the abilities of one of skill in the art.
The IMD microprocessor initiates a gradient field operating mode at block 306 . The gradient field operating mode is initiated in response to receipt of an external command provided to the IMD using a programmer or other device enabled for telemetric communication with the IMD (block 304 ). The gradient field operating mode is alternatively initiated in response to the detection of external or internal high level signals corresponding to an MRI or other time-varying EM environment by gradient field sensor circuit at block 302 .
Upon initiation of the gradient field mode, switches included in isolation circuitry are opened at block 310 . A gradient magnetic field may induce currents on implanted lead conductors large enough to cause tissue stimulation. Opening of isolation circuitry switches opens the circuit path through the capacitive feedthrough elements and the IMD housing and patient's body, preventing conduction of induced currents and unwanted tissue stimulation.
At decision block 314 , timing and control module 152 determines if a therapeutic stimulation pulse is needed based on programmed therapy delivery mode. Upon triggering the generation of a therapy stimulation pulse, timing and control 152 generates a signal to transiently close one or more isolation circuitry switches included in a stimulation circuit path in order to allow stimulation pulse delivery at block 318 .
Throughout the gradient field mode, the IMD microprocessor monitors for receipt of an external command indicating that a normal operating mode should be restored at decision block 322 . Additionally or alternatively, the IMD microprocessor automatically monitors for an end to the detection of gradient signals by a gradient field sensor. In other embodiments, the gradient field mode may be maintained for a fixed interval of time after gradient field mode initiation. For example, the gradient field mode may be maintained for 30 minutes, one hour, or another interval of time that is expected to extend safely beyond the completion of an MRI procedure. As long as the gradient field mode is maintained, timing and control module 152 continues to control transient closure of stimulation circuit path switches included in isolation circuitry contemporaneously with the generation of therapeutic stimulation pulses at block 318 .
Upon expiration of the gradient field mode according to a predetermined time interval, receipt of an external termination command, or loss of gradient field signal detection at decision block 318 , isolation circuitry switches are closed at block 326 . Closure of isolation switches restores normally closed sensing and stimulation circuit paths for normal IMD operation. The gradient field operation mode is then terminated at block 330 .
Thus, an IMD and associated methods for protecting a patient from unwanted tissue stimulation during exposure to time-varying electrical or magnetic fields has been presented in the foregoing description with reference to specific embodiments. It is appreciated that various modifications to the referenced embodiments may be made without departing from the scope of the invention as set forth in the following claims. | An implantable medical device is provided for isolating an elongated medical lead from internal device circuitry in the presence of a gradient magnetic or electrical field. The device includes an isolation circuit adapted to operatively connect an internal circuit to the medical lead in a first operative state and to electrically isolate the medical lead from the internal circuit in a second operative state. | 0 |
This application is a continuation-in-part of U.S. application Ser. No. 09/912,977, filed Jul. 25, 2001, now U.S. Pat. No. 6,401,842, which claims the benefit of U.S. Provisional Patent Application No. 60/221,413, filed Jul. 28, 2000.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a drill device for a drilling a hole in the earth.
2. Description of the Prior Art
U.S. Pat. Nos. 4,281,723, 4,953,638, 5,423,388, 5,490,569, 5,957,222, 6,050,350, and 6,082,470 disclose drilling apparatus.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a drill device for drilling a hole in the earth. The drill device comprises a body having a front end and a rear end with a central axis extending between the front and rear ends and being connectable to a rotatable means. At least one slot is formed in the exterior of the body which is located outward relative to the central axis and which extends between the front and rear ends. The slot has a lip extending from its front and rear ends respectively. A cutting means is provided for the slot with the cutting means comprising a connecting portion located in the slot and having a forward end and a rearward end. The connecting portion comprises a hook near its front and rear ends respectively for connection to the lips of the slot. A removable stop means is positioned to prevent longitudinal movement of the connecting portion of the cutting means relative to the slot.
In another aspect, the plurality of angularly spaced apart slots are formed in the exterior of the body each for holding one of the cutting means.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 illustrates the top view of a drilling apparatus in the straight drilling mode.
FIG. 2 illustrates the side view of the drilling apparatus in the straight drilling mode.
FIG. 3 is a side cross sectional view of the parts of the apparatus that are locked longitudinally with the guide housings.
FIG. 4 is a top cross sectional view of the parts of the apparatus that are locked longitudinally with the guide housings.
FIG. 5 is a side cross sectional view of the parts of the apparatus that are locked longitudinally with the shaft.
FIG. 6 illustrates the top cross sectional view of the parts that are locked longitudinally with the shaft.
FIG. 7 is a cross sectional view of FIG. 1 taken along the lines 7 — 7 thereof.
FIG. 8 is a cross sectional view of FIG. 1 taken along the lines 8 — 8 thereof.
FIG. 9 is a top view of the drilling apparatus in the shifting mode.
FIG. 10 is a side view of the drilling apparatus in the shifting mode positioned in a curved hole.
FIG. 11 is a cross sectional view of FIG. 9 taken along the lines of 11 — 11 thereof.
FIG. 12 is the cross sectional view of FIG. 9 taken along the lines of 12 — 12 thereof.
FIG. 13 is a cross sectional view of FIG. 10 taken along the lines of 13 — 13 thereof.
FIG. 14 is a cross sectional view of FIG. 7 taken along the lines of 14 — 14 thereof.
FIG. 15 is a cross sectional view of FIG. 8 taken along the lines of 15 — 15 thereof.
FIG. 16 is a cross sectional view of FIG. 11 taken along the lines of 16 — 16 thereof.
FIG. 17 is a cross sectional view of FIG. 12 taken along the lines of 17 — 17 thereof.
FIG. 18 is a cross sectional view of FIG. 12 taken along the lines of 18 — 18 thereof when the clutch is in the neutral position.
FIG. 19 is a cross sectional view of FIG. 12 taken along the lines of 18 — 18 thereof, which is the same lines as FIG. 18 was taken from but when the shaft has been rotated in order to rotate the drilling apparatus.
FIG. 20 is a top view of the drilling apparatus in the major turn mode.
FIG. 21 is a side view of the drilling apparatus in the major turn mode.
FIG. 22 is a cross sectional view of FIG. 20 taken along the lines of 22 — 22 thereof.
FIG. 23 is a cross sectional view of FIG. 20 taken along the lines of 23 — 23 thereof.
FIG. 24 is a cross sectional view of FIG. 22 taken along the lines of 24 — 24 thereof.
FIG. 25 is a cross sectional view of FIG. 23 taken along the lines of 25 — 25 thereof.
FIG. 26 is a top view of the drilling apparatus in the minor turn mode.
FIG. 27 is a side view of the drilling apparatus in the minor turn mode.
FIG. 28 is a cross sectional view of FIG. 26 taken along the lines of 28 — 28 thereof.
FIG. 29 is a cross sectional view of FIG. 26 taken along the lines of 29 — 29 thereof.
FIG. 30 is a top view of the drilling apparatus in the partially pulled back mode.
FIG. 31 is a side view of the drilling apparatus in the partially pulled back mode.
FIG. 32 is a cross sectional view of FIG. 30 taken along the lines of 32 — 32 thereof.
FIG. 33 is a cross sectional view of FIG. 30 taken along the lines of 33 — 33 thereof.
FIG. 34 is an isometric view of the shifting cam.
FIG. 35 is 360-degree flat view of the exterior of the shifting cam
FIG. 36 is a 180-degree flat view of the shifting cam and the shifting cam follower in the straight drilling mode.
FIG. 37 is a 180-degree flat view of the shifting cam lug contacting the shifting cam groove intersection.
FIG. 38 is a 180-degree flat view of the shifting cam with the shifting cam followers in full rearward position.
FIG. 39 is a 180-degree flat view of the shifting cam with the shifting cam follower lug contacting an intersection of the shifting cam grooves.
FIG. 40 is a 180-degree flat view of the shifting cam with the shifting cam follower in transition between the full rearward position and the full forward position.
FIG. 41 is a 180-degree flat view of the shifting cam with the shifting cam follower in the fully forward position.
FIG. 42 is a 360-degree flat view of the shifting cam with the shifting cam follower lugs contacting an intersection of the shifting cam grooves.
FIG. 43 is a 360-degree flat view of the shifting cam with the shifting cam followers in transition between the major turn position and the rearward position before drilling straight.
FIG. 44 is a 360-degree flat view of the shifting cam with the shifting cam followers by-passing the by-pass groove of the shifting cam.
FIG. 44A is a 180-degree flat view of the shifting cam with the shifting cam follower lug stopped by the end of the shifting cam groove.
FIG. 44B is a 180-degree flat view of the shifting cam with the shifting cam follower lug contacting the intersection of the grooves in the shifting cam.
FIG. 44C is a 180-degree flat view of the shifting cam with the shifting cam follower in the straight position.
FIG. 44D is a 180-degree flat view of the shifting cam with the shifting cam follower contacting an intersection of the shifting cam grooves.
FIG. 44E is a 180-degree flat view of the shifting cam with the shifting cam follower in the full rearward position.
FIG. 44F is a 180-degree flat view of the shifting cam with the shifting cam follower lug contacting an intersection of the shifting cam grooves.
FIG. 44G is a 180-degree flat view of the shifting cam with the shifting cam follower's forward displacement halted in preparation to start the minor turn sequence.
FIG. 44H is a 180-degree flat view of the shifting cam with the shifting cam follower contacting an intersection of the shifting cam grooves.
FIG. 44 (I) is a 180-degree flat view of the shifting cam with the shifting cam follower fully rearward in the minor turn sequence.
FIG. 44J is a 360-degree flat view of the shifting cam with the shifting cam followers in transition from the fully rearward position to the minor turn position.
FIG. 44K is a 360-degree flat view of the shifting cam with the shifting cam followers exiting the by-pass groove.
FIG. 44L is a 360-degree flat view of the shifting cam with the shifting cam followers heading toward the minor turn stop.
FIG. 44M is a 360-degree flat view of the shifting cam with the shifting cam follower lugs stopped by the minor turn stop.
FIG. 44N is a 180-degree flat view of the shifting cam with the shifting cam follower in transition between the minor turn and the rearward stop before going straight. This view shows the shifting cam follower missing the by-pass groove.
FIG. 44 (O) is a 180-degree flat view of the shifting cam with the shifting cam follower in transition between the minor turn and the rearward stop before going straight.
FIG. 44P is a 180-degree flat view of the shifting cam with the shifting cam follower in the fully rearward position before going straight.
FIG. 45 is an isometric view of the clutch stop.
FIG. 45A is an enlargement of the clutch stop lug.
FIG. 46 is an isometric view of the front of the female clutch member.
FIG. 47 is an isometric view of the rear of the female clutch member.
FIG. 48 is an isometric view of the rear of the male clutch member.
FIG. 49 is a cutout section of the guide housing showing the clutch members in a relaxed position.
FIG. 50 is a cutout section of the guide housing showing the clutch members engaging each other.
FIG. 51 is a front view of the shaft retainer cut to hold the rotational cutting means.
FIG. 52 is a side view of the shaft retainer.
FIG. 53 is a rear view of the shaft retainer.
FIG. 54 is a cross sectional view of FIG. 52 taken along the line 54 — 54 thereof.
FIG. 55 is a side view of the assembled rotational cutting means.
FIG. 56 is a front view of the assembled rotational cutting means.
FIG. 57 is a rear view of the assembled rotational cutting means.
FIGS. 58-65 shows the coupling procedure of the rotational cutting means.
FIG. 66 is a cross sectional view of the front end of the drilling apparatus showing the magnetic displacement device in use.
FIG. 67 is a cross sectional view of FIG. 66 taken along the line 67 — 67 thereof.
FIG. 68 is an isometric view of the transmitter housing with magnetic sensitive wires positioned to indicate longitudinal displacement of the shaft.
FIG. 69 is a cross sectional view of the rear of the apparatus using a longer clutch means.
FIG. 70 is a top view of the drilling apparatus with a third housing attached.
FIG. 71 is a side view of the drilling apparatus with a third housing attached.
FIG. 72 is a cross sectional view of FIG. 70, using a standard transmitter, taken along the lines 72 — 72 thereof.
FIG. 73 is a cross sectional view of FIG. 70, using a Wireline transmitter, taken along the lines 73 — 73 thereof.
FIG. 74 is an illustration of the alternative drilling apparatus using a percussion type cutting means in the straight drilling mode.
FIG. 75 is an illustration of the alternative drilling apparatus using a percussion type cutting means in the shifting mode.
FIG. 76 is an illustration of the alternative drilling apparatus using a percussion type cutting means in the turning mode.
FIG. 77 is an illustration of the alternative drilling apparatus using a rotational type cutting means in the straight drilling mode.
FIG. 78 is an illustration of the alternative drilling apparatus using a rotational type cutting means in the shifting mode.
FIG. 79 is an illustration of the alternative drilling apparatus using a rotational type cutting means in the turning mode.
FIG. 80 is a cross sectional view of FIG. 74 and FIG. 77 taken along the lines of 80 — 80 thereof.
FIG. 81 is a cross sectional view of FIG. 75 and FIG. 78 taken along the lines of 81 — 81 thereof.
FIG. 82 is a cross sectional view of FIG. 76 and FIG. 79 taken along the lines of 82 — 82 thereof.
FIG. 83 is a cross sectional view of FIG. 79 taken along the lines of 83 — 83 thereof.
FIG. 84 is a 180-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower in the fully forward position.
FIG. 85 is a 180-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower contacting an intersection of the alternative shifting cam grooves.
FIG. 86 is a 180-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower in transition between fully forward and fully rearward positions.
FIG. 87 is a 180-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower in the fully rearward position.
FIG. 88 is a 180-degree view of the alternative-shifting cam with the alternative-shifting cam follower contacting an intersection of the alternative-shifting cam grooves.
FIG. 89 is a 180-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower in transition between the fully rearward position and the straight position.
FIG. 90 is a 180-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower in the straight position.
FIG. 91 is a 180-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower in contact with an intersecting groove.
FIG. 92 is a 180-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower in transition from the straight position to the fully rearward position.
FIG. 93 is a 180-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower in the fully rearward position.
FIG. 94 is a 180-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower contacting an intersection of the grooves.
FIG. 95 is a 270-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower in transition between fully rearward and fully forward positions.
FIG. 96 is the rear view of a hole-opener body.
FIG. 97 is a cross sectional view of the hole-opener body taken along the lines 97 — 97 thereof.
FIG. 98 is a front view of the hole-opener body.
FIGS. 99-104 shows the rotational cutting means being mounted on to the hole-opener body.
FIG. 105 shows the side view of the hole-opener body with the rotational cutting means mounted thereto.
FIG. 106 illustrates the hole opener device of FIG. 105 in use enlarging a hole.
FIG. 107 illustrates a single modified wing type cutting means installed in a single slot of a shaft retainer.
FIG. 108 illustrates a single roller cone but attached to a plate holding mechanism installed in a single slot of a shaft retainer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-65 of the drawings, the apparatus comprises a shaft 101 having a rear end 101 R connectable to a drilling system 103 and a rotational cutting means 105 connectable to the front end 101 F. The shaft 101 extends through a front housing 111 and a rear housing 113 . The drilling system is a conventional system that can rotate and push the shaft 101 forward for drilling purposes and it can also pull the shaft 101 rearward. Additional stem members can be attached to the rear 101 R of the shaft 101 and to the drilling system 103 as the hole being drilled gets longer or deeper. The shaft 101 can rotate within each of units 111 and 113 , and can move forward a small distance to a drilling position and rearward a small distance to a shifting position relative to units 111 and 113 . Units 111 and 113 cannot rotate relative to each other, but they can bend or pivot lengthwise relative to each other, as shown in FIGS. 21-23 and 27 - 29 .
A front ball joint 115 with pivot pins 117 located at the front of unit 111 supports unit 111 on the front of the shaft 101 F. A middle ball joint 119 with a rear end 119 R connects the rear of unit 111 with the front of unit 113 . A rear ball joint 121 with pivot pins 121 A similar to the front ball joint 115 supports the rear of unit 113 on the rear of shaft 101 R.
A main cam 123 and a main cam follower 163 are employed in unit 113 to cause the apparatus to drill straight as shown in FIGS. 1 and 2 or to tilt or pivot units 111 and 113 relative to the shaft 101 as shown in FIGS. 21-23 and 27 - 29 to cause the front of the shaft 101 F to turn up, down, left, or right or any fraction thereof while drilling operations are being carried out. A shifting cam 145 is also located in unit 113 for the purpose of regulating the straight and turn drilling by regulating the amount of longitudinal displacement between the main cam 123 and the main cam follower 163 .
For reference, in the drawings, the top of the drilling apparatus is on the inside of the radius being drilled, such that if the hole is being turned up relative to the earth, the top of the drilling apparatus is up relative to the earth. Likewise if the bore is being turned downward relative to the earth, the drilling apparatus is turned upside down, and so on. Referring to FIG. 3 and FIG. 4, the front housing 111 has fixedly attached to it, a front socket 127 , a transmitter case 129 , a middle socket 131 , and a front wear pad 133 . The front socket 127 encases the front ball 115 so that the front housing 111 may pivot relative to the shaft 101 . The transmitter case 129 is accessible through a cutout 135 in the side of the front housing 111 . The door 129 D covers the transmitter 137 . The transmitter case 129 holds the compartment for the transmitter 137 employed by the drilling apparatus. The middle socket 131 encases the middle ball 119 so that the front housing 111 may pivot relative to the rear housing 113 . The middle socket 131 and the middle ball 119 are pinned together so that they cannot rotate relative to each other, such that the two housings 111 and 113 cannot rotate relative to each other. The front wear pad 133 is located on the bottom of the drilling apparatus, such that it pushes against the bore wall 179 to cause the drilling apparatus to turn. The rear of the middle ball 119 R is fixedly attached to the front of the rear housing 113 . The rear housing 113 has fixedly attached to it a main cam 123 , a stop plate 141 , a shifting cam bushing 143 , a stop bushing 167 B, a clutch stop 147 , a rear socket 149 , and a rear wear pad 151 . The shifting cam bushing 143 supports a shifting cam 145 . The shifting cam 145 is free to rotate, but is locked longitudinally relative to the rear housing 113 . The clutch stop 147 is fixedly attached to the housing 113 and limits the rotational and forward movement of a female clutch member 153 . The rear socket 149 limits the rearward movement of the female clutch member 153 . The female clutch member 153 is free to rotate relative to the rear housing 113 only enough to allow the male clutch member 171 to engage with female clutch member 153 without regards to their starting rotational orientation.
Referring to FIGS. 5 and 6 the shaft 101 has attached to it a shaft retainer 155 upon which; in this case, a rotational cutting means 105 is mounted. The cutting means 105 may be a conventional rotary type as shown or it may be a hammering system that is commonly employed in harder strata and illustrated in FIGS. 74-76. Behind the shaft retainer 155 are two sleeves 157 and 159 that rotate with the shaft 101 and hold the other components longitudinally in place. Behind the sleeves 157 and 159 are a thrust bearing 161 , a main cam follower 163 , a cam follower spacer 165 , a thrust bearing 169 , and a male clutch member 171 . The cam follower 163 and cam follower spacer 165 are free to rotate relative to the shaft 101 , but are tied longitudinally to the shaft 101 by the shaft retainer 155 , the two sleeves 157 and 159 , the thrust bearings 161 and 165 and the shoulder 101 S of the shaft 101 . The shaft 101 can rotate relative to the cam follower 163 and spacer 165 . Mounted on the rear of the shaft 101 R is a rearward cutter 173 . The rearward cutter 173 contains threads for accepting a thread adapter 175 that joins the drilling apparatus to the drill string and ultimately the drilling system 103 . Two shifting cam followers 177 A and 177 B are mounted 180 degrees from each other and 90 degrees from the cam follower lugs 163 S and 163 L on the outside of the cam follower 163 . The shifting cam followers 177 A and 177 B are free to pivot relative to the cam follower 163 , but are locked longitudinally to the cam follower 163 by pins 163 P. The shifting cam followers 177 A and 177 B are locked rotationally to the housing 113 but are free to move longitudinally relative to the housing 113 . The followers 177 A and 177 B cannot rotate relative to the housing 113 .
Referring to FIGS. 3-44 the main cam 123 has two slots cut into it, 180 degrees apart. The bottoms of the slots stay relatively parallel to each other. The bottom of the slots start out in the rear of the main cam 123 close to the bottom of the drilling apparatus and progress in several stages close to the top of the drilling apparatus as they progress to the front. The slots accept the main cam follower lugs 163 S and 163 L. The sides of slots keep the main cam follower 163 rotationally engaged to the rear housing 113 for rotation with the rear housing 113 as well as giving support for side loaded pressure placed on the drilling apparatus. The large cam follower lug 163 L is located on the bottom of the drilling apparatus, while the small cam follower lug 163 S is located on the top of the drilling apparatus. As the main cam follower 163 is displaced forward relative to the main cam 123 , the main cam follower lugs 163 S and 163 L follow the slots in the main cam 123 . This causes the front of the rear housing 113 and the rear of the front housing 111 to pivot downward away from the shaft 101 , such that the bore wall 179 is pushed on by the wear pad 133 and the drilling apparatus is caused to change directions. When the main cam follower 163 is displaced fully rearward, the front of the rear housing 113 and the rear of the front housing 111 are pivoted upward toward the shaft 101 . This causes the wear pad 133 to be pulled in as close as possible to the shaft 101 .
Referring to FIGS. 34-44P, the shifting cam 145 and shifting cam followers 177 A and 177 B regulate the amount of longitudinal displacement that the main cam 123 and main cam follower 163 undergo. In FIGS. 35-44P the exterior surface of the cam 145 is shown laid out flat. The two cam followers 177 A and 177 B are located 180 degrees apart. In FIGS. 35, 42 - 44 , and 44 J- 44 M, 360 degrees of the cam is shown and in FIGS. 42-44 and 44 J- 44 M both cam followers 177 A and 177 B are shown. In FIGS. 36-41, 44 A- 44 (I) and 44 N- 44 P only 180 degrees of the cam 145 is shown and only one cam follower 177 B is shown although it is to be understood that the complete cam of FIGS. 34 and 35 and both followers 177 A and 177 B will be employed. In FIGS. 36-44P the horizontal arrows depict the direction of longitudinal travel of the followers 177 A and 177 B and the vertical arrows next to the cam 145 depict the direction of rotation of the cam 145 . In FIGS. 36-44P, rearward movement of the followers 177 A and 177 B is to the right and forward movement of the followers 177 A and 177 B is to the left. The lugs 177 AL and 177 BL of the cams 177 A and 177 B can be moved between positions displaced fully rearward as shown by follower 177 B in FIG. 38 and to positions fully displaced forward as shown by follower 177 B in FIG. 41 and to intermediate positions. Grooves 145 A- 145 E are cut into the outside of the shifting cam 145 at an angle such that when the shifting cam followers 177 A and 177 B are displaced longitudinally they contact the walls of the grooves 145 A- 145 E, which rotate the shifting cam 145 . Furthermore, the lugs 177 AL and 177 BL on the shifting cam followers 177 A and 177 B are shaped in such away as to ride along the walls of the grooves 145 A- 145 E and to enter into an intersecting groove 145 AB- 145 DE when the appropriate displacement and rotational positioning is achieved.
FIG. 36 shows the shifting cam follower 177 B in the straight drilling position. In this position the shifting cam followers 177 A and 177 B, and thus the main cam follower 163 , cannot progress any further forward relative to the shifting cam 145 , and thus the main cam 123 , because the shifting cam follower lugs 177 AL and 177 BL are in contact with end of the shifting cam grooves 145 E. Displacing the shifting cam followers 177 A and 177 B rearward causes them to contact the next set of intersecting grooves 145 DE (FIG. 37 ). When the shifting cam followers 177 A and 177 B are displaced further rearward the shifting cam 145 is forced to rotate by the shifting cam follower lugs 177 AL and 177 BL pushing on the walls of the shifting cam grooves 145 D. The contact of the main cam follower lugs 163 S and 163 L and the stop ring 141 halt the rearward longitudinal displacement of the shifting cam followers 177 A and 177 B relative to the shifting cam 145 (FIG. 38 and FIG. 12 ). In this longitudinal position the clutch members 153 and 171 are engaged and the housing 113 may be rotated with the shaft 101 . When the desired rotational position is achieved, the shifting cam followers 177 A and 177 B can be moved forward relative to the shifting cam 145 until they contact the next set of intersecting grooves 145 AD (FIG. 39 ). As the shifting cam followers 177 A and 177 B are further displaced forward relative to the shifting cam 145 , the shifting cam follower lugs 177 AL and 177 BL push on the wall of the shifting cam grooves 145 A forcing the shifting cam 145 to rotate relative to the housing 113 (FIG. 40 ). The shifting cam followers 177 A and 177 B do not rotate relative to the housing 113 because they are held rotationally locked to the housing 113 by the shifting cam bushings 143 . The contact of the stop washer 167 and the stop bushing 167 B halts the further forward displacement of the shifting cam followers 177 A and 177 B relative to the shifting cam 145 as well as the forward displacement of the main cam follower 163 relative to the main cam 123 (FIG. 41 and FIG. 23 ). In this position the tightest radius is being drilled. Displacing the shifting cam followers 177 A and 177 B rearward causes them to contact yet another set of intersecting grooves 145 AC (FIG. 42 ). Further rearward displacement causes the shifting cam follower lugs 177 AL and 177 BL to push on the walls of shifting cam grooves 145 C, forcing the shifting cam 145 to rotate relative to the housing 113 (FIG. 43 ). FIG. 44 shows the shifting cam followers 177 A and 177 B moving passed the by-pass groove 145 B without entering it. This is possible by the widening of the grooves 145 C in this location. The contact of the end of the shifting cam grooves 145 C and the shifting cam follower lugs 177 AL and 177 BL stops the rearward displacement of the shifting cam followers 177 A and 177 B relative to the shifting cam 145 (FIG. 44 A). In this embodiment the clutch members 171 and 153 are not engaged in this position, allowing the operator to know that upon pushing forward he will be drilling straight because the next intersecting groove leads to the straight position. Displacing the shifting cam followers 177 A and 177 B forward causes the shifting cam follower lugs 177 AL and 177 BL to contact the intersections of yet another set of shifting cam grooves 145 CE (FIG. 44 B). Further forward displacement of the shifting cam followers 177 A and 177 B causes the shifting cam follower lugs 177 AL and 177 BL to push on the shifting cam groove walls, which causes the shifting cam 145 to rotate relative to the housing 113 . The contact of the shifting cam follower lugs 177 AL and 177 BL and the end of the shifting cam grooves 145 E stops the forward displacement of the shifting cam followers 177 A and 177 B relative to the shifting cam 145 and thus, the forward displacement of the main cam follower 163 relative to the main cam 123 (FIG. 44 C). In this position the housings 111 and 113 are virtually parallel with the shaft 101 , thus causing zero effect on the direction of travel, which allows the drilling apparatus to drill straight. In this embodiment the clutch members 171 and 153 are not engaged, which allows the shaft 101 to rotate without rotating the housing 113 . While drilling straight the housings 111 and 113 slide through the bore being drilled. Rearward displacement of the shifting cam followers 177 A and 177 B causes them to contact the next set of intersecting grooves 145 DE (FIG. 44 D). Further rearward displacement causes the shifting cam 145 to rotate relative to the housing 113 . Contact between the main cam follower lugs 163 S and 163 L and the stop plate 141 stops the rearward displacement between the shifting cam followers 177 A and 177 B and the shifting cam 145 (FIG. 44 E and FIG. 12 ). Forward displacement of the shifting cam followers 177 A and 177 B causes the shifting cam follower lugs 177 AL and 177 BL to contact the next set of intersecting grooves 145 AD (FIG. 44 F). Further forward displacement of the shifting cam followers 177 A and 177 B causes the shifting cam follower lugs 177 AL and 177 BL to push on the shifting cam groove walls causing the shifting cam 145 to rotate relative to the housing 113 . By halting the forward displacement of the shifting cam followers 177 A and 177 B relative to the shifting cam 145 before the shifting cam follower lugs 177 AL and 177 BL are displaced enough to enter the intersecting grooves 145 AC, but after they have passed the entrance of the by-pass grooves 145 AB, the operator has a choice to either drill straight or at least drill a lesser deviated hole (FIG. 44 G). The forward displacement of the shifting cam followers 177 A and 177 B may be stopped by the operator or by the hard surface of the bore wall. For example, if the cutting means 105 or 247 is not activated, by either the rotation of the shaft or the supply of a compressed medium, such as air or water, after the main cam follower 163 is displaced forward enough to put sufficient pressure on the housing 113 to deflect it against the bore wall, the apparatus will not cut off to the side and thus the pressure from the wear pads 151 and 133 and the non-activated cutting means 105 or 247 will halt the forward displacement of the main cam follower 163 relative to the main cam 123 and thus the shifting cam followers 177 A and 177 B relative to the shifting cam 145 . Rearward displacement of the shifting cam followers 177 A and 177 B relative to the shifting cam 145 causes the shifting cam follower lugs 177 AL and 177 BL to contact the shifting cam groove walls causing the shifting cam 145 to rotate. This time the shifting cam 145 is rotating in the opposite direction from what it normally rotates. Further rearward displacement causes the shifting cam follower lugs 177 AL and 177 BL to contact the intersections of the bypass grooves 145 AB (FIG. 44 H). Still more rearward displacement of the shifting cam followers 177 A and 177 B causes the shifting cam 145 to rotate in its normal direction. The contact of the main cam follower lugs 163 S and 163 L and the stop ring 141 halts the rearward displacement (FIG. 44 (I) and FIG. 12 ). In this position the clutch members 153 and 171 are engaged and the housing 113 may be rotated if desired. Forward displacement of the shifting cam followers 177 A and 177 B causes the shifting cam follower lugs 177 AL and 177 BL to contact the next set of intersecting grooves 145 BA. Further forward displacement of the shifting cam followers 177 A and 177 B causes the shifting cam 145 to rotate in its normal direction (FIG. 44 J and FIG. 44 K). The shifting cam 145 is rotated until the shifting cam follower lugs 177 AL and 177 BL exit the by-pass grooves 145 B (FIG. 44 L). The continued forward displacement of shifting cam followers 177 A and 177 B causes the shifting cam follower lugs 177 AL and 177 BL to enter into a set of short grooves 145 M, which stops the forward displacement of the shifting cam followers 177 A and 177 B relative to the shifting cam 145 (FIG. 44 M). In this position the main cam follower 163 is displaced forward relative to the main cam 123 enough to deflect the housings 111 and 113 only part of their total deflection capabilities (FIGS. 27 - 29 ). If the operator chooses to drill forward the drilling apparatus will turn at a lesser degree than would otherwise be possible. If the operator chooses not to drill forward he can continue to manipulate the drill stem in order to position the drilling apparatus in the desired mode. Rearward displacement of the shifting cam followers 177 A and 177 B causes the shifting cam follower lugs 177 AL and 177 BL to contact the walls of shifting cam groove 145 C on the other side of the by-pass groove 145 B thus allowing the shifting cam 145 to be rotated in the normal direction (FIG. 44 N). Further rearward displacement of the shifting cam followers 177 A and 177 B relative to the shifting cam 145 causes the shifting cam follower lugs 177 AL and 177 BL to push on the shifting cam groove wall, which causes the shifting cam 145 to rotate relative to the housing 113 (FIG. 44 (O)). Contact between the shifting cam follower lugs 177 AL and 177 BL and the end of the shifting cam grooves 145 C stops the rearward displacement of the shifting cam followers 177 A and 177 B relative to the shifting cam 145 (FIG. 44 P). Further longitudinal displacement causes this sequence to repeat.
Referring to FIGS. 1, 2 , 7 , 8 and 36 , when the shifting cam followers 177 A and 177 B are stopped by shifting cam grooves 145 E the drilling apparatus is drilling with the main cam follower 163 only partially displaced relative to the main cam 123 , such that a straight bore is produced.
Referring to FIGS. 9-13, 38 , 44 E, and 44 (I) when the shifting cam followers 177 A and 177 B are allowed to regress backward without hindrance from the shifting cam 145 the longitudinal displacement of the main cam follower 163 relative to the main cam 123 is stopped by the main cam follower lugs 163 S and 163 L and the stop plate 141 . In this position all of the parts of the drilling apparatus are rotationally locked by the engagement of the clutch means 171 and 153 .
Referring to FIG. 10 the bore illustrated is curved downwards while the drilling apparatus is in the shifting position and oriented to drill upwards. The rear of the front housing 111 and the front of the rear housing 113 are bent upward allowing the drilling apparatus to be rotated a full 360 degrees in a tighter radius bore than might otherwise be possible. This allows the drilling apparatus to be with drawn through a smaller radius bore without becoming stuck.
Referring to FIGS. 20-25 and 41 when the shifting cam followers 177 A and 177 B are allowed to progress forward unimpeded by the shifting cam 145 the forward displacement of the main cam follower 163 relative to the main cam 123 is stopped by the contact of the stop washer 167 and the stop bushing 167 B. In this position the drilling apparatus is producing the tightest turn possible.
Referring to FIGS. 21-23 and 27 - 29 the middle wear pad 133 is mounted on the rear of the front housing 111 such that when the rear of the front housing 111 is bent downward the wear pad 133 is forced against the bottom of the bore 179 , which pushes laterally on the drilling apparatus until the rear wear pad 151 hits the opposite side of the bore 179 , then the front of the drilling apparatus is pivoted toward the opposite side changing the direction of travel.
Referring to FIGS. 26-29 and 44 M, when the shifting cam followers 177 A and 177 B are stopped by shifting cam groove 145 M the drilling apparatus is drilling with the main cam follower 163 only partially displaced relative to the main cam 123 , such that a larger radius is drilled.
Referring to FIGS. 30-33, 44 A and 44 P, when the shifting cam followers 177 A and 177 B are stopped by shifting cam groove 145 C the male clutch member 171 is halted from engaging the female clutch member 153 such that the housing 113 cannot be rotated when the shaft is rotated. This lets the operator know that upon pushing forward he will be drilling straight.
Referring to FIGS. 18 , 19 and 45 - 50 the clutch stop 147 has two lugs 147 L protruding toward the rear of the drilling apparatus. Each lug is identical. Each has a cam groove 147 C cutout that acts like a cam and a pin 147 P protruding radially outward. The pin 147 P is designed to hold the end of one of two elastic bands 153 R or 153 S whose other end is attached to one of two cam follower pins 153 P, that are attached to the clutch ring 153 . The elastic bands may be o-rings made from a suitable elastomer. The clutch ring 153 has two cutouts 153 C cut into its outer edge. Within these cutouts 153 C are mounted the two cam follower pins 153 P that act as cam followers. The interior of the ring 153 has teeth 153 T protruding toward the center. Each tooth 153 T has a beveled surface 153 B on its forward face. Cut radially around the clutch rings 153 outer edge is a groove 153 G that is wide enough and deep enough for the unobstructed acceptance of the elastic bands 153 R and 153 S. A male clutch member 171 is mounted fixedly on the shaft 101 . On the outer edge of the male clutch member are mounted teeth 171 T. Each tooth 171 T has a beveled surface 171 B facing rearward.
FIG. 49 shows the clutch assembly in a relaxed state. The housing 113 supports the clutch ring 153 and the clutch stop 147 . The male clutch member 171 is forward of the clutch ring 153 . The clutch ring 153 is positioned so that the lugs 147 L on the clutch stop 147 are located in and engaged with the cutouts 153 C on the clutch ring 153 . The cam pins 153 P are positioned in the cam groove 147 C. The elastic bands 153 R and 153 S are position so that one end is held by a cam pin 153 P and stretches through the groove 153 G to the pin 147 P that is mounted on the opposite lug 147 L. In this relaxed state, the elastic bands 153 R and 153 S keep the clutch ring 153 rotated clockwise as seen from the rear of the drilling apparatus. Being fully rotated clockwise the cam follower pins 153 P are positioned in the apex of the cam grooves 147 C and the clutch ring 153 is fully forward, resting against the face of the clutch stop 147 .
When the male clutch member 171 is pulled rearward, it will either enter into the clutch ring 153 without any interference, or the respective teeth 153 T and 171 T will hit. If the teeth 153 T and 171 T hit, the clutch ring 153 will be forced rearwards. This will cause the cam follower pins 153 P to contact the cam grooves 147 C, which will force the clutch ring 153 to rotate counter-clockwise as seen from the rear. As the counter clockwise rotation is taking place the elastic bands 153 R and 153 S are stretching and gaining potential energy. The rearward displacement of the clutch ring 153 is stopped when it contacts the rear ball socket 149 . By the time the clutch ring 153 has been displaced fully rearward the cam groove 147 C has exhausted its influence on the cam follower pin 153 P (FIG. 50 ). In this position the beveled surfaces 153 B and 171 B on the clutch rings teeth 153 T and the male clutch members teeth 171 T will be rotationally aligned so that any further rearward displacement of the male clutch member 171 relative to the clutch ring 153 will cause these surfaces 153 B and 171 B to push on each other, which will continue the counter-clockwise rotation of the clutch ring 153 relative to the clutch stop. The counter-clockwise rotation will stop when the clutch ring 153 and the male clutch member 171 are located such that each tooth 171 T is located between adjacent teeth 153 T.
In this position, the male clutch member 171 may be rotated in either direction to rotate the clutch ring 153 and hence the housing 113 in either direction. If it is rotated counter clockwise, the clutch ring 153 will be rotated relative to the housing 113 until the clutch stop lugs 147 L contact the edges of the cutouts 153 C on the clutch ring 153 . Further counter-clockwise rotation of the clutch ring 153 will rotate the housing 113 counter-clockwise. If the male clutch member 171 is rotated clockwise, the cam follower pins 153 P will contact the cam grooves 147 C, which will force the clutch ring 153 forward. The clutch ring 153 will stop being rotated relative to the housing 113 when the edges of the cutouts 153 C in the clutch ring 153 contacts the clutch stop lugs 147 L. In this position the clutch ring 153 is back in its starting position. Further clockwise rotation of the clutch ring 153 will rotate the housing 113 clockwise. If the male clutch member 171 has moved forward enough to disengage with the clutch ring 153 but has not rotated the clutch ring 153 clockwise enough to reposition the clutch ring 153 in its starting position, the elastic bands 153 R and 153 L will contract. This will rotate the clutch ring 153 clockwise causing the cam follower pin 153 P to contact the cam groove 147 C. As the cam follower pin 153 P is rotated clockwise it is being forced forward by the cam groove 147 C. The rotation and the forward travel relative to the housing 113 stop when the edges of the cutouts 153 C on the clutch ring 153 contact the clutch stop lugs 147 L. In this position the clutch ring 153 is in its starting position.
Referring to FIGS. 51-65 the rotational cutting means 105 are individual wings positioned on the shaft retainer 155 in radial positions to form a drill bit. Three slots 155 S are cut lengthwise into the shaft retainer 155 . On the front and rear of the shaft retainer 155 are cut six slots 155 LS perpendicular to the slots 155 S such that they leave behind a lip 155 L corresponding to the front and rear of each slot 155 S. Two dowel-pin holes 155 P are drilled perpendicular to each slot 155 S such that they are in a position to allow dowel-pins 155 D to lock the rotational cutting wings 105 in place. The dowel-pin holes 155 P are drilled so that the dowel-pins 155 D can be inserted and extricated from the direction of rotation such that upon rotation in the proper and common direction, the dowel-pins 155 D will not be pushed out of the dowel-pin holes 155 P. Smaller diameter hole portions are formed in the member 155 on the side of each slot to allow the dowel-pins to be pressed out. On the front of the shaft retainer are three openings 155 H that allow water or other medium to escape from inside the shaft 101 . The individual cutting wings 105 have a section behind the actual cutting area 105 C that is called the shank 105 S. The shank 105 S is of a shape that will fit into one of the slots 155 S with little clearance. On the front is a front hook 105 F. On the rear is a rear hook 105 R. A second cutting surface 105 B faces toward the rear. Two dowel-pin holes 105 D are drilled in the middle of the shank 105 S. FIGS. 58-65 show the rotational cutting means 105 being mounted onto the shaft retainer 155 in steps. First the shank 105 S is held in line with the slot 155 S, then lowering the rear end of the shank 105 S so that the rear hook 105 R is engaged with the rear lip 155 L of the shaft retainer 155 . Then the rotational cutter 105 is rotated downwards into the slot 155 S until it comes to rest in the bottom of the slot 155 S. In this position the rotational cutting means 105 can be pulled rearwards. This engages the front hook 105 F with the front lip 155 L and lines up its dowel-pin holes 105 D with the dowel pin holes 155 P in the shaft retainer 155 . Then dowel-pins 155 D are inserted into each dowel-pin hole 155 P.
Referring to FIGS. 66-68, a magnet 183 is magnetically isolated from but locked onto the shaft 101 in a position which allows it to pass longitudinally in the area of the transmitter case 129 when the shaft 101 is displaced longitudinally relative to the front housing 111 . The transmitter case 129 is made of non-magnetic material and has a number of magnetic conducting strips 185 isolated from each other. Each strip 185 has an end positioned in a different longitudinal position with its other end positioned in a different radial position around the transmitter cavity 135 . A special transmitter 137 B such as the Digitrac Eclipse produced by Digital Control Inc. has to be used. This transmitter 137 B is built with magnetically sensitive switches 187 that when activated send signals to the receiver to be viewed by the locator and ultimately by the operator
Referring to FIG. 69 the female clutch member 153 and the clutch stop 147 of FIGS. 1-68 are replaced in the drilling apparatus by a longer female clutch member 153 L and a corresponding clutch stop 147 B. This makes the housings 111 and 113 of the drilling apparatus of FIGS. 1-68 rotate while the bore is being drilled straight as well as when it is in the shifting mode. The clutch will be disengaged when the drilling apparatus is in the turning mode.
Referring to FIGS. 70-72 a third housing 189 may be attached to the rear of the drilling apparatus via the rear ball 121 such that it is rotationally and longitudinally locked to the drilling apparatus. A third housing shaft 101 H is attach to the rear end of the shaft 101 R via a standard collar 191 such that the third housing's axis is parallel to the shaft 101 and the third housing shaft 101 H is fixedly attached to the shaft 101 . The rear of the third housing 189 is supported on the third housing shaft 101 H via a bearing compartment 189 B. The third housing 189 is designed to hold a larger transmitter 137 L than can be held in the normal transmitter compartment 135 , which is sometimes needed or preferred to produce a bore. One such transmitter is the Subsite produced by Charles Machine Works Incorporated.
Referring to FIG. 73 in the third housing 189 a ring collar 191 R can be used, instead of the standard collar 191 , to attach the rear of the shaft 101 and the front of the third housing shaft 101 H. On the inside of the ring collar 191 R is attached a wire 193 . The wire 193 is fed back through the shaft 101 H and ultimately to the drilling rig 103 and onto a receiver. The wire 193 is spliced and made longer upon the addition of each new drill stem. A brush 195 is provided to transmit a signal from a wireline transmitter 137 W that is housed in the third housing 189 . The brush 195 is touching but not solidly attached to the ring collar 191 R such that a constant connection is achieved even when the shaft 101 is rotating or moving longitudinally relative to the third housing 189 . Wireline transmitters are special but not uncommon for longer and/or deeper bores.
Operation
After the crew foreman has determined the bore path, the crew sets up the drill rig, in this case a Vermeer 24/40 produced by Vermeer Manufacturing Incorporated. With the lead drill stem already on the drill rig, the crew threads the drilling apparatus onto it. The crew will then insert transmitter 137 and calibrate it with the receiver located at the surface. The foreman has chosen to use a cutting means/wear pad ratio that would allow the drilling apparatus to rotate 360-degrees about its own axis when in the shifting position even in a curved hole. He could have chosen a number of different ratios, anywhere from barely turning for sewer bores, to a 1/1 ratio which would give him the tightest turn, but would not allow the drilling apparatus to rotate about its own axis in a curved hole. Although, rotating about it's own axis in a curved hole is not necessary to its operation, at times it can be handy. Starting at a 15-degree angle with the horizon and the drilling apparatus set to drill straight, the operator of the drill rig begins the bore.
Initially, the operator of the system will start out with the followers 177 A and 177 B in the groove positions 145 E as shown in FIG. 36 in order to drill straight. The operator drills straight until the drilling apparatus is about 4′ deep. At this time, he pulls back on the drill stem. This causes reactions in the drilling apparatus, 1) the clutch engages 171 to 153 , 2) the shifting cam followers 177 A and 177 B pull back spinning the shifting cam 145 , and 3) the cam follower lugs 163 S and 163 L slide rearward relative to the guide housings 111 and 113 .
The operator can now rotate the drilling apparatus to the desired orientation, in this case 12:00. This places the front wear pad 133 on the bottom of the drilling apparatus and the rear wear pad 151 on the top of it. The operator can now push the drill stem forward. This causes 1) the clutch to disengage 171 from 153 , 2) the shifting cam followers 177 A and 177 B are pulled forward rotating the shifting cam 145 , and 3) the cam follower lugs 163 S and 163 L ride up the main cam 123 which causes the guide housings 111 and 113 to bend or pivot relative to each other and the shaft 101 so that the front wear pad 133 pushes against the bottom of the bore 179 , in the middle of the drilling apparatus, while the rear wear pad 151 pushes on the top of the bore. This reaction forces the cutting means 105 , located on the front of the drilling apparatus upward, changing the direction of travel. When the drilling apparatus has reached its full deflection using the chosen cutting means/wear pad ratio, the turning radius is approximately 110 feet. (Note: choosing other cutting means/wear pad ratios will change the radius of the bore.)
The operator can continue turning until he has achieved his desired degree of deviation or until he has to add another drill stem. While adding another drill stem, it is a good time for the crew's locator to check the position of the drilling apparatus, which includes its inclination, and its X, Y and Z position, with the receiver. For a consistent reading the drilling apparatus needs to be positioned in the same clock position every time. For the best reading, the drilling apparatus needs to be in a 3:00 rotational position, as indicated by the receiver. To do this the operator pulls back on the drill stem approximately 5 inches, then pushes forward approximately 2 inches, and finally pulls back approximately 3 inches. This causes the lugs of followers 177 A and 177 B to be located in the cam groove positions 145 C as depicted in FIG. 44A, 145 E, as depicted in FIG. 44C, and 145 D and as depicted in FIG. 44E respectively. In this position the clutch is engaged and the drill stem can rotate the drilling apparatus until the receiver indicates a 3:00 position. While the drill stem is being changed the locator can take his reading.
After adding a new drill stem and calculating his heading the foreman chooses to drill straight. To do this the operator needs to push forward approximately 2 inches and then pull back approximately 2 inches and then forward approximately 4 inches and then back ward approximately 2 inches. This causes the lugs of the cam followers 177 A and 177 B to be located in the cam groove positions 145 A as depicted in FIG. 44G, 145 B, as depicted in FIG. 44 (I), 145 M, as depicted in FIG. 44M, and 145 C, and as depicted in FIG. 44P respectively. In this position he should be able to rotate the drill stem without rotating the drilling apparatus. This indicates that the next time he pushes forward he will be drilling straight. Then pushing forward, he can drill straight for as long as he wants. After drilling for a short distance he notices that the drilling apparatus has drifted slightly off course. Since he is installing steel casing and does not want a major bend in the bore where the pipe will be placed, he decides to use the minor turn feature of the drill head. To do this the operator moves the drill stem back approximately 2 inches, then forward approximately 1 inch, then backward approximately 1 inch, and then pushing forward he can start to drill. This locates the lugs of the followers 177 A and 177 B in the groove positions 145 D as depicted in FIG. 44E, 145 A, as depicted in FIG. 44G, 145 B, as depicted in FIG. 44 (I), and 145 M, and as depicted in FIG. 44M respectively. This will cause the drilling apparatus to change directions, but not as quickly as when using the major turn feature.
By oscillating or moving the shaft 101 in and out relative to the drilling apparatus the operator has the choice of a major turning radius, a minor turning radius, or drilling straight. The foreman continues to manipulate the drilling apparatus to achieve his goal of installing steel casing in a directional bore. Furthermore, the foreman has control of the degree of turn that each turning radius gives him by adjusting the diameter of the cutting means in relation to the diameter of the front wear pad and/or the diameter of the rear wear pad before the bore is even started. In this embodiment, while the drilling is being carried out the housings 111 and 113 slide along the bore hole being drilled by the cutting means 105 .
FIGS. 74-83 refer to another embodiment of the invention. This embodiment has a single housing 201 . A shaft 203 passes through the housing 201 such that its forward end 203 F passes out of the front of the housing 201 and its rear end 203 R passes out of the rear of the housing 201 . On the shaft's front end 203 F is mounted a cutting means. The cutting means may be a rotary type 245 as shown in FIGS. 77-79 or a percussion type 247 as shown in FIGS. 74-76. In this embodiment the housing 201 rotates with the shaft 203 while straight drilling is being carried out and the housing 201 does not rotate with the shaft while turn drilling is being carried out. The housing 201 is supported on both ends by bearings 205 and is sealed by seals 207 . The shaft 203 is free to rotate and move longitudinally relative to the housing 201 . The housing supports a front wear pad 209 and a rear wear pad 211 . The two wear pads 209 and 211 are 180 degrees from each other and on opposite ends of the housing 201 . The resulting central axis of the housing 201 is offset from the central axis of the shaft 203 which allows the wear pads 209 and 211 to influence the direction of travel by contacting the bore wall outside of the cutting diameter. The outside of at least one of the wear pads lies outside of the cutting diameter of the cutting means. On the outside of the housing 201 are three spring-loaded friction arms 219 that add resistance to rotation.
Inside of the housing 201 , from front to back, is a front housing support 213 , a transmitter housing 215 , a forward stop 217 , a rearward stop 221 , a shifting cam bushing 223 which supports a shifting cam 225 and ties the shifting cam follower 235 rotationally to the guide housing 201 , a female clutch member 227 , and a rear housing support 229 . All of these parts, except the shifting cam 225 , are fixedly attached to the housing 201 . The shifting cam 225 is longitudinally locked to, but is free to rotate relative to, the housing 201 . The cam 225 has grooves formed in its outer surface.
On the shaft is a front sleeve 231 , a front thrust bearing 233 , a shifting cam follower body 235 supported on the shaft by bearings 235 B, a rear thrust bearing 237 , a rear spacer 239 , and a male clutch member 241 . The shifting cam follower body 235 has two shifting cam follower arms 235 D and 235 A positioned 180 degrees from each other. The shifting cam follower lugs 235 L on the shifting cam follower arms 235 D and 235 A ride in the grooves 225 A- 225 D of the shifting cam 225 . All of the parts except the shifting cam follower body 235 which holds arms 235 D and 235 A are locked to the shaft 203 . The shifting cam follower 235 is longitudinally locked to the shaft 203 but is free to rotate relative to the shaft 203 . The shifting cam follower 235 is free to move longitudinally with the shaft 203 relative to the housing 201 but is tied rotationally to the guide housing 201 , such that it cannot rotate relative to the guide housing 201 .
FIGS. 84-95 show the shifting cam follower 235 being longitudinally displaced relative to the shifting cam 225 . Since the shifting cam follower 235 is locked rotationally to the housing 201 by the shifting cam bushings 223 , the shifting cam 225 is rotated by the lugs 235 L of the shifting cam follower 235 pushing on the walls of the shifting cam grooves 225 A- 225 D.
In FIGS. 84-95, the exterior surface of the cam 225 is shown laid flat. The two cam followers 235 A and 235 D are located 180 degrees apart. In FIG. 95, 270 degrees of the cam 225 is shown and in FIG. 95 both cam followers 235 A and 235 D are shown. In FIGS. 84-94, only 180 degrees of the cam 235 is shown and only one cam follower 235 D is shown although it is to be understood that the complete cam 225 and both followers 235 A and 235 D will be employed. In FIGS. 84-95 the horizontal arrows depict the direction of longitudinal travel of the followers 235 A and 235 D and the vertical arrows next to the cam 225 depict the direction of rotation of the cam 225 . In FIGS. 84-95, rearward movement of the followers 235 A and 235 D is to the right and forward movement of the followers 235 A and 235 D is to the left. The lugs 235 L of the followers 235 A and 235 D can be moved between positions displaced fully rearward as shown by follower 235 D in FIG. 87 and to positions fully displaced forward as shown by follower 235 D in FIG. 84 and to intermediate positions.
FIG. 84 shows the shifting cam follower arm 235 D in the fully forward or turning position. Shifting cam follower arm 235 A is not pictured in any of the FIGS. 84-94, but is understood to exist. In this position the clutch means is not engaged. Pulling back on the shifting cam follower arm 235 D causes it to contact the shifting cam groove intersection 225 AB (FIG. 85 ). Further rearward displacement causes the shifting cam 225 to be rotated by the shifting cam follower lugs 235 L pushing on the wall of the shifting cam groove 225 B (FIG. 86 ). Rearward displacement is stopped when the shifting cam follower body 235 contacts the rearward stop 221 (FIG. 87 and FIG. 82 ). In this position the clutch means is engaged. Forward displacement of the shifting cam follower arm 235 D causes the shifting cam follower lug 235 L to contact the shifting cam groove intersection 225 BC (FIG. 88 ). Further forward displacement of the shifting cam follower arm 235 D causes the shifting cam follower lug 235 L to push on the wall of the shifting cam groove 225 C (FIG. 89 ). This causes the shifting cam 225 to rotate. Forward displacement of the shifting cam follower arm 235 D is halted when the shifting cam follower lug 235 L contacts the end of the shifting cam groove 225 C (FIG. 90 ). This is the straight drilling position. In this position the clutch means is still engaged and the whole drilling apparatus, including the housing 201 , is being rotated as the hole is drilled (FIG. 80 ). Rearward displacement of the shifting cam follower arm 235 D causes the shifting cam follower lug 235 L to contact the shifting cam groove intersection 225 CD (FIG. 91 ). Further rearward displacement of the shifting cam follower arm 235 D causes the shifting cam follower lug 235 L to push on the wall of the shifting cam groove 225 D (FIG. 92 ). This causes the shifting cam 225 to rotate relative to the housing 201 . Again the rearward displacement of the shifting cam follower arm 235 relative to the shifting cam 225 is halted when the shifting cam body 235 C contacts the rearward stop 221 (FIG. 93 and FIG. 82 ). In this position the housing 201 can be rotated to a desired clock position in preparation for drilling a curved hole in the chosen direction. Forward displacement of the shifting cam follower arm 235 D causes the shifting cam follower lug 235 L to contact the shifting cam groove intersection 225 DA. Further forward displacement of the shifting cam follower arms 235 D and 235 A causes the shifting cam follower lugs to push on the walls of the shifting cam grooves 225 A (FIG. 95 ). This causes the shifting cam 225 to rotate. Forward displacement is halted when the shifting cam body 235 C contacts the forward stop 217 (FIG. 81 and FIG. 84 ). In this position the clutch means is disengaged and the housing 201 is held from rotating by friction on the walls of the bore. While the drill stem is rotating and thrusting forward the cutting means 245 or 247 , the drilling apparatus is drilling a curved hole. Further manipulations of the drill stems allow the operator to control the direction of travel.
When using a rotary type cutting means 245 with this embodiment, a hole-opener 243 is to be employed directly behind housing 201 . The hole-opener 243 is fixedly attached to the shaft 203 and is designed to enlarge the bore enough to allow the entire drilling apparatus to rotate around its own axis, even in a curved hole. If the drilling apparatus is not positioned in a sufficiently large void to allow the drilling apparatus to be rotated about its own axis without hindrance from the bore walls, undue strain and stress will be placed on the drilling apparatus. Furthermore the complete rotation of the drilling apparatus may not be possible in a non-enlarged bore, thus hindering the ability to control the path of the bore.
To use this embodiment with a percussion type cutting means 247 , the drilling crew would first thread the drilling apparatus onto the lead drill stem. Then they would mount the percussion head 247 on the front of the drilling apparatus. Next, the transmitter 137 would be inserted under the front wear pad 209 . With these things done the bore is ready to begin. Starting with the drilling apparatus in the straight drilling mode and the percussion bit 247 pressed up against the ground, the fluid medium usually either compressed air or water is switched on. This causes the bit 247 to vibrate in and out pulverizing even the hardest rock. As the drilling apparatus is advanced, it is rotated. This makes the bit 247 move in a circular motion with the center of the bore off center from the center of the bit 247 . The resultant bore diameter is larger than the cutting bit diameter. As long as the apparatus is moved forward and rotated with the percussion cutting means 247 activated it will drill relatively straight. When the operator wants to change direction, he pulls back on the drill stem. This causes the shifting cam follower 235 to rotate the shifting cam 225 . The rearward displacement ceases when the shifting cam follower 235 encounters the rearward stop 221 . The drill stem can now rotate the drilling apparatus to the desired rotational position. Once in the desired position, the drill stem can be pushed forward causing the shaft 203 to be forwardly displaced relative to the housing 201 . This disengages the clutch means 241 from 227 and causes the shifting cam follower 235 to rotate the shifting cam 225 . The forward displacement is halted when the shifting cam follower 235 hits the forward stop 217 . The bit 247 is pressed against the earth and the fluid medium is switched on. This causes the bit 247 to vibrate in and out pulverizing the rock. The drill stem can be rotated allowing the bit 247 to impact various spots on the face of the rock being drilled. The bit 247 is rotated about its own center. While turning, the housing 201 is held from rotating by the friction arms 219 that are contacting the wall of the bore. Since the housings wear pads 209 and 211 lay outside of the cutting radius of the percussion means 247 , they push on the wall of the bore which in turn pushes on the drilling apparatus moving the cutting means 247 in the opposite direction. The bore can be drilled in the turning mode as far as needed. To drill straight again the drill stem is pulled back. This causes the shifting cam follower 235 to rotate the shifting cam 225 and engages the clutch means 241 to 227 . The drill stem is then pushed forward causing the shaft 203 to be displaced relative to the housing 201 until the grooves 225 C (FIG. 90) in the shifting cam 225 stop the shifting cam follower 235 . In this position the clutch means 241 to 227 is still engaged such that when the drill stem rotates the shaft 203 , the entire drilling apparatus, including the housing 201 , is rotated. Since the curved hole that the drilling apparatus is now in, is too small to allow the rotation of the drilling apparatus about its axis at first, the percussion means 247 is activated and slowly rotated along with the housing 201 which enlarges the bore diameter. After one revolution, normal drilling can be resumed. The operator can choose between straight and curved drilling at any time. The operator knows that he is drilling straight when he is drilling and the transmitter is showing that the drilling apparatus is rotating. Likewise he knows when he is drilling a curved hole when he is drilling and the transmitter is showing that the drilling apparatus is not rotating.
To use this embodiment with a rotary type cutting means 245 . The drilling crew would first thread the drilling apparatus onto the lead drill stem. Then the crew would mount the rotary drill bit 245 on the front of the drilling apparatus. Next, the transmitter 137 would be inserted under the front wear pad 209 . Starting with the drill head in the straight drilling mode, the drill stem is rotated and then thrust forward. This makes the drilling apparatus, including the housing 201 , as well as the rotary drill bit 245 to do the same, which drills a straight hole.
When the operator wants to turn, he pulls back on the drill stem, which pulls back on the shaft 203 causing it to be displaced relative to the housing 201 . At the same time the shifting cam follower 235 rotates the shifting cam 225 . The drill stem can be rotated which rotates the shaft 203 , which in turn rotates the drilling apparatus until the desired rotational direction is reached. Then pushing forward the shifting cam follower 235 rotates the shifting cam 225 and the clutch means 241 is disengaged from 227 . The forward displacement is stopped when the shifting cam follower 235 hits the forward stop 217 . With the housing held rotationally in place by the friction arms 219 , the drill stem, the shaft 203 , and rotary drill bit 245 are rotated and thrust forward cutting the hole. Since at least one wear pad 209 and/or 211 lies outside of the cutting diameter of the rotary bit 245 , the protruding wear pad 209 and/or 211 contacts the wall causing the drilling apparatus to be deflected in the opposite direction. While the curved hole is being drilled a hole opener 243 on the rear of the drilling apparatus is enlarging the hole, which is also true when a straight hole is being drilled, but to a lesser extent, because a straight hole is bigger than a curved hole. The curved hole can be cut until the operator chooses to drill straight. When he does desire to drill straight, he pulls back on the drill stem for at least five feet, which positions the entire drilling apparatus in the enlarged hole. While pulling back the shaft 203 and shifting cam follower 235 are displaced relative to the housing 201 and the shifting cam 225 . This causes the shifting cam follower 235 to rotate the shifting cam 225 and the clutch means 241 and 227 to engage. The drill stem is then pushed forward which causes the shaft 203 , the shifting cam follower 235 and the male clutch means 241 to be displaced relative to the housing 201 , the shifting cam 225 and the female clutch member 227 . The shifting cam follower 235 hitting the grooves 225 C (FIG. 90) in the shifting cam 225 stops the forward displacement. In this position the clutch members 241 to 227 are still engaged which causes the housing 201 to rotate and the bore to be drilled straight. The drill stem is now thrust forward and rotated which causes the entire drilling apparatus to be rotated and thrust forward. The resulting bore is relatively straight and of a larger diameter than the diameter of the rotary drill bit 245 . The operator knows that he is drilling straight, if while he is drilling the transmitter is indicating that the housing 201 is rotating and conversely he is turning if the transmitter indicates that the housing 201 is not rotating.
After the bore has reach its destination the drilling crew may wish to enlarge the hole using a hole-opener. If so, they would use a system that attaches rotational cutting means to a hole-opener in a manner similar to the way the rotational cutting means 105 were attached to the shaft retainer 155 . (NOTE: the rotational cutting means may be one or more of any style on the market, including roller cones and bullet teeth, with the only change being the mounting shank made special for this application.)
Referring to FIGS. 96-106 the rotational cutting means 251 are individual wings positioned on the hole-opener body 249 in radial positions to form a hole-opener 255 . Four slots 249 S are cut lengthwise into the hole-opener body 249 . On the front and rear of the hole-opener body 249 are cut eight slots 249 LS perpendicular to the slots 249 S such that they leave behind a lip 249 L corresponding to the front and rear of each slot 249 S. Two dowel-pin holes 249 P are drilled perpendicular to each slot 249 S such that they are in a position to allow dowel-pins 253 to lock the rotational cutting means 251 in place. The dowel-pin holes 249 P are drilled so that the dowel-pins 253 can be inserted and extricated from the direction of rotation such that upon rotation in the proper and common direction, the dowel-pins 253 will not be pushed out of the dowel-pin holes 249 P. Smaller diameter hole portions are formed in the body 249 on the other side of each slot to allow the dowel-pins 253 to be pressed out. On the front of the hole-opener body 249 are four openings 249 H that allow water or other medium to escape from inside the hole-opener body 249 . The rotational cutting means 251 have a section behind the actual cutting area 251 C that is called the shank 251 S. The shank 251 S is of a shape that will fit into one of the slots 249 S with little clearance. On the front is a front hook 251 F. On the rear is a rear hook 251 R. Two dowel-pin holes 251 P are drilled in the middle of the shank 251 S. FIGS. 99-104 show the rotational cutting means 251 being mounted onto the hole-opener body 249 in steps. First the shank 251 S is held in line with the slot 249 S, then lowering the rear end of the shank 251 S so that the rear hook 251 R is engaged with the rear lip 249 L of the hole-opener 249 . Then the rotational cutting means 251 is rotated downwards into the slot 249 S until it comes to rest in the bottom of the slot 249 S. In this position the rotational cutting means 251 can be pulled rearwards. This engages the front hook 251 F with the front lip 249 L and lines up its dowel-pin holes 251 P with the dowel-pin holes 249 P in the hole-opener body 249 . Then dowel-pins 253 are inserted into each dowel-pin hole 249 P. With the rotational cutting means 251 attached to the hole-opener body 249 the hole-opener 255 is ready for use.
To use this hole-opener 255 the drilling crew would attach the hole-opener 249 body to the drill-string 175 D. Then the drill rig operator would rotate the drill string 175 D and begin to pull the hole-opener 255 through the previously bored hole 257 leaving behind an enlarged hole 259 . (NOTE: the hole-opener 255 can be mounted and used to be pulled through the previously bored hole or it can be mounted and used to be pushed through the previously bored hole.)
In hole-opener 255 , four slots 249 S were used and in the shaft retainer 155 three slots 155 S were used. If desired as few as only one slot 249 S maybe used in the hole-opener 255 and also only one slot 155 S may be used in the shaft retainer 155 . If only one slot 249 S is used in the hole-opener 255 or if only one slot 155 S is used in the shaft retainer 155 the single rotational cutting means 105 or 251 would cut the entire diameter when rotated in a complete revolution.
In the single slot shaft retainer 155 a different version of the rotational cutting means 105 may be more desirable. In this version the rotational cutting means 261 would extend across the desired diameter of the hole as in FIGS. 107 and 108. In FIG. 107 cutting edges are shown at 217 and 273 and 155 A is the axis of rotation. In FIG. 108, a cutting edge is shown at 271 and member 275 is a roller cutting cone. | The drill device has a body with a front end and a rear end and which is connectable to the shaft of a drilling apparatus. A plurality of angularly spaced apart slots are formed in the exterior of the device which extend between the front and rear ends. Each slot has a lip extending from each of its front and rear ends respectively. A cutting member is provided for each of the slots with each cutting member having a connecting portion located in one of the slots and having a forward end and a rearward. Each connecting portion has a hook near its front and rear ends respectively for connection to the lips of the slot in which it is located. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present applications benefits from U.S. application 61/050268 filed on May 5, 2008 by the same inventor.
FIELD AND BACKGROUND
[0002] 1. Field
[0003] The present invention relates to energy conversion and specifically to circuitry which combines multiple voltage inputs from serially connected direct current sources into a combined output.
[0004] 2. Description of Related Art
[0005] Sunlight includes a spectrum of electromagnetic radiation emitted by the Sun onto the surface of the Earth. On the Earth, sunlight is filtered through the atmosphere, and the solar irradiance (Watts/meter square/nanometer W/m 2 /nm) is obvious as daylight when the Sun is above the horizon. The Earth receives a total solar irradiance determined by its cross section (π·R E 2 , R E =radius of the earth), but as the Earth rotates the solar energy is distributed across the entire surface area (4·π·R E 2 ). The solar constant is the amount of incoming solar electromagnetic irradiance per unit area, measured on the outer surface of Earth's atmosphere in a plane perpendicular to the solar rays. The solar constant is measured by satellite to be roughly 1366 watts per square meter (W/m 2 ) or 1.366 W/m 2 /nm. Hence the average incoming solar irradiance, taking into account the angle at which the rays strike and that at any one moment half the planet does not receive any solar irradiance, is one-fourth the solar constant (approximately 0.342 W/m 2 /nm). At any given moment, the amount of solar irradiance received at a location on the Earth's surface depends on the state of the atmosphere and the location's latitude.
[0006] The performance of a photovoltaic cell depends on the state of the atmosphere, the latitude and the orientation of the photovoltaic cell towards the Sun and on the electrical characteristics of the photovoltaic cell.
[0007] FIG. 1 shows schematically a graph of a solar irradiance 100 versus wavelength. Irradiance 100 is distributed around a peak wavelength at about 550 nanometers. FIG. 1 also shows schematically an absorption spectrum 102 of a typical solar photovoltaic (PV) cell with a given band-gap which allows only a portion of the solar irradiance to be converted into electrical power. The finite characteristic of the band-gap of the photovoltaic cell causes a substantial part of the sun's energy to remain unutilized. In order to improve photovoltaic efficiency, multiple junction cells have been designed which include multiple pn junctions. Solar irradiance not absorbed, because its energy is less than the band gap is transmitted to the next junction(s) with a smaller band gap and the transmitted radiation is preferentially absorbed and converted into electrical energy.
[0008] FIG. 2 shows the graph of solar irradiance 100 versus wavelength and three absorption spectra 202 , 204 and 206 respectively of three photovoltaic junctions used in a single multi junction cell designed to absorb different parts of the solar spectrum. The first photovoltaic junction having the largest band gap has an absorption spectrum 206 , the second photovoltaic junction has an absorption spectrum 204 , and the third photovoltaic junction which has the smallest band gap has an absorption spectrum 202 . Combining the three pn junctions of photovoltaic junctions into a single multi junction 30 cell increases the efficiency, theoretically to about 60% and practically today to above 40%.
[0009] FIG. 3 illustrates multiple multi junction cells 30 connected in series. Each multi-junction cell 30 has three serially connected photovoltaic junctions 300 , 302 , and 304 which operate with three absorption spectra 206 , 204 and 202 respectively. Multiple multi junction cells 30 connected in series form a multi-spectral photovoltaic panel 3000 with output terminals 310 and 308 .
[0010] FIG. 4 illustrates characteristic current-voltage curves of a single photovoltaic junction cell at different illumination levels. Curve 400 shows the maximum power point (MPP) for low light levels, curve 402 show the maximum power point MPP for higher light levels, and curve 404 shows the maximum power point MPP yet higher light levels assuming a constant temperature of the cell. As can be seen, at the different light levels the maximum power point is achieved at nearly identical voltages, but at different currents depending on the incident solar irradiance.
[0011] Reference is now made to conventional art in FIGS. 5 a and 5 b which shows a typical photovoltaic installation 50 operating in dark or partially shaded conditions and bright mode respectively. Bypass diodes 500 a - 500 c are connected in parallel across photovoltaic panels 502 a - 502 c respectively for instance according to IEC61730-2 solar safety standards (sec. 10.18). Photovoltaic panels 502 a - 502 c are connected in series to form a serial string of photovoltaic panels. Referring to FIG. 5 a, bypass diode 500 a provides a path 510 around photovoltaic panel 502 a during dark or partially shaded conditions. Current path 510 allows current to flow through bypass diode 500 a in the forward mode, preventing common thermal failures in photovoltaic panel 502 a like cell breakdown or hot spots. During forward mode, bypass diode 500 a preferably has low forward resistance to reduce the wasted power. FIG. 5 b refers to normal operation or bright mode, forward current 512 will flow through photovoltaic panels 502 a - 502 c while bypass diodes 500 a - 500 c will operate in the reverse blocking mode. In reverse blocking mode, it is important that bypass diodes 500 a - 500 c have the lowest high temperature reverse leakage current (I R ) to achieve the highest power generation efficiency for each photovoltaic panel 502 a - 502 c.
BRIEF SUMMARY
[0012] According to the present invention there is provided a circuit including multiple direct current (DC) voltage inputs which including one or more shared terminals. A primary transformer winding includes a high voltage end and a low voltage end. The primary transformer winding has a tap or taps operatively connected to the shared terminals through a first switch. A secondary transformer winding includes a high voltage end and a low voltage end. The secondary transformer winding is electromagnetically coupled to the primary transformer winding. The secondary transformer winding has one or more taps operatively connected to the shared terminal(s) through a second switch. A direct current voltage output terminal connects the high voltage ends of the primary and secondary transformer windings. A low voltage direct current output terminal operatively connecting said low voltage ends of said primary and secondary transformer windings.
[0013] Diodes are typically connected in parallel with the first and second switches or the diodes are integrated with a transistor in a single package. The switches may be metal oxide semiconductor field effect transistor (MOSFET), junction field effect transistor (JFET), insulated gate field effect transistor (IGFET), n-channel field effect transistor, p-channel field effect transistor, silicon controlled rectifier (SCR) and/or bipolar junction transistor (BJT). A third switch optionally connects the low voltage end of the primary transformer winding to a common terminal; and a fourth switch optionally connects the low voltage end of the secondary transformer winding to the common terminal. Diodes are typically connected in parallel with the third switch and the fourth switch. Bypass diodes are operatively connected across the DC voltage inputs. Photovoltaic cells are optionally connected to the DC voltage inputs. The photovoltaic cells may be optimized for maximal optical absorption of different respective portions of the electromagnetic spectrum. The direct current voltage output terminal may be connected to a DC to DC converter.
[0014] According to the present invention there is provided a circuit including multiple direct current (DC) voltage inputs; multiple transformers including primary windings and secondary windings; multiple first switches connected respectively in series with the primary windings into a multiple of switched primary windings; and multiple second switches connected respectively in series with the secondary windings into multiple switched secondary windings. The switched secondary windings are parallel connected respectively with the switched primary windings by the DC voltage inputs. The switched secondary windings are adapted for connecting to a combined direct current power output combining the DC voltage inputs. The first and second switches are: metal oxide semiconductor field effect transistor (MOSFET), junction field effect transistor (JFET), insulated gate field effect transistor (IGFET), n-channel field effect transistor, p-channel field effect transistor, silicon controlled rectifier (SCR) and/or bipolar junction transistor (BJT).
[0015] According to the present invention there is provided a circuit for combining direct current (DC) power including multiple direct current (DC) voltage inputs; multiple tapped coils including respectively primary ends, secondary ends and taps. The taps are adapted for connecting individually to the DC voltage inputs. The first switches connect respectively in series with the tapped coils at the primary ends of the coils. The second switches connect respectively in series with the coils at the secondary ends of the coils. The taps serially connect respectively the first and second switches. A combined direct current power output is adapted for connecting between the tap of highest voltage and a reference to both the inputs and the output.
[0016] According to the present invention there is provided a circuit for combining direct current (DC) power including multiple direct current (DC) voltage inputs; multiple inductive elements. The inductive elements are adapted for operatively connecting respectively to the DC voltage inputs. Multiple switches connect respectively with the inductive elements. A controller is configured to switch the switches periodically. A direct current voltage output is connected across one of the DC voltage inputs and a reference to both the inputs and the output.
[0017] According to the present invention there is provided a method for combining direct current (DC) power. Multiple direct current (DC) voltage inputs are connected to respective inductive elements. Multiple switches are connected respectively with the inductive elements. The switches are switched periodically.
[0018] A direct current voltage output is combined by connecting across one of the DC voltage inputs and a reference common to both the DC voltage inputs and the direct current voltage output.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein:
[0020] FIG. 1 is a graph illustrating typical spectra of solar irradiance and solar absorption of a single photovoltaic junction, according to conventional art.
[0021] FIG. 2 is a graph illustrating three different absorption spectra of three stacked photovoltaic junctions of a multi junction photovoltaic cell, according to conventional art.
[0022] FIG. 3 illustrates serially connected multi junction cells, according to conventional art.
[0023] FIG. 4 illustrates a current-voltage (TV) characteristic curve (arbitrary units) of a photovoltaic cell at three different illumination levels, according to conventional art.
[0024] FIGS. 5 a and 5 b illustrates a typical photovoltaic installation operating in during dark or partially shaded conditions and bright mode respectively, according to conventional art.
[0025] FIG. 6 illustrates a block diagram of photovoltaic installation with a power combiner according to an embodiment of the present invention.
[0026] FIG. 7 illustrates a power combiner circuit, according to an embodiment of the present invention.
[0027] FIG. 8 illustrates a power combiner circuit, according to another embodiment of the present invention.
[0028] FIG. 9 illustrates a photovoltaic system including multiple power combiners, according to an exemplary embodiment of the present invention.
[0029] FIG. 10 illustrates a flow diagram of a method, according to an embodiment of the present invention.
[0030] The foregoing and/or other aspects will become apparent from the following detailed description when considered in conjunction with the accompanying drawing figures.
DETAILED DESCRIPTION
[0031] Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below to explain the present invention by referring to the figures.
[0032] By way of introduction, different embodiments of the present invention are directed toward compensating for current variations in multiple junctions cells or in serially connected photovoltaic cells and/or panels such as during partial shading while maximizing power gain, by avoiding the loss of power from one or more photovoltaic cells and/or panels shorted by the cells and/or panels respective bypass diode.
[0033] Reference is now made back to FIG. 3 , which illustrates conventionally multiple multi-junction cells 30 connected in series, each with multiple serially connected photovoltaic junctions 300 , 302 , and 304 . It is well known that the spectrum of solar irradiance on the Earth's surface is not a constant but varies according to many variables such as season, geographic location, time of day, altitude, atmospheric conditions and pollution. Hence, it becomes apparent that photovoltaic junctions 300 , 302 , and 304 sensitive to different spectrum bands may be absorbing a different amount of light depending on season, geographic location, time of day, altitude, atmospheric conditions and pollution. Since photovoltaic junctions 300 , 302 , and 304 are connected in series, the same current flows through all of the junctions. Thus, the best power point of serially connected photovoltaic junctions 300 , 302 , and 304 maximizes the overall power from photovoltaic junctions 300 , 302 , and 304 , while each junction is typically producing a less than optimal amount of electrical power. On the other hand, a parallel connection of photovoltaic junctions and/or multi junction cells, while allowing a better maximum power control for all photovoltaic junctions or multi-junction cells suffers among other possible power losses from an increase of ohmic power loss of the system since ohmic power loss is proportional to the square of the current. Furthermore, a parallel electrical connection of stacked pn junctions in a multi-junction cell is not particularly practical since multi junction cells are typically stacked in a single production process and since the MPP voltage of each of these stacked pn junctions is different; the bandgap voltage for each pn junction is different.
[0034] The present invention in different embodiments may be applied to multiple photovoltaic cells and/or multi-junction photovoltaic cells connected in various series and parallel configurations with power converters/combiners to form a photovoltaic panel. Multiple series and parallel configurations of the photovoltaic panel and substrings within a panel with multiple power converters/combiners are used to form a photovoltaic installation. The present invention in further embodiments may be applied to other direct current power sources including batteries, fuel cells and direct current generators.
[0035] Embodiments of the present invention may be implemented by one skilled in the electronics arts using different inductive circuit elements such as transformers, auto-transformers, tapped coils, and/or multiple coils connected in serial and/or in parallel and these devices may be connected equivalently to construct the different embodiments of the present invention.
[0036] The terms “common”, “common terminal, “common reference” are used herein interchangeably referring to a reference common to both inputs and the output in the context of embodiments of the present invention. Typically, “common terminal” is ground, but the whole circuit may also be ungrounded. References to common terminal as ground are only illustrative and made for the reader's convenience.
[0037] Reference is now made to FIG. 6 which illustrates a block diagram of photovoltaic installation 600 with a power combiner 604 according to an embodiment of the present invention. A photovoltaic panel 60 has three photovoltaic cells 606 a - 606 c connected in series. Photovoltaic cells 606 a - 606 c are preferably multi-junction photovoltaic cells, photovoltaic cells or other direct current sources. An anode and cathode of a bypass diode D 1 connects across in parallel with photovoltaic cell 606 c at node F and node A respectively. An anode and cathode of a bypass diode D 2 connects across in parallel with photovoltaic cell 606 b at node A and node B respectively. An anode and cathode of a bypass diode D 3 connects across in parallel with photovoltaic cell 606 a at node B and node C respectively. Voltages V 1 , V 2 and V 3 are the voltage outputs of photovoltaic cells 606 c, 606 b and 606 a respectively. Voltages V 1 , V 2 and V 3 are applied to three voltage 15 inputs of power combiner 604 as between nodes C & B, B & A and nodes A & F respectively. Power combiner 604 has a single output voltage V out .
[0038] Reference is now made to FIG. 7 which illustrates, according to an embodiment of the present invention, circuit details of DC power combiner 604 . Three voltages V 1 , V 2 and V 3 are input to power combiner 604 between nodes A and F, nodes B and A and nodes C and B respectively. Node B is on a “shared input terminal” of V 2 and V 3 . Similarly, node A is on a “shared input terminal” of V 1 and V 2 . One end of inductor L 1 connects to node C, the other end of inductor L 1 connects to one end of inductor L 3 to form node W. The other end of inductor L 3 connects to one end of inductor L 5 to form node X. The other end on inductor L 5 connects to the drain of MOSFET G 1 and the source of G 1 connects to node F (ground). One end of inductor L 2 connects to node C, the other end of inductor L 2 connects to one end of inductor L 4 to form node D. The other end of inductor L 4 connects to one end of inductor L 6 to form node E. The other end on inductor L 5 connects to the drain of MOSFET G 2 and the source of MOSFET G 2 connects node F (ground). The drain of MOSFET G 5 is connected to node W, the source of MOSFET G 5 connects to the source of MOSFET G 6 . The drain of MOSFET G 6 connects to node D. The drain of MOSFET G 4 is connected to node X, the source of MOSFET G 4 connects to the source of MOSFET G 3 . The drain of MOSFET G 3 connects to node E. The output voltage V out of power combiner 604 is derived between nodes C and F (ground). A transformer core 601 is used to electromagnetically couple all inductors L 5 , L 6 , L 3 , L 4 ,L 1 and L 2 . The winding polarity of L 5 , L 3 and L 1 is preferably opposite of the winding polarity of L 6 , L 4 and L 2 . The two inductors within each of the inductor pairs L 5 -L 6 , L 3 -L 4 and L 1 -L 2 typically have the same number of winding turns, although there can be a different number of turns to each of the inductor pairs (eg. L 1 and L 2 , L 3 and L 4 and L 5 and L 6 ), to adjust the typical relative MPP voltage of each of the input voltages. Each of the three voltages V 1 , V 2 and V 3 are applied across each of inductors L 5 , L 3 and L 1 respectively with for instance a 50% duty cycle when switches G 1 , G 4 and G 5 are closed and switches G 2 , G 3 and G 6 are opened. Each of the three voltages V 1 , V 2 and V 3 are applied across each of the inductors L 6 , L 4 and L 2 respectively with typically a 50% duty cycle when switches G 1 , G 4 and G 5 are opened and switches G 2 , G 3 and G 6 are closed, thus completing a full switching cycle. The output voltage (V out ) of power combiner 604 is the sum of the input voltages V 1 , V 2 and V 3 . The input voltages V 1 , V 2 and V 3 of power combiner 604 are forced by power combiner 604 to have the same ratio as the winding ratio of their inductor pair (L 5 , L 6 ), (L 3 , L 4 ) and (L 1 , L 2 ) respectively; a result of applying control pulses to switches G 1 -G 6 for instance with a 50% duty cycle. Switches G 1 -G 6 are optionally metal oxide semiconductor field-effect transistors (MOSFET). Alternatively the switches can, in different embodiments of the invention, be a silicon controlled rectifier (SCR), insulated gate bipolar junction transistor (IGBT), bipolar junction transistor (BJT), field effect transistor (FET), junction field effect transistor (JFET), switching diode, mechanically operated single pole double pole switch (SPDT), SPDT electrical relay, SPDT reed relay, SPDT solid state relay, insulated gate field effect transistor (IGFET), DIAC, and TRIAC.
[0039] Reference is now made to FIG. 8 which illustrates, according to another embodiment of the present invention, an alternative circuit of DC power combiner 604 . Three voltages V 1 , V 2 and V 3 are input to power combiner 604 between nodes A & F, B & A and nodes C & B respectively. One end of inductor L 1 connects to node C, the other end of inductor 30 L 1 connects to the drain of MOSFET G 1 the source of G 1 connects to node B. One end of inductor L 3 connects to node B, the other end of inductor L 3 connects to the drain of MOSFET G 3 , the source of G 3 connects to node A. One end of inductor L 5 connects to node A, the other end of inductor L 5 connects to the drain of MOSFET G 5 , the source of G 5 connects to node F (ground). One end of inductor L 2 connects to node C, the other end of inductor L 2 connects to the drain of MOSFET G 2 , the source of G 2 connects to node B. One end of inductor L 4 connects to node B, the other end of inductor L 4 connects to the drain of MOSFET G 4 , the source of G 4 connects to node A. One end of inductor L 6 connects to node A, the other end of inductor L 6 connects to the drain of MOSFET G 6 , the source of G 6 connects to node F (ground). The output voltage V out of power combiner 604 is derived between nodes C and F (ground). A transformer core 601 is used to electromagnetically couple all inductors L 5 , L 6 , L 3 , L 4 , L 1 and L 2 . The winding polarity of L 5 , L 3 and L 1 is preferably opposite of the winding polarity of L 6 , L 4 and L 2 respectively. The two inductors within each of the inductor pairs (L 5 and L 6 ), (L 3 and L 4 ) and (L 1 and L 2 ) preferably have the same number of winding turns, although there can be a different number of turns to each of the inductor pairs, so as to adjust the typical relative MPP voltage of each of the input voltages.
[0040] Reference is now made to FIG. 9 which illustrates a photovoltaic system 90 including multiple power combiners 604 , according to an exemplary embodiment of the present invention. Photovoltaic system 90 has multiple series strings 902 connected in parallel to the input of DC to AC converter 900 . Series strings 902 have photovoltaic cells 904 a - 904 c which are for instance multi-junction photovoltaic cells which have three voltage 20 outputs V 1 , V 2 and V 3 with three bypass diodes connected across each voltage output of photovoltaic cells 904 a - 904 c. Connected to each photovoltaic cells 904 a - 904 c is a three voltage input power combiner 604 . Power combiner 604 has a single voltage output (V out ) which is applied across the input of DC to DC converters 92 a - 92 c. The outputs of DC to DC converters 92 a - 92 c are connected in series to form the input to DC to AC converter 900 and the output of multiple series strings 902 .
[0041] Reference is now made to FIG. 10 which illustrates a method 10 according to an embodiment of the present invention. In step 11 , DC voltage inputs are connected to inductive elements. In step 13 , the inductive elements are switched at a high frequency dependent on the inductance values so that the inductive elements do not tend to “short ” the input DC voltages. In step 15 , a single output combines the DC inputs by connecting across typically the highest input voltage and a reference or ground common to both the DC inputs and the single output.
[0042] The definite articles “a”, “an” is used herein, such as “a multi-junction photovoltaic cell”, “a power combiner” or “a coil” have the meaning of “one or more multi-junction photovoltaic cells”, “one or more power combiners ” or “one or more coils”.
[0043] Although selected embodiments of the present invention have been shown and described, it is to be understood the present invention is not limited to the described embodiments. Instead, it is to be appreciated that changes may be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and the equivalents thereof. | A circuit for combining direct current (DC) power including multiple direct current (DC) voltage inputs; multiple inductive elements. The inductive elements are adapted for operatively connecting respectively to the DC voltage inputs. Multiple switches connect respectively with the inductive elements. A controller is configured to switch the switches periodically at a frequency sufficiently high so that direct currents flowing through the inductive elements are substantially zero. A direct current voltage output is connected across one of the DC voltage inputs and a common reference to both the inputs and the output. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a nozzle device and a cleaning apparatus equipped with the nozzle device, and more particularly to a high performance nozzle device suitable for use in single wafer cleaning in the manufacture of semiconductor integrated circuits and the like and a cleaning apparatus equipped with the nozzle device.
2. Description of the Related Art
In recent years, the main stream of the cleaning step as part of the manufacturing process of semiconductor integrated circuits and the like is shifting from the batch watching system, by which wafers are dipped in cleaning fluid, to the single wafer cleaning system to address the need for small lot production of many different types. The following systems are known to be suitable for such single wafer cleaning (see, for instance, Handbook of Industrial Cleaning Techniques (in Japanese), Realize Riko Center 1994 and Q&A: Manual on the Theory of Cleaning and Applied Operations (in Japanese), R&D Planning Shuppan 2001).
1) Brush cleaning system
2) Low pressure shower cleaning system
3) Ultrasonic shower cleaning system
4) Cavitation jet cleaning system
5) Two-fluid cleaning system
6) High pressure jet cleaning system
SUMMARY OF THE INVENTION
The conventional cleaning systems listed above, however, involve one or another of the following problems, which at present are found extremely difficult to overcome.
1) The brush cleaning system, though powerful in cleaning effect, suffers from re-adhesion of contamination or destruction of the pattern by the shearing force applied by the brush.
2) The low pressure shower cleaning system is insufficient in cleaning power because of the low speed of jetted liquid droplets.
3) The ultrasonic shower cleaning system may invite destruction of the pattern by cavitation due to ultrasonic oscillation. Moreover, as the object of cleaning is determined by the ultrasonic frequency, only specific contamination (particles) can be cleaned.
4) The cavitation jet cleaning system can exert little cavitation effect and accordingly is insufficient in cleaning power.
5) The double-fluid cleaning system, though excelling in cleaning power, involves difficulty in controlling the fluid droplet size and the speed of droplets (changing the fluid droplet size or the speed of droplets requires replacement of the nozzle). Moreover, the presence of large droplets or fast moving droplets may destroy the pattern.
6) The high pressure jet cleaning system, though excelling in cleaning power, involves the same problems as 5). Namely, it is difficult to control the fluid droplet size and the speed of droplets (changing the fluid droplet size or the speed of droplets requires replacement of the nozzle). Moreover, the presence of large droplets or fast moving droplets may destroy the pattern.
An object of the present invention, attempted in view of these circumstances, is to provide a nozzle device suitable for use in single wafer cleaning in the manufacture of semiconductor integrated circuits and the like, which can solve these problems, and a cleaning apparatus equipped with this nozzle device.
In order to achieve the foregoing object, according to a first aspect of the invention, there is provided a nozzle device comprising a substantially cylindrical nozzle body and a cup member which is arranged within the cylinder of the nozzle body and jets out fluid droplets from the tip thereof while being driven to turn, wherein two or more fluids including a detergent and a gas are mixed and jetted out of the tip of the nozzle.
According to the first aspect of the invention, since the nozzle device comprises a nozzle body and a cup member which jets out fluid droplets from the tip thereof while being driven to turn, wherein two or more fluids including a detergent and a gas are mixed and jetted out of the tip of the nozzle, the fluid droplets can be controlled to a smaller size than the conventional double-fluid cleaning system or high pressure jet system, enabling the problems noted above to be successfully overcome.
According to a second aspect of the invention, there is provided a version of the nozzle device according to the first aspect, wherein the cup member is driven to turn by turbine air fed to the nozzle device. According to the second aspect of the invention, as the cup member is driven to turn by turbine air, the number of revolutions of the cup member can be set higher. Also, by adjusting the quantity of the turbine air that is fed to the nozzle device, it is made possible to control the droplet size and droplets speed of the fluid to respectively desired values and to achieve cleaning in a broad range of conditions.
According to a third aspect of the invention, there is provided a version of the nozzle device according to the first or second aspect, wherein the opening angle of the mixed fluid that is jetted out of the tip of the nozzle is controlled with the shaving air that is fed to the nozzle device. According to the third aspect of the invention, as the opening angle of the mixed fluid that is jetted out is controlled with shaving air, cleaning can be achieved in a broad range of conditions.
According to a fourth aspect of the invention, there is provided a version of the nozzle device according to any one of the first through third aspects, wherein the cup member is rotationally supported without contact by bearing air that is fed to the nozzle device. According to the fourth aspect of the invention, as the cup member is rotationally supported without contact by bearing air, dust generation from the apparatus can be restrained, and the cup member can be easily turned at high speed.
According to a fifth aspect of the invention, there is provided a version of the nozzle device according to any one of the first through fourth aspects, further provided with a sensor device which detects the number of revolutions of the cup member, wherein the number of revolutions is controlled according to the feedback of the number of revolutions of the cup member detected by the sensor device. According to the fifth aspect of the invention, since the cup member is subjected to the feedback control as detected by the sensor device, the number of revolutions of the cup member can be easily accomplished.
According to a sixth aspect of the invention, there is provided a version of the nozzle device according to any one of the first through fifth aspects, further provided with a sensor device which detects the number of revolutions of the cup member, wherein the number of revolutions of the cup member detected by the sensor device is displayed.
According to a seventh aspect of the invention, there is provided a version of the nozzle device according to any one of the first through sixth aspects, wherein a plurality of through holes are formed in the cup member in the circumferential direction, and the detergent is jetted out of the through holes. According to the seventh aspect of the invention, as a plurality of through holes are formed in the cup member in the circumferential direction, the detergent can be jetted out evenly.
According to an eighth aspect of the invention, there is provided a version of the nozzle device according to the seventh aspect, wherein the through holes are inclined outward at an angle α to the axis of the cup member. According to the eighth aspect of the invention, as the through holes are inclined outward at an angle α to the axis, a preferable spray pattern can be formed.
According to a ninth aspect of the invention, there is provided a version of the nozzle device according to any one of the first through eighth aspects, wherein the tip part of the cup member is formed to be concave inward, and the inner circumferential edge of the concave is formed to be inclined outward at an angle α to the axis of the cup member. According to the ninth aspect of the invention, as the tip part of the cup member is formed to be concave inward, an even more preferable spray pattern can be formed.
According to a tenth aspect of the invention, there is provided a version of the nozzle device according to the ninth aspect, wherein a plurality of grooves are formed in the inner circumferential edge of the concave in the tip part of the cup member. According to the tenth aspect of the invention, as a plurality of grooves are formed in the inner circumferential edge of the concave in the tip part of the cup member, an even more preferable spray pattern can be formed.
According to an eleventh aspect of the invention, there is provided a version of the nozzle device according to any one of the first through tenth aspects, wherein the shaving air is fed to the outer circumferential side of the cup member. According to the eleventh aspect of the invention, as the shaving air is fed to the outer circumferential side of the cup member, the spray pattern can be controlled with the shaving air.
According to a twelfth aspect of the invention, there is provided a version of the nozzle device according to any one of the first through tenth aspects, wherein the shaving air is fed between an air cap arranged on the outer circumferential side of the cup member and the nozzle body. According to the twelfth aspect of the invention, the shaving air is fed between an air cap and the nozzle body, the spray pattern can be controlled with the shaving air.
According to a thirteenth aspect of the invention, there is provided a version of the nozzle device according to the twelfth aspect, wherein spirally shaped air guides are formed on the outer circumference of the air cap. According to the thirteenth aspect of the invention, as spirally shaped air guides are formed on the outer circumference of the air cap, the flow of the shaving air can be swirled, and the spray pattern can be even more preferably controlled with the shaving air.
According to a fourteenth aspect of the invention, there is provided a version of the nozzle device according to any one of the first through thirteenth aspects, wherein the speed of fluid droplets jetted out of the nozzle tip is 0.1 to 100 m/second. According to a fifteenth aspect of the invention, there is provided a version of the nozzle device according to any one of the first through fourteenth aspects, wherein the droplet size of the fluid jetted out of the nozzle tip is not more than 100 μm. According to the fourteenth and fifteenth aspects of the invention, as the speed and size of the fluid droplets are controlled within the optimal range, satisfactory cleaning results can be achieved.
The present invention can help provide satisfactory cleaning results.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an overall configuration of a cleaning apparatus to which a nozzle device according to the invention is applied;
FIG. 2 shows a plan of the configuration of the essential part of FIG. 1 ;
FIG. 3 shows a rear view of the nozzle device according to the invention;
FIG. 4 shows the A-A section of FIG. 3 ;
FIG. 5 shows an exploded perspective view of the process of assembling the nozzle device;
FIG. 6 shows the B-B section of FIG. 3 ;
FIG. 7 shows the C section of FIG. 3 ;
FIG. 8 shows the D section of FIG. 3 ;
FIG. 9 shows the E section of FIG. 3 ;
FIG. 10 shows the front view of an air cap;
FIG. 11 shows a frontal section of a cup member;
FIG. 12 shows a left profile of the cup member; and
FIG. 13 shows a partially enlarged view of the cup member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A nozzle device and a cleaning apparatus equipped with this nozzle device embodying the present invention in a preferred mode will be described in detail below with reference to the accompanying drawings.
FIG. 1 shows an overall configuration of the cleaning apparatus to which the nozzle device according to the invention is applied, and FIG. 2 , a plan of the configuration of its essential part. As shown in FIG. 1 and FIG. 2 , this cleaning apparatus 10 comprises a wafer turning device 12 which holds and turns a wafer W to be cleaned and a detergent spraying device 30 which sprays a detergent in an atomized state onto the wafer W being held and turned by that wafer turning device 12 .
Incidentally in FIG. 1 and FIG. 2 , illustration of a turbine air feeding device (feed piping), a shaving air feeding device (feed piping) and a bearing air feeding device (feed piping) to be described afterwards is dispensed with.
First, the configuration of the wafer turning device 12 will be described. A turntable 18 formed in a disk shape is arranged within a cleaning tub 16 installed on a pedestal 14 . A vacuum chuck 20 is provided over the turntable 18 , and the wafer W is sucked and held by this vacuum chuck 20 .
On the other hand, a spindle 22 is linked to the lower part of the turntable 18 , and the output shaft of a turntable driving motor 24 is linked to the lower end of this spindle 22 . The turntable 18 is turned by being driven by this turntable driving motor 24 .
Next, the configuration of the detergent spraying device 30 will be described. A detergent tank 36 is connected to the input side of a detergent pump 32 which supplies the detergent to the detergent spraying device 30 via a pipe 34 . On the other hand, a gun 40 is connected to the output side of the detergent pump 32 via a pipe 38 . A spray nozzle 42 , which is the nozzle device, is disposed at the tip of the gun 40 , and the detergent in an atomized state is sprayed from this spray nozzle 42 onto the wafer W.
This gun 40 is supported by the tip of an arm 44 disposed within the cleaning tub 16 as shown in FIG. 1 and FIG. 2 , and the base of this arm 44 is fastened to the output shaft of a motor 46 . The motor 46 is supported on the inner wall face of the cleaning tub 16 via a bracket 48 , and by driving this motor 46 the arm 44 is swung to cause the gun 40 to move horizontally above the wafer W.
In the detergent spraying device 30 of the above-described configuration, when the detergent pump 32 is driven, the detergent in the detergent tank 36 is sucked into the detergent pump 32 and fed to the gun 40 in a pressurized state. The detergent fed to the gun 40 is sprayed in an atomized state from the jet outlet of the spray nozzle 42 . The detergent sprayed from the spray nozzle 42 , after hitting the wafer W, falls into the cleaning tub 16 and is guided to a liquid drain 28 via ribs 26 disposed within the cleaning tub 16 . It is discarded (or recycled) via a pipe 50 linked to that liquid drain 28 .
Next, the configuration of the nozzle device (the spray nozzle 42 ), which is a characteristic part of the invention, will be described in detail. FIG. 3 shows a rear view (the top view in FIG. 1 ) of the nozzle device 42 , FIG. 4 shows the A-A section of FIG. 3 , and FIG. 5 shows an exploded perspective view of the process of assembling the nozzle device 42 . FIG. 6 shows the B-B section of FIG. 3 , FIG. 7 shows the C section of FIG. 3 , FIG. 8 shows the D section of FIG. 3 , and FIG. 9 shows the E section of FIG. 3 .
This spray nozzle 42 is provided with a substantially cylindrical nozzle body 52 and a cup member 54 which is arranged within the cylinder of this nozzle body 52 and jets out fluid droplets from the tip while being driven to turn. The nozzle body 52 is formed of a tip cover 52 A and a barrel 52 B.
A base 52 C is fixed to the rear face of the barrel 52 B so as to seal the barrel 52 B. A supporting shaft 52 D extends to this base 52 C.
Whereas this spray nozzle 42 is a nozzle device which jets out from the tip a mixture of two or more fluids including the detergent and a gas, it is so configured that not only the detergent is fed to it by the detergent pump 32 already described but also turbine air, shaving air and bearing air are supplied into it.
As shown in FIG. 3 , FIG. 4 , FIG. 5 and FIG. 6 , the detergent is fed from a detergent feeding joint 56 fixed to the base 52 C and, as shown in FIG. 4 , is jetted out of the tip of the cup member 54 as fluid droplets via a detergent channel 56 A which penetrates the axis of the spray nozzle 42 . Incidentally, this detergent channel 56 A is formed of a field tube 56 B shown in FIG. 4 and FIG. 5 or the like.
As shown in FIG. 3 , FIG. 4 and FIG. 5 , turbine air is fed from a turbine air feeding joint 58 fixed to the base 52 C, is supplied to a spindle 60 via a turbine air channel 58 A as shown in FIG. 4 , and is enabled to drive the rotation of the rotation shaft 60 B of the spindle 60 shown in FIG. 5 .
Incidentally, the spindle 60 comprises a cylindrical stator 60 A, which is the spindle body, and the rotation shaft 60 B disposed rotatably in the cylinder of this stator 60 A. The rotation of the rotation shaft 60 B is driven by turbine air fed from the rear face of the stator 60 A.
The cup member 54 is fixed to the tip of the rotation shaft 60 B of the spindle 60 . Therefore, the turbine air drives the rotation of the cup member 54 .
As shown in FIG. 3 , FIG. 5 and FIG. 9 , bearing air is fed from a bearing air feeding joint 62 fixed to the base 52 C, fed to the spindle 60 via a bearing air channel 62 A as shown in FIG. 9 , and can rotationally support the rotation shaft 60 B of the spindle 60 without contact as shown in FIG. 5 . Therefore, the cup member 54 is rotationally supported by the bearing air without contact.
As shown in FIG. 3 , FIG. 5 and FIG. 6 , a fibrous sensor device 64 B is inserted from a sensor joint 64 fixed to the base 52 C, and the tip of the sensor device 64 B is so arranged as to be positioned on the rear face of the spindle 60 via a sensor passage 64 A as shown in FIG. 6 to be enabled to detect the number of revolutions of the rotation shaft 60 B of the spindle 60 shown in FIG. 5 . Therefore, the number of revolutions of the cup member 54 can be detected by the sensor device 64 B.
The number of revolutions of the cup member 54 is controlled by a control device not shown on the basis of the feedback of the number of revolutions of the cup member 54 detected by this sensor device 64 B.
Turbine air and bearing air fed into the spray nozzle 42 pass a discharged air channel 66 A as shown in FIG. 7 , and are discharged to the rear face of the spray nozzle 42 from an air discharging joint 66 fixed to the base 52 C as shown in FIG. 3 , FIG. 4 and FIG. 7 . Incidentally, a muffler 66 B shown in FIG. 5 is fitted to the rear face of the air discharging joint 66 .
As shown in FIG. 3 , FIG. 5 and FIG. 8 , shaving air is fed from a shaving air feeding joint 68 fixed to the base 52 C, and is supplied to the periphery of the spindle 60 via a shaving air channel 68 A as shown in FIG. 8 , with the opening angle of the mixed fluid jetted out from the tip of the nozzle being controlled. Details of this aspect will be described below.
As shown in FIG. 4 and FIG. 5 , gaps are formed between an air cap 70 and the tip cover 52 A (the nozzle body 52 ) arranged on the outer circumferential side of the cup member 54 , and the shaving air that is fed jets out of these gaps.
FIG. 10 shows the front view of the air cap 70 . A tapered face 70 A constituting these gaps is formed on the outer circumference of this air cap 70 , and air guides 70 B, which are spiral convex strips, are formed on this tapered face 70 A.
The above-described configuration of the air cap 70 causes the shaving air fed into the gaps between the air cap 70 and the tip cover 52 A to form air flows along the spiral shape of the air guides 70 B and to be jetted out from the nozzle tip while turning counterclockwise. These flows of shaving air enable the opening angle of the mixed fluid jetted out from the nozzle tip to be controlled.
Next, the detailed configuration of the cup member 54 will be described. FIG. 11 shows a frontal section of the cup member 54 , and FIG. 12 , a left profile of the cup member 54 . As shown in FIG. 11 , this cup member 54 is configured by combining three members including an outer 54 A, an inner 54 B and an insert 54 C.
A female thread is cut inside a through hole in the rear face of the outer 54 A to enable the tip of the rotation shaft 60 B of the spindle 60 to be screwed in. Therefore, the detergent can be fed from the detergent channel 56 A into the cup member 54 .
The tip part of the cup member 54 is formed to be concave inward, and the inner circumferential edge 54 D of this concave is formed to be inclined outward at an angle α to the axis of the cup member 54 . It is preferable for this angle α to be 15 to 45 degrees.
Grooves 54 E, 54 E . . . of a prescribed pitch P are formed all around the inner circumferential edge 54 D (more specifically the inner circumferential edge of the outer 54 A) of this concave as the partially enlarged view of FIG. 13 shows. Though there is no particular limitation to the pitch P of these grooves 54 E, it can be 0.1 to 0.5 mm. Nor is there any particular limitation to the depth D of these grooves 54 E, but it can also be 0.1 to 0.5 mm.
It is preferable for the opening angle β of these grooves 54 E to be 30 to 60 degrees. It is also preferable for these grooves 54 E, 54 E . . . to have no flat part between them.
As shown in FIG. 11 and FIG. 12 inner 54 B has through holes 72 , 72 . . . all over at a prescribed pitch in two concentric radial positions. These through holes 72 are formed to be inclined outward at an angle α to the axis of the cup member 54 . It is preferable for this angle α to be 15 to 45 degrees. These through holes 72 , 72 . . . cause the detergent fed from the detergent channel 56 A to be jetted forward at a prescribed angle.
The combination of the constituent elements of the spray nozzle 42 described above enables a desired spray pattern to be formed.
Though not illustrated in any of FIG. 3 through FIG. 9 referred to so far, bolt members N for combining different constituent elements and sealing members R (mainly O rings) for keeping airtightness and watertightness among the constituent elements are also used.
The cleaning method which uses the cleaning apparatus 10 configured as described above as shown in FIG. 1 and FIG. 2 will now be described. First, a carrier robot not shown carries the wafer W, which is the work to be cleaned, onto the vacuum chuck 20 and mounts it there. The wafer W is then sucked and held by that vacuum chuck 20 .
Next, the turntable driving motor 24 is driven to turn the turntable 18 , and the wafer W starts turning. At the same time, the motor 46 is driven, and the arm 44 swings from a prescribed standby position (the position indicated by double-dot chain lines in FIG. 2 ) to a prescribed cleaning start position (the position indicated by solid lines in FIG. 2 ).
Then, the arm 44 starts oscillating horizontally within a prescribed range of angles. As a result, the gun 40 disposed at the tip of the arm 44 starts reciprocating horizontally above the wafer W.
Next, the detergent pump 32 is driven, and the detergent in the detergent tank 36 is sucked into the detergent pump 32 . The detergent sucked into the detergent pump 32 is fed to the gun 40 in a pressurized state, and jetted out in an atomized state from the spray nozzle 42 of the gun 40 onto the wafer W. The jetted detergent is sprayed onto the wafer W turning on the turntable 18 to clean the wafer W.
In this process, turbine air, shaving air and bearing air as referred to above are fed to the spray nozzle 42 in addition to the detergent, and jetted onto the wafer W in an atomized state in a prescribed spray pattern.
First, the cup member 54 is rotationally supported without contact by the bearing air that is fed. Therefore, dust generation from the apparatus can be restrained, and the cup member 54 can be easily turned at high speed (e.g. 70000 rpm at the maximum).
Also, the cup member 54 is driven into rotation by the turbine air that is fed. Therefore, the droplet size and droplets speed of the fluid can be controlled to respectively desired values by adjusting the quantity of the turbine air that is fed to achieve cleaning in a broad range of conditions.
Further, the sensor device 64 B which detects the number of revolutions of the cup member 54 is provided and the number of revolutions is controlled according to the feedback of the number of revolutions of the cup member 54 , which facilitates the control of the number of revolutions of the cup member 54 .
Also, the opening angle of the mixed fluid jetted out of the tip of the nozzle is controlled with the shaving air that is fed. Therefore, as the opening angle of the mixed fluid that is jetted out is controlled with the shaving air, cleaning can be accomplished in a broad range of conditions.
In particular, the mixed fluid that is jetted out can be controlled to a desired state by regulating the shaving air that is fed, the above-described various configurational factors applied to the cup member 54 (including the angle α of the inner circumferential edge 54 D, the grooves 54 E, the angle β of the grooves 54 E, the through holes 72 and the angle α of the through holes 72 ) and the above-described various configurational factors applied to the air cap 70 (including the tapered face 70 A and the air guides 70 B).
As the spray nozzle 42 so far described jets out of its tip a mixture of two or more fluids including the detergent and a gas, the fluid droplets can be controlled to a smaller size than the conventional double-fluid cleaning system or high pressure jet system, enabling the problems noted above to be successfully overcome.
The speed of fluid droplets jetted out of this spray nozzle 42 can be kept at, for instance, 0.1 to 100 m/second. Further, the droplet size of the fluid jetted out of the spray nozzle 42 can be reduced to, for instance, 100 μm or less.
Referring back to FIG. 1 and FIG. 2 , the spraying of the detergent is continued for a prescribed length of time, after the lapse of which the driving of the detergent pump 32 and the feeding of various airs are stopped. This ends the spraying of the detergent. After that, the driving of the motor is stopped, and so is the swinging of the arm 44 , which then returns to its initial standby state.
On the other hand, the turntable 18 continues to be turned even after this end of the spraying of the detergent, and the centrifugal force generated by the turning of the turntable 18 shakes off the detergent remaining on the wafer W, which is thereby subjected to so-called spin drying. This spin driving of the wafer W is also continued for a prescribed length of time, after the lapse of which the driving of the turntable driving motor 24 is stopped.
After the turntable 18 stops turning, the wafer W is released from chucking by the vacuum chuck 20 , and the cleaned wafer W is carried by the carrier robot not shown to the next step.
Incidentally, there is no particular limitation to the detergent to be used in implementing the invention, but the suitable one for the particular purpose of cleaning can be selected for use.
For instance, the SPM detergent which is a mixture of sulfuric acid and hydrogen peroxide water, the APM detergent which is a mixture of ammonia, hydrogen peroxide water and water, the HPM detergent which is a mixture of hydrochloric acid, hydrogen peroxide water and water, the DHF liquid obtained by diluting hydrofluoric acid with water 50 to 200 times, the BHF liquid which is a mixture of hydrofluoric acid and ammonium fluoride, or isopropyl alcohol (IPA) can be used.
The nozzle device and the cleaning apparatus equipped with the nozzle device embodying the present invention in the preferred mode have been hitherto described, but the invention is not limited to this preferred embodiment, but can be implemented in various other ways.
For instance, though the cleaning apparatus 10 is used in this preferred mode, an apparatus in any other appropriate mode, such as a resist removing device, a developing device or a wet etching device can be used as well.
Resist removal and other such procedures are ways of cleaning in a broader sense of the term, to which the nozzle device according to the invention can be applied with equally significant effectiveness. | The present invention provides a nozzle device comprising a substantially cylindrical nozzle body and a cup member which is arranged within the cylinder of the nozzle body and jets out fluid droplets from the tip thereof while being driven to turn, wherein two or more fluids including a detergent and a gas are mixed and jetted out of the tip of the nozzle in order to achieve sufficient cleaning of a single wafer without a re-adhesion of contamination or destruction of the pattern of the wafer. Therefore, the fluid droplets can be controlled to a smaller size than the conventional double-fluid cleaning system or high pressure jet system. | 1 |
This is a Divisional application of U.S. Application Ser. No. 09/312,951 filed May 17, 1999, issued as U.S. Pat. No. 6,441,741 on Aug. 27, 2002.
FIELD OF THE INVENTION
The present invention generally relates to products and materials in the field of over-molding devices having ferrite cores, powdered metal cores and high energy product magnet cores, and more particularly to the materials and products made by overmolding electronic components incorporating such core materials. The invention has particular applications in the field of electronic identification (“EID”) or radio frequency identification (“RFID”) components and devices manufactured by the overmolding process.
BACKGROUND OF THE INVENTION
Ferrite cores, powdered metal cores and high energy product magnets such as samarium cobalt and neodymium-iron-boron magnets have certain advantageous magnetic and electric field properties making them ideal for use in certain types of electronic components and circuitry. These types of materials are frangible, yet the materials can be fabricated into a variety of shapes and generally exhibit good mechanical characteristics under compression loads. However, these frangible materials are generally weak in tensile strength, tending to crack or fracture when subject to relatively modest tensile loading, binding loads or impact loading. Cracks and fractures within the fabricated frangible materials can substantially decrease the beneficial magnetic and electric field properties, negatively impacting their desirable characteristics. Thus, maximum utilization of these types of frangible materials requires consideration of, and accommodation for, their limiting physical properties.
An exemplary application which can benefit from the use of a ferrite core as part of an electronic circuit is an Electronic Identification (“EID”) or Radio Frequency Identification (“RFID”) transponder circuit used in EID or RFID systems. EID and RFID systems generally include a signal emitter or “reader” which is capable of emitting a high frequency signal in the kilohertz (kHz) frequency band range or an ultra-high frequency signal in the megahertz (MHz) frequency band range. The emitted signal from the reader is received by a “transponder” which is activated in some manner upon detection or receipt of the signal from the reader. In EID and RFID systems, the transponder generates a signal or inductively couples to the reader to allow the reader to obtain identification codes or data from a memory in the transponder.
Generally, the transponder of an EID or RFID system will include signal processing circuitry which is attached to an antenna, such as a coil. For certain applications, the coil may be wrapped about a ferrite, powdered metal, or magnetic core. The signal processing circuitry can include a number of different operational components including integrated circuits, as known in the art, and many if not all of the operational components can be fabricated in a single integrated circuit which is the principal component of the signal processing circuitry of EID and RFID devices.
For example, certain types of “active” RFID transponders may include a power source such as a battery which may also be attached to the circuit board and the integrated circuit. The battery is used to power the signal processing circuit during operation of the transponder. Other types of transponders such as “Half Duplex” (“HDX”) transponders include an element for receiving energy from the reader, such as a coil, and elements for converting and storing the energy, for example a transformer/capacitor circuit. In an HDX system, the emitted signal generated by the reader is cycled on and off, inductively coupling to the coil when in the emitting cycle to charge the capacitor. When the emitted signal from the reader stops, the capacitor discharges to the circuitry of the transponder to power the transponder which then can emit or generate a signal which is received by the reader.
A “Full Duplex” (“FDX”) system, by comparison, includes a transponder which generally does not include either a battery or an element for storing energy. Instead, in an FDX transponder, the energy in the field emitted by the reader is inductively coupled into the antenna or coil of the transponder and passed through a rectifier to obtain power to drive the signal processing circuitry of the transponder and generate a response to the reader concurrently with the emission of the emitted signal from the reader.
Notably, many different circuit designs for active, HDX and FDX transponders are known in the art and have been described in a number of issued patents, and therefore they are not described in greater detail herein. Many of the types of EID and RFID transponders presently in use have particular benefits resulting from their ability to be imbedded or implanted within an object to be identified in a manner whereby they are hidden from visual inspection or detection. For such applications, the entire transponder may preferably be encased in a sealed member, for example to allow implantation into biological items to be identified, or to allow use in submerged, corrosive or abusive environments. Accordingly, various references, including U.S. Pat. Nos. 4,262,632; 5,025,550; 5,211,129; 5,223,851, 5,281,855 and 5,482,008, disclose completely encapsulating the circuitry of various transponders within a ceramic, glass or metallic container.
For an encapsulated transponder, it is generally the practice to assemble the transponder circuitry and then insert the circuitry into the glass, ceramic or metallic cylinder, one end of which is already sealed. The open end of a glass-type cylinder is generally melted closed using a flame, to create a hermetically sealed capsule. Other types of glass, ceramic or metallic containers utilize a cap to seal the open end, with the cap glued or mechanically connected to the open ended cylinder, as discussed for example in U.S. Pat. No. 5,482,008. Furthermore, as discussed in the aforementioned patent, to prevent the transponder circuitry from moving around inside of the capsule, it is also known to use an epoxy material to bond the circuitry of the transponder to the interior surface of the capsule.
As shown for example in U.S. Pat. No. 4,262,632 (hereby incorporated by reference), the potential advantages of utilizing EID and RFID devices in biological applications, such as the identification of livestock, have been under investigation for several years. As discussed in the 4,262,632 patent, studies show that an EID “bolus” transponder suitable for placement in the reticulum of a ruminant animal will remain in the reticulum for an indefinite time if the specific gravity of the bolus transponder is two or greater, and/or the total weight of the bolus transponder exceeds sixty grams. Accordingly, for such applications, the bolus transponder generally requires a weight element as the EID circuitry can generally be very small and lightweight, requiring merely the integrated circuit and antenna and few other components. It has therefore been disclosed, for example in the 4,262,632 patent to incorporate a ferrite weight element within an encapsulant which also contains an EID transponder.
The design of a bolus transponder suitable for use in a ruminant animal may be also benefit from the appropriate use of a magnet or a ferrite core to enhance the signal transmission characteristics of the transponder while also providing the necessary weight to maintain the specific gravity of the bolus transponder at two or greater, and/or to have the total weight of the bolus transponder exceed sixty grams. In order to obtain widespread acceptance and use of the EID bolus transponder devices for ruminant animals, however, the devices must also be designed and fabricated with an understanding of the physical and economic requirements of the livestock application. Thus, while ceramic encapsulated bolus transponders suited to the reticulum environment are being investigated, the cost and fragile physical characteristics of the ceramics impact their commercial acceptance. Thus, an encapsulant for fabricating the capsule or casing for EID transponders which does not have the limitations of ceramic, glass or metallic encapsulants, particularly for bolus transponders, would be highly beneficial.
SUMMARY OF THE INVENTION
The present invention contemplates a method and apparatus for overmolding ferrite, powdered metal and magnet core materials and associated circuitry, for example circuitry for an EID or RFID transponder, whereby the encapsulant is a plastic, polymer or elastomer or other injection molded material compatible with the intended application environment. According to the invention, the encapsulant material applied in an injection molding or extrusion molding process to overmold the core and electronic circuitry of the transponder.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional side view of a transponder including an overmolded core fabricated according to the present invention;
FIG. 2 is a cross-sectional view of the transponder of FIG. 1;
FIG. 3 depicts a perspective view of the mold tooling utilized for the overmolding process to fabricate the transponder of FIG. 1;
FIG. 4 depicts a cross-sectional view through the mold tooling of FIG. 3 during the initial stage of the injection of molding material into the mold tooling;
FIG. 5 depicts a second cross-sectional view of the mold tooling of FIG. 3 showing a later stage in the molding process;
FIG. 6 depicts another cross-sectional view of the tooling of FIG. 3 showing a further stage in the molding process;
FIG. 7 depicts another cross-sectional view of the tooling of FIG. 3 showing the molding process wherein the pins are being retracted into the tooling;
FIG. 8 depicts a side view of an alternative configuration for a transponder which has not yet been coated with molding material;
FIG. 9 depicts the front view of the transponder of FIG. 8;
FIG. 10 depicts the transponder of FIGS. 8 and 9 placed within the mold tooling of FIG. 3 during the injection molding process at the same stage as depicted in FIG. 6;
FIG. 11 depicts a frangible core element placed within the tooling of FIG. 3 during the overmolding injection process at the same stage as the step depicted in FIG. 6;
FIG. 12 depicts a cross sectional view of a frangible core overmolded with an overmolding material according to the process of the present invention;
FIG. 13 depicts a perspective view of a transponder within an alternative design for the mold tooling, and positioned therein by one or more centering elements during the overmolding process;
FIG. 14 depicts a perspective view of a centering element as shown in FIG. 13 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 depicts a cross-sectional side view of a transponder 10 made according to the present invention. FIG. 2 depicts an end view of the transponder 10 of FIG. 1 . The transponder 10 includes signal processing circuitry such as an integrated circuit 12 mounted on a circuit board 14 together with other circuit elements such as a capacitor 16 . The signal processing circuitry may be an active, Half Duplex (HDX) or Full Duplex (FDX) transponder circuit.
The integrated circuit 12 and capacitor 16 are affixed to the circuit board 14 and electrically coupled to a wire 18 formed into a coil 20 , at the leads or ends 22 and 24 of the wire 18 . In the embodiment illustrated in FIGS. 1 and 2, the coil 20 is wrapped about a bobbin 26 and then positioned over a core 30 , with the circuit board 14 affixed to an end of the core 30 to form a transponder assembly 10 a . As discussed below, the transponder assembly 10 a may preferably be over-molded within an injection molding material 32 , which may be a plastic, polymeric or epoxy material to form the completed transponder 10 .
The relative axial location of the coil 20 about the core 30 may be important to the optimal operation of the transponder 10 . Specifically, the transponder 10 preferably includes a tuned coil 20 and capacitor 16 combination. Generally, in a transponder, tuning is accomplished by matching the length of the wire 18 forming coil 20 to the capacitance of capacitor 16 . However, when the wire 18 has to be wrapped around the bobbin 26 and installed over the core 30 , the exact length of wire 18 , as well as its inductance, cannot be as advantageously controlled during design and fabrication so as to allow matching of the inductance of the coil 20 to the capacitance of the capacitor 16 in order to tune the circuit of the transponder 10 . It should be appreciated that if the transponder is not properly tuned, the reading and data transfer capabilities of the transponder may be diminished.
It has been found, however, that by the proper axial placement of the core 30 within the coil 20 , the transponder 10 can be tuned even without optimizing the length of the wire 18 , as the inductance of the coil 20 changes due to the axial positioning of the ferrite core 30 . For a given set of design parameters for a ferrite core 30 and coil 20 combination, including the core's circumference and length as well as the length of the wire 18 and the capacitance of the capacitor 16 , a tuned transponder assembly 10 a can be fabricated by moving the coil 20 axially along the long axis of the ferrite core 30 until a tuned inductor/capacitor system is established and then securing the bobbin 26 with coil 20 to the ferrite core 30 during the manufacturing process.
Following assembly of the circuitry of the transponder assembly 10 a , the transponder assembly 10 a is transferred to an injection molding machine, Specifically, the transponder assembly 10 a is placed within the mold tooling 40 , 42 illustrated in FIGS. 3-7. FIG. 3 depicts a perspective view of the mold tooling 40 , 42 without the transponder assembly 10 a installed therein. The mold tooling 40 , 42 , when closed, defines a cavity 44 sized to receive the transponder 10 a in preparation for over-molding with the plastic, polymeric or epoxy injection molding material 32 . It should be noted, however, that while depicted as cylindrical, the interior walls of the mold tooling 40 , 42 can have surface features to define a variety of shapes or patterns on the outer surface of the completed transponder 10 , as may be beneficial to particular applications. The potential variations for the design of the exterior shape of the completed transponder, thus, for example, may be cylindrical, bullet shaped, tapered at opposite ends or a flattened oval, and the outer walls may be smooth, rough or bumpy, depending on the intended application.
As depicted in FIG. 3, the mold tooling 40 , 42 includes inwardly projecting pins 46 , 48 which serve to position and secure the transponder assembly 10 a within the tooling 40 , 42 during the injection process. The pins 46 , 48 are configured to be retracted by pressure response pin retractors 50 , 52 into the mold tooling 40 , 42 near the end of the injection cycle. At one end of the mold tooling 40 , 42 is a sprue 56 through which the injection molding material 32 is injected by an injection molding machine (not shown). As also shown in the perspective view of FIG. 3, the mold tooling 40 , 42 may include guide pins 60 on tooling 42 which align with and engage guide pin receiving holes 62 on tooling 40 when the mold tooling is closed, to maintain the alignment of the mold tooling 40 , 42 during the injection cycle.
FIGS. 4-7 depict cross-sectional views of the mold tooling 40 , 42 , and a transponder assembly 10 a positioned therein, illustrating in sequential the advance of the plasticized molding material 32 during the injection molding process. As depicted, the pins 46 , 48 act to co-axially position and center the transponder assembly 10 a within the mold cavity 44 . When the heated and plasticized molding material 32 is injected under pressure by the injection molding machine, the plasticized molding material 32 flows in through the sprue 56 and impinges upon the end 64 of the core 30 as shown by arrow 70 , and axially compresses the core 30 against pins 48 which are positioned to contact the opposite end 66 of the transponder assembly 10 a.
The molding material 32 then flows radially outward along the end 64 of the ferrite core 30 as depicted by arrows 72 in FIGS. 4 and 5. When enough molding material 32 has been injected to fill up the end of the cavity 44 , the advancing face of the molding material 32 proceeds longitudinally along the radially outer surface 68 of the transponder assembly 10 a , as shown by arrows 74 in FIG. 6 . This over-molding injection process only subjects the core 30 to compressive loads, and does not subject the core 30 to tensile loading at any time during the entire injection cycle. Thus, by the overmolding injection process of the present invention the core 30 will not be damaged in a manner which would diminish the electrical or magnetic properties of the core.
When the mold cavity 44 is completely filled with the plasticized molding material 32 , the internal pressure within the cavity 44 increases. The pins 46 , 48 , which position the transponder assembly 10 a within the cavity 44 , are connected to pin retractors 50 , 52 , which are pressure sensitive. When the pressure in the mold cavity reaches a predetermined level, the pins 46 , 48 retract into the mold cavity wall as shown by arrows 76 , 78 , and the space vacated by the pins 46 , 48 is filled by the molding material 32 as shown in FIG. 7 . Since the molding material 32 has already encased the transponder 10 , however, the molding material 32 will hold the transponder 10 in place during the curing or hardening stage of the injection over-molding cycle. Upon completion of the over-molding process, the mold tooling 40 , 42 is opened and the completed transponder 10 is ejected.
FIGS. 8 and 9 depict a side view and a front view, respectively, of an alternative embodiment of a transponder 80 which does not include the core 30 of the transponder 10 of FIG. 1 . Instead, for the transponder 80 , the wire 18 forming the coil 20 is wrapped about the circuitboard 14 upon which the integrated circuit 12 and capacitor 16 are mounted. The coil 20 is interconnected to the circuitboard 14 and the integrated circuit 12 thereon, via leads 22 and 24 generally as discussed above with respect to FIG. 1 . The transponder 80 of FIGS. 8 and 9 is generally much smaller than the assembly of FIG. 1, in that it particularly does not include the core 30 and the added weight and size attendant to the use of the core 30 as depicted in FIG. 1 . The transponder 80 of FIGS. 8 and 9, however, can also be over-molded in a process similar to the process described with respect to FIGS. 4-7.
To briefly illustrate this process, the transponder 80 is depicted Within the assembled mold tooling as shown in FIG. 10, which is comparable to mold tooling 40 and 42 discussed above with respect to FIGS. 3-7. In the illustration of FIG. 10, the injection of the plastisized molding material 32 has progressed to essentially the same stage as shown in FIG. 6, in that the advancing face of the molding material 32 is proceeding longitudinally up the outer surface of the transponder 80 and the pins 46 and 48 are centrally positioning the transponder 80 within the mold tooling 40 , 42 . Again, the exterior configuration of the resulting overmolded transponder assembly 60 may be any desired shape which is limited only by the moldability of the shape. It should be noted that transponder 80 may be encased in glass prior to the overmolding process, however, the glass capsule is not shown.
FIG. 11 illustrates another application for the overmolding process according to the present invention in which a frangible core 110 is placed within the mold tooling 40 and 42 of FIG. 3 and positioned by pins 46 and 48 , during the over-molding process. The over-molding process proceeds generally in the same manner as discussed above with respect to FIGS. 4-7. FIG. 11 thus illustrates the stage generally corresponding to FIG. 6, wherein the advancing face of the plasticized molding material 32 is proceeding longitudinally along the outer radial surface of the frangible core 110 . Following completion of the over-molding process, the encapsulated frangible core 110 is ejected from the mold tooling. The completed assembly 100 , as shown in the cross-sectional view of FIG. 12, is a frangible core 110 encased within an overmolding material 112 . In this embodiment, the frangible core may be formed from ferrite, powdered metals or high energy product magnets such as samarium cobalt and neodymium-iron-boron materials.
FIG. 13 depicts a cross-sectional view of a transponder within an alternative design for the mold tooling, and positioned therein by one or more centering elements 120 during the overmolding process to fabricate the transponder like that of FIG. 1 . The centering elements 120 are designed with a center portion such as a sleeve 122 , designed to fit around the core 30 . The centering elements 120 may also include radially outwardly projecting fins or pins 124 , which will center the transponder within the tooling during the overmolding process, and thereby eliminate the need for the retractable pins illustrated and described above.
The over-molding process of the present invention encapsulates the frangible core 110 in a protective shell, which allows the frangible core materials to be used in applications which the frangible physical property of such materials would not otherwise allow. For example, samarium cobalt and neodymium-iron-boron magnets encased in a relatively thin coating of plastic or polymeric materials by the over-molding process could be used in objects subject to shock, impact or vibrational loads which would otherwise lead to the cracking, fracturing or other physical and magnetic degradation of the magnetic core.
FIG. 14 depicts a perspective view of the centering element 120 , showing the sleeve 122 and the radial projecting fins or pins 124 . The centering element 120 may be formed from plastic, or from the same type of material used to overmold the transponder. It is also contemplated that the centering element may simply be a part of, or connected, to the bobbin 26 of FIG. 1, wherein the pins 124 simply extend radially outward from one end or both ends of the bobbin.
The material selected for over-molding of the transponder assembly 10 a , transponder 80 or frangible core 110 , depends in part upon the specific application for the completed component. Various types of thermoplastic materials are available for injection molding such components. As used herein, thermoplastic is to be construed broadly, including for example linear polymers and straight-chain or branch-chained macromolecules that soften or plasticize when exposed to heat and return to a hardened state when cooled to ambient temperatures. The term polymer is to be understood broadly as including any type of polymer such as random polymers, block polymers, and graft polymers.
A large number of thermoplastic polymeric materials are contemplated as being useful in the overmolding of transponders and frangible cores of the present invention. The thermoplastic materials may be employed alone or in blends. Suitable thermoplastic materials include, but are not limited to, rubber modified polyolefins, mettallocene, polyether-ester block copolymers, polyether-amide block copolymers, thermoplastic based urethanes, copolymers of ethylene with butene and maleic anhydride, hydrogenated maleic anhydride, polyester polycaprolactone, polyester polyadipate, polytetramethylene glycol ether, thermoplastic elastomer, polypropylene, vinyl, chlorinated polyether, polybutylene terephalate, ploymethylpentene, silicone, polyvinyl chloride, thermoplastic polyurethane, polycarbonate, polyurethane, polyamide, polybutylene, polyethylene and blends thereof.
Preferred thermoplastic materials include rubber modified polyolefins, metallocenes, polyether-amide block copolymers and polyether-ester block copolymers. Preferred rubber modified polyolefins are commercially available under the tradenames of VISTAFLEX™ from Advanced Elastomer Systems Corporation, KRATON™ from Shell Corporation, HIFAX™ from Montell Corporation, X1019-28™ from M. A. Hanna, SARLINK™ from DSM Corporation, and SANTOPRENE™ from Advanced Elastomer Systems Corporation. Preferred metallocenes are available from Dow Corporation under the tradenames ENGAGE™ and AFFINITY™. Preferred polyether-amide block copolymers are available under the tradename PEBAX™ from EIG Auto-Chem. Preferred polyether-ester block copolymers are commercially available from DuPont under the tradename HYTREL™.
The thermoplastic overmolded casings of the present invention may also include a suitable filler or weighting material in order to adjust the properties of the finished casing and/or transponder. For example, the specific gravity or density of the overmolded casing may be adjusted by the addition of a suitable material, such as barium sulfate, zinc oxide, calcium carbonate, titanium dioxide, carbon black, kaolin, magnesium aluminum silicate, silica, iron oxide, glass spheres and wollastonite. The filler or weighting material may be present in an amount that will adjust the specific gravity of the overmolded casing and the resulting transponder. Thus, the weighting material may be added in a range from about 5 percent by weight to about 70 percent by weight. Additionally, the over-molding material for the casings of the present invention may also include a suitable plasticizer or other additives, in order to improve the processability and physical properties, such as the flow properties and ejectability of the over-molding material. The plasticizer may be present in an amount that will adjust the flow properties during the injection molding process as necessary for various applications.
Notably, for many of the foregoing types of injection molding materials, particularly those whose density is increased by the addition of a densifier, the material in its plasticized state for the injection process has a low viscosity. Thus, injection molding such materials requires high injection pressures in turn leading to high stress forces being imposed on the core materials during the injection process. For these reasons, minimizing or eliminating any loading other than compressive loading on the frangible cores during the injection process is highly preferred.
The over-molded casing of the present invention preferably have a wall thickness of between about 0.010 inches to over one inch, however, for most applications the wall thickness will preferable be less than 0.5 inches. Depending on the desired exterior shape of the completed assembly and the shape of the core, the wall thickness of the casing may be uniform or may vary significantly at various locations about the core.
For a bolus transponder 10 intended for use within ruminant animals, it is necessary to have specific physical properties for the over-molded casing material. Thus, the over-molded casing material must be able to withstand the acidic environment in the digestive tract of a ruminant-animal, it must be impervious to the microbes and enzymes which are active within the digestive tract of the ruminant animal, and it should preferably have certain physical properties to allow ease in shipping and handling of the bolus transponder 10 prior to administration to the ruminant animal. In addition, it is preferable that the bolus transponder 10 have a specific gravity of at least 1.7 and preferably at least 2. Thus, it is generally desirable to use a weighting material to increase the bulk density or specific gravity of the over-molding material, so that the over-molding material has a specific gravity which assists in maintaining the specific gravity of the fabricated bolus transponder 10 in the desired range.
For a bolus transponder 10 , therefore, it has been determined that a preferred combination of a thermoplastic polyester elastomer sold by DuPont under the trade name HYTREL 3078™, combined with barium sulfate as a densifier provides an acceptable combination for use as the over-molding material for a bolus, and, in appropriate ratios, provides an injection molding material with a specific gravity in the range of between 1.7 and 2. Such a material may be introduced by DuPont and available under the trade name HYTREL 8388.™
By way of providing a specific example, an acceptable over-molding material can be made from a blend of HYTREL 3078™, or a similar thermoplastic polyester elastomer (TPE), mixed with barium sulfate in a ratio of between about 20 to 90% TPE and 80% to 10% barium sulfate. This blend provides a suitable over-molding material to form the casing for the bolus transponder 10 . Purified USP grade barium sulfate or barite fines are preferred as the densifying agents, as these materials have previously been blended with a carnauba wax and a medicant to form boluses for ruminant animals, as described for example, in U.S. Pat. No. 5,322,697 issued to American Cyanamid Company.
The advantages of the foregoing method for use in fabricating boluses have been found to be significant. First, eliminating the necessity of the ceramic encapsulate has resulted in a substantial reduction in material costs as compared to the costs of fabricating a ceramic encapsulated bolus. In addition, the fabrication costs, i.e. the costs of manufacturing the bolus separate and distinct from the component costs, are substantially decreased due to the efficiency and automation associated with the injection molding process. Accordingly, the overall costs savings over the equivalent costs of fabricating bolus transponder encased in a ceramic material may exceed 50%. While the ceramic encased boluses have been found to be relatively fragile such that they can be damaged if they are dropped or even rattled together during shipping, the boluses encased with the HYTREL 8388™—barium sulfate over-molding material has demonstrated physical characteristics which have eliminated these problems. In addition, the bolus transponder 10 of the present invention can be packaged in bulk with minimal packing material because vibrations during shipping between respective boluses does not cause breakage. Finally, the HYTREL 8388™; TPE-barium sulfate combination provides the physical characteristics required for utilization in the stomach of a ruminant animal. The blend is not effected by the acidic conditions, is neutral to the biologic fuana, microbes and enzymes, and it has a preferred specific gravity so as to maintain retention within the stomach of a ruminant animal.
For the transponder 80 of FIGS. 8-10 which is intended for implantation applications, it may be preferable to use a class 6 medical grade epoxy. Alternatively, the transponder 80 may be encased in a glass material by known methods, and then overmolded with the plastic or polymeric materials discussed herein to provide added strength, impact resistance and toughness, which properties are lacking in the glass encased transponders.
It will be appreciated by those skilled in the art that, upon review of the foregoing description of the present invention, other alternatives and variations of the present invention will become apparent. Accordingly, the scope of the protection afforded is to be limited only by the appended claims. | A method of fabricating, a composition and overmolded components fabricated by the method and with the composition such as an overmolded transponder circuitry for a radio frequency identification device. | 1 |
BACKGROUND OF THE INVENTION
Many Integrated Circuits (ICs) require a high voltage to operate. Among such ICs are the so called non-volatile memory ICs, which include EPROMs, EEPROMs and Flash-EPROMs. For a non-volatile memory IC, a high voltage, generated either internally or provided externally, is needed in order to program or erase the memory transistors that are used to store data.
In recent years demand for integrating different classes of functions, which until recently required several different ICs to achieve, has arisen. Combining the functions performed by several ICs into a single IC requires the development of new transistor structures capable of operating under different biasing conditions. ICs containing both non-volatile memory devices, e.g. memory transistors and the supporting circuitry, as well as circuits performing a variety of analog and digital functions are currently available in the market. Furthermore, a new generation of ICs use embedded Flash-EPROM memory transistors to program or erase a programmable logic device formed within the same IC.
In most such ICs, one or more p-channel or n-channel MOS transistors are typically placed in the path that carries a high voltage to the memory transistors. MOS transistors are employed in the high voltage path to either pass the high voltage to or inhibit the high voltage from being applied to the memory transistor during a programming/erase cycle. When an n-channel MOS transistor is used to inhibit a positive high voltage from being applied to a memory transistor, it must be able to withstand the high voltage that is applied to its drain terminal without entering a gated-diode breakdown region.
FIG. 1 shows the biasing condition that an n-channel MOS transistor 10 experiences when it is used to block a high voltage 30 applied to its drain terminal 24. As can be seen from FIG. 1, gate terminal 22 and source terminal 26 of transistor 10 are connected to ground while a high voltage 30 is applied to the transistor drain terminal 24.
To prevent transistor 10 from entering the gated-diode breakdown region, the electric field near the interface between drain 14 and channel 18 must be reduced.
One method of reducing the electric field near the drain-channel interface is to raise the potential of gate 12. For example, in FIG. 2A voltage supply 40 is applied to raise the potential of gate terminal 22. FIG. 2B illustrates the effect of increasing the gate-to-source voltage V gs of n-channel MOS transistor 10 on the transistor gated-diode breakdown voltage characteristic. In FIG. 2B, the x-axis designates the drain-to-source voltage V ds and the y-axis designates the drain current I ds flowing through drain terminal 24. Three graphs of drain current as a function of drain voltage are shown in FIG. 2B, with each graph representing a different gate-to-source V gs voltage. As can be seen form FIG. 2B, as the magnitude of gate-to-source voltage V gs increases, the magnitude of gated-diode breakdown voltage BV also increases (i.e. BV3 has a greater magnitude than BV2.) However, the increase in the gate-to-source voltage V gs causes transistor 10 to turn on, rendering transistor 10 inoperable as a high voltage switching device.
Exposing a conventional p-channel or n-channel MOS transistor to a high voltage for an extended period of time leads to other undesirable effects. Most notably, a high electric field in a transistor channel region adjacent a drain causes electrons to be injected from the channel into the gate oxide. This phenomenon which is commonly known as the "hot electron effect" leads to many long-term problems, e.g. transistor performance degradation and reduced reliability. The high-voltage induced problems become more pronounced as transistor dimensions decrease.
Techniques developed to reduce the high electric field near the drain-channel interface in order to increase the gated-diode breakdown voltage and to reduce the hot electron effect typically modify the dopant concentration of the drain so as to create a more gradual and a reduced doping concentration at the drain-channel interface. Two such techniques, widely known in the art, are the Lightly Doped Drain (LDD) and the Double Diffused Drain (DDD).
FIG. 3 shows a prior art MOS transistor 30 which includes LDD regions 12, as described in "VLSI TECHNOLOGY", by S. M. Sze, published by McGraw-Hill International 1988, pages 482-483. The dopant concentration in n LDD regions 12 are several orders of magnitude smaller than those in n+ regions 14. The reduction in the electric field near the drain-channel region (or the source-channel region) stemming from the reduction in the dopant concentration near the drain-channel interface results in an increase in the gated-diode breakdown voltage for transistor 30.
A disadvantage of transistor 30 is that it requires extra masking and implant steps to form LDD regions 12.
FIG. 4 show a transistor 40 which includes DDD to lower the electric field and thereby increase the gated-diode breakdown voltage, as described in U.S. Pat. No. 4,851,360 issued to Haken et al. As shown in FIG. 4, both the source and the drain regions of transistor 40 include two diffusion regions 14 and 18. To form doubled diffused regions 14 and 18, a first mask is used to implant regions 14 with phosphorous. Thereafter, using the same mask, arsenic is implanted into the same region, subsequent to which transistor 20 is implant annealed. Because phosphorous atoms have a greater diffusivity than arsenic atoms, they diffuse laterally during the implant anneal process to form region 18 which has a lower dopant concentration than does adjacent region 14.
A disadvantage of transistor 40 is that DDD regions 14 increase the source/drain junction capacitances. The increase in the RC time constants, caused by the increase in source/drain junction capacitances leads to longer propagation delays and slower performance of circuits that use transistor 40.
Another disadvantage of transistor 40 is that it requires an extra implant step to form DDD regions 14.
SUMMARY OF THE INVENTION
In accordance with the present invention, a high voltage split gate MOS transistor has a reduced electric field near the drain-channel interface region and hence an increased gated-diode breakdown voltage. The split gate transistor includes two separate and distinct but partially overlapping gates. A first gate partially overlaps the source region and extends along a portion of the channel in an area located directly above the channel region. A second gate partially overlaps the drain region and extends along the remaining portion of the channel region.
The high voltage split gate MOS transistor does not require an additional fabrication processing step when constructed in a standard double-poly fabrication process.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts an n-channel MOS transistor configured to block a high voltage applied to its drain terminal.
FIG. 2A depicts an n-channel MOS transistor which has its gate and drain terminals connected to a positive voltage supply and which has its source and substrate terminals connected to ground.
FIG. 2B depicts the effect of increasing the gate-to-source voltage of the n-channel MOS transistor of FIG. 2A on the transistor gated-diode breakdown voltage characteristic.
FIG. 3 depicts a prior art n-channel MOS transistor including a lightly diffused drain.
FIG. 4 depicts a prior art n-channel MOS transistor including a double diffused drain.
FIG. 5 depicts a high voltage n-channel MOS split gate transistor, in accordance with the present invention.
FIG. 6 depicts a high voltage p-channel MOS split gate transistor, in accordance with the present invention.
FIG. 7 depicts a high voltage n-channel MOS split gate transistor configured to block a high voltage applied to its drain terminal.
FIG. 8 depicts a high voltage n-channel MOS split-gate transistor configured to pass a high voltage applied to its drain terminal.
DETAILED DESCRIPTION
As shown in FIG. 5, a high voltage n-channel MOS split gate transistor 100, in accordance with the present invention, includes: an n-type source 102, an n-type drain 104, a p-type substrate 106, a gate oxide 108, a first channel region 114, a second channel region 116, a first poly-silicon gate 110 and a second poly-silicon gate 112. Poly-silicon gates 110 and 112 partially overlap each other to form an overlap region 138 which is filled by a dielectric material, e.g. silicon-dioxide. Overlap region 138, which is defined by a lower surface of poly-silicon 112 and an upper surface of poly-silicon 110 ensures that a continuous channel is formed between source 102 and drain 104 when so required.
Transistor 100 when fabricated using a standard double-poly non-volatile memory Integrated Circuit (IC) fabrication process requires no additional processing step. Poly-silicon gates 110 and 112 are formed and patterned after the first and second poly-silicon layer deposition steps of a standard double-poly non-volatile memory IC fabrication process, respectively. Therefore, transistor 100 is ideally suited for use as a high voltage switch in a non-volatile memory IC.
FIG. 6 depicts a high voltage PMOS split gate transistor 200, in accordance with the present invention. PMOS transistor 200 includes: a p-type source 102, a p-type drain 104, an n-type substrate 106, a gate oxide 108, a first channel region 114, a second channel region 116, a first poly-silicon gate 110 and a second poly-silicon gate 112. Poly-silicon gates 110 and 112 partially overlap each other to form an overlap region 138, defined by a lower surface of poly-silicon 112 and an upper surface of poly-silicon 110, which is filled by a dielectric material, e.g. silicon-dioxide. It is understood that the discussion below applies equally to both n-channel and p-channel high voltage split gate MOS transistors and as such only the operation of n-channel transistors is discussed.
FIG. 7 shows the voltages that are applied to transistor 100 when placed in a high voltage path, e.g. a programming path, of a memory transistor (not shown) that is not to be programmed during a programming cycle, requiring transistor 100 to inhibit the high voltage from being applied to the memory transistor. When configured to block a high voltage, the typical voltages applied to various terminals of transistor 100 are as follows: voltage supply 150, which is typically at twelve volts, is applied to drain terminal 118; voltage supply 170, which is typically at zero volts, is applied to source terminal 122, substrate terminal 130 and first gate terminal 134; voltage supply 160, which is typically at five volts, is applied to second gate terminal 136. The above biasing voltages place transistor 100 in what is commonly known in the art as a gate-diode configuration mode.
Transistor 100, as shown in FIG. 7, blocks the high voltage 150 applied to its drain terminal 118 while advantageously avoiding the gated-diode breakdown. Voltage supply 160 applied to gate terminal 136 inverts channel region 114, thereby, reducing the electric field near the drain-channel interface region. As a result, the gated-diode breakdown voltage increases, allowing transistor 100 to sustain high voltage 150 without entering the gated-diode breakdown region. Advantageously, because gate 110 is held at zero volts, channel region 116 remains uninverted keeping transistor 100 in an off state.
FIG. 8 shows the voltages that are applied to transistor 100 when placed in a high voltage path, e.g. a programming path, of a memory transistor (not shown) that is to be programmed during a programming cycle, requiring transistor 100 to pass the high voltage to the memory transistor. As can be seen from FIG. 8, when acting as a high voltage passing device the voltages applied to various terminals of transistor 100 are as follows: voltage supply 150, which is typically at twelve volts, is applied to drain terminal 118 and first and second gate terminals 134 and 136; voltage supply 170, which is typically at zero volts, is applied to substrate terminal 130. Source terminal 122 is connected to a circuitry which delivers the high voltage to memory transistors (not shown).
As shown in FIG. 8, transistor 100 is configured to operate in the normal active mode. Voltage supply 150 applied to gate terminals 134 and 136 inverts channel regions 114 and 116, thereby forming a conduction path between the source and drain terminals of the transistor. Transistor 100 thus configured passes high voltage 150 from its drain terminal 118 to its source terminal 122.
The split-gate MOS transistor, advantageously reduces the electric field near its drain-channel interface region without requiring additional processing steps when manufactured using a standard double-poly CMOS process, therefore, it is constructed at no additional cost. The reduction in the electric field prevents the transistor from entering the gated-diode breakdown region when the transistor is used as a high voltage switching device.
The split-gate MOS transistor advantageously minimizes hot-electron induced effects and, consequently, enjoys a diminished performance degradation and offers improved reliability. | A split-gate MOS transistor includes two separate but partially overlapping gates to reduce the electric field near the drain-channel interface region and, thereby, has an increased gated-diode breakdown voltage. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefit of priority as a divisional application of U.S. patent application Ser. No. 11/008,477 filed Dec. 9, 2004, which claims the benefit of priority from Korean Application Number 2003-90187, filed Dec. 11, 2003, the disclosures of which are hereby incorporated herein by reference in their entirety as if set forth fully herein.
FIELD OF THE INVENTION
[0002] The present invention relates to methods, systems and computer program products for measuring a width of a fine pattern, and more specifically to methods, systems and computer program products for measuring a width of a fine pattern using a scanning electron microscope.
BACKGROUND OF THE INVENTION
[0003] The Scanning Electron Microscope (SEM) is an external observation device for projecting an electron beam onto a sample and detecting reflected secondary electrons to display a picture with pixels having a luminosity proportional to the number of secondary electrons. An SEM may be used for external inspecting and measuring a line width of fine patterns and micro dimensions.
[0004] In a semiconductor fabrication process, a line width of a fine pattern of a semiconductor device may be measured using a scanning electron microscope. A conventional method for measuring a micro line width uses a picture to judge a similarity between an inspection pattern and a standard pattern (i.e., pattern matching). That is, an SEM image of a standard pattern is compared with an SEM image of a real inspection pattern by pixels. A line width is measured only when the inspection pattern is determined to be non-defective as a result of the comparison. That is, the line width is not measured when the inspection pattern is determined to be defective.
[0005] However, according to the conventional method for matching a pattern, a pattern that is within a permissible modification range of a process may be determined to be defective. In this case, the measuring of line width may not be performed even though the measuring should be performed.
SUMMARY OF THE INVENTION
[0006] Some embodiments of the invention measure a fine pattern by pattern matching using a secondary electron signal profile. A secondary electron signal profile of an inspection pattern and a secondary electron profile of a standard pattern are compared to determine whether the inspection pattern is non-defective or defective.
[0007] In some embodiments, a secondary electron signal profile is acquired from a scanning electron microscope picture. The pattern matching using the secondary electron signal profile judges modifications of the inspection pattern to be non-defective when the modifications are within a permissible range.
[0008] In some embodiments, the secondary electron signal profile can be acquired by a secondary electron signal measured along a line connecting two measuring points of a scanning electron microscope picture. For a contact hole pattern, both measuring points may be measured by rotating on a center of the contact hole for several times, and an average thereof may be determined for the secondary electron signal.
[0009] Pattern matching using the secondary electron signal profile can compare and determine a peak height H p and a distance D p between the peaks, or a slant distance S p of a peak and a horizontal distance D s of a slant of the secondary electron signal profiles.
[0010] In other exemplary embodiments of the present invention, pattern matching is performed by comparing the secondary electron signal profiles of the inspection pattern and the standard pattern and by comparing pictures of the inspection pattern and the standard pattern by pixels.
[0011] In some embodiments, if the inspection pattern is determined to be defective by comparing the scanning electron microscope picture of the inspection pattern with the scanning electron microscope picture of the standard pattern, pattern matching may be performed, using the secondary electron signal profiles.
[0012] Specifically, methods of measuring a fine pattern according to some exemplary embodiments of the present invention acquire a scanning electron microscope of inspection pattern. A secondary electron signal profile of the inspection pattern is acquired from the scanning electron microscope picture of the inspection pattern. A determination is made as to whether the inspection pattern is defective by comparing a standard secondary electron signal profile with the secondary electron signal profile of the inspection pattern. Finally, a line width of an inspection pattern that is determined to be non-defective is measured.
[0013] Methods for measuring a fine pattern according to other exemplary embodiments of the present invention load a sample on a stage of a scanning electron microscope and move to an inspection pattern on the sample to acquire a secondary electron signal profile and a scanning electron microscope picture of the inspection pattern. A determination is made as to whether the inspection pattern is defective by comparing the scanning electron microscope picture of the inspection pattern and the secondary electron signal profile thereof with a scanning electron microscope of a standard pattern and a secondary electron signal profile thereof, respectively. Finally, a line width of an inspection pattern that is determined to be non-defective is measured.
[0014] Other embodiments of the present invention provide systems for measuring a line width. A picture forming unit is configured to form a scanning electron microscope picture of an inspection pattern. A secondary electron signal profile forming unit is configured to form a secondary electron signal profile from the scanning electron microscope picture of the inspection pattern. A storage unit is configured to store a scanning electron microscope picture and a secondary electron signal profile of a standard pattern. A pattern matching unit is configured to determine whether the inspection pattern is non-defective or defective by comparing the scanning electron signal microscope pictures and the secondary electron signal profiles. Finally, a measuring unit is configured to measure a line width of an inspection pattern that is determined to be non-defective.
[0015] Still other embodiments of the present invention provide computer program products. Computer-readable program code is configured to form a scanning electron microscope picture of an inspection pattern in the computer. Computer-readable program code is also configured to form a secondary electron signal profile from the scanning electron signal microscope picture of the inspection pattern. Computer-readable program code is also configured to store a scanning electron microscope picture and secondary electron signal profile of a standard pattern. Computer-readable program code is also configured to determine whether the inspection pattern is non-defective or defective by comparing the scanning electron microscope pictures and the secondary electron signal profiles. Finally, computer-readable program code is also configured to measure a line width of the inspection pattern that is determined to be non-defective.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a block diagram illustrating systems, methods and computer program products for measuring a line width of fine patterns according to various embodiments of the present invention;
[0017] FIG. 2 and FIG. 3 illustrate scanning electron microscope pictures of inspection patterns for a contact hole and secondary electron signal profiles with respect to one cross-section thereof;
[0018] FIG. 4 and FIG. 5 illustrate scanning electron microscope pictures of inspection patterns for lines and secondary electron signal profiles with respect to one cross-section thereof;
[0019] FIG. 6 illustrates a cross-section of a contact hole pattern and a secondary signal profile thereof;
[0020] FIG. 7 is a flowchart of operations for measuring line widths of fine patterns according to various embodiments of the present invention; and
[0021] FIG. 8 is a flowchart of operations for measuring line widths of fine patterns according to other embodiments of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0022] The present invention now will be described more fully hereinafter with reference to the accompanying figures, in which embodiments of the invention are shown. This invention may, however, be embodied in many alternate forms and should not be construed as limited to the embodiments set forth herein.
[0023] Accordingly, while the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit the invention to the particular forms disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the claims. Like numbers refer to like elements throughout the description of the figures.
[0024] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein the term “and/or” includes any and all combinations of one or more of the associated listed items.
[0025] The present invention is described below with reference to block diagrams and/or flowchart illustrations of methods, apparatus (systems) and/or computer program products according to embodiments of the invention. It is understood that each block of the block diagrams and/or flowchart illustrations, and combinations of blocks in the block diagrams and/or flowchart illustrations, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, and/or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer and/or other programmable data processing apparatus, create means for implementing the functions/acts specified in the block diagrams and/or flowchart block or blocks.
[0026] These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instructions which implement the function/act specified in the block diagrams and/or flowchart block or blocks.
[0027] The computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer-implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions/acts specified in the block diagrams and/or flowchart block or blocks.
[0028] Accordingly, the present invention may be embodied in hardware and/or in software (including firmware, resident software, micro-code, etc.). Furthermore, the present invention may take the form of a computer program product on a computer-usable or computer-readable storage medium having computer-usable or computer-readable program code embodied in the medium for use by or in connection with an instruction execution system. In the context of this document, a computer-usable or computer-readable medium may be any medium that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device.
[0029] The computer-usable or computer-readable medium may be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, device, or propagation medium. More specific examples (a non-exhaustive list) of the computer-readable medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, and a portable compact disc read-only memory (CD-ROM). Note that the computer-usable or computer-readable medium could even be paper or another suitable medium upon which the program is printed, as the program can be electronically captured, via, for instance, optical scanning of the paper or other medium, then compiled, interpreted, or otherwise processed in a suitable manner, if necessary, and then stored in a computer memory.
[0030] It should also be noted that in some alternate implementations, the functions/acts noted in the blocks may occur out of the order noted in the flowcharts. For example, two blocks shown in succession may in fact be executed substantially concurrently or the blocks may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
[0031] Finally, it will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these tenns. These terms are only used to distinguish one element from another.
[0032] The present invention relates to methods, systems and computer program products for measuring a fine pattern using a scanning electron microscope. Embodiments of the present invention can be employed to measure a line width of the fine pattern in a semiconductor fabrication process. Methods for measuring a line width of a pattern can match a standard pattern with an inspection pattern. Embodiments of the present invention can use a picture and a secondary electron signal profile. The pattern matching using a secondary electron signal profile may be more accurate than the pattern matching using a picture.
[0033] FIG. 1 illustrates micro line width measuring systems, methods and computer program products using a scanning electron microscope in accordance with various embodiments of the present invention. An electron beam 100 is projected from an electron beam source and scanned to a sample 104 lying on a stage 102 by operation of a condenser lens 106 , a deflection coil 108 and an objective lens 110 . In this case, secondary electrons 105 are projected from the sample 104 due to the electron beam 100 scanned on the sample. The secondary electrons 105 projected from the sample 104 are detected by a detector 112 and converted into an electric signal. The converted electric signal is converted to a digital signal by an analog/digital (A/D) converter 114 and processed by a picture processor 116 , thereby seen on a screen of a display unit 120 . A computer controller 118 controls the operations. The computer controller 118 and the picture processor 116 may be embodied as one or more enterprise, application, personal, pervasive and/or embedded computer systems, and may also be combined into one or more enterprise, application, personal, pervasive and/or embedded computer systems.
[0034] The picture processor 116 comprises a scanning electron microscope picture forming unit 122 , a secondary electron profile forming unit 124 , a pattern matching unit 126 , and a line width measuring unit 128 . The scanning electron microscope picture forming unit 122 processes the digital signal received from the analog/digital converter 114 to form a scanning electron microscope picture. For instance, the scanning electron microscope forming unit 122 may include a memory as a storage for storing the formed picture. The luminosity of each pixel comprising the picture of the scanning electron microscope depends on an intensity of the secondary electrons projected from the sample 104 . As an amount of the projected secondary electrons becomes larger, the pixel becomes brighter. The picture of the scanning electron microscope comprises pixels arranged in a plane (i.e., in two-dimensions).
[0035] The secondary electron signal profile forming unit 124 forms a secondary electron signal profile for indicating an intensity of the secondary electrons projected in a specific direction of the inspection pattern (a direction of measuring a line width). For example, the secondary electron signal profile forming unit 124 may include a memory as a storage for storing the secondary electron signal profile.
[0036] The pattern matching unit 126 confirms a similarity between the inspection pattern and a prestored standard pattern. Information on the standard pattern (i.e., information on the picture of the scanning electron microscope and the secondary electron signal profile with respect to the standard pattern) is stored in an additional memory 119 and read by the computer 118 and/or stored in an internal memory 119 ′ of the computer 118 . Alternatively, the information on the standard pattern may be stored in a memory (not shown) in the picture processor 116 . The pattern matching unit 126 determines a similarity between the standard pattern and the inspection pattern (e.g., whether the inspection pattern is defective or non-defective) through a comparison of pictures of the scanning electron microscope and a comparison of the secondary electron signal profiles. When the inspection pattern is determined to be non-defective by the pattern matching unit 126 , the line width measuring unit 128 measures a line width of the inspection pattern.
[0037] Referring to FIGS. 2 through 5 , pattern matching according to various embodiments of the present invention will be explained, as may be performed by the pattern matching unit 126 .
[0038] FIG. 2 illustrates a picture of a non-defective pattern and a secondary electron signal profile shown in the display unit 120 and FIG. 3 illustrates a picture of a modified pattern in a permissible error range and a secondary electron signal profile shown in the display unit 120 . The non-defective pattern of FIG. 2 may constitute a standard pattern and the modified pattern of FIG. 3 may constitute an inspection pattern in some embodiments. In the drawings, a line MP indicates a direction of measuring a line width. As the number of secondary electrons projected from around an edge of the inspection pattern is large, and as the number (the intensity) of projected secondary electrons becomes larger (higher), the pixels comprising a picture of the scanning electron microscope are displayed more brightly. Therefore, it will be understood that the patterns in FIGS. 2 and 3 are contact holes.
[0039] Meanwhile, FIGS. 4 and 5 show typical diagrams of the scanning electron microscope pictures with respect to a line pattern and a modified pattern in a permissible range. The non-defective pattern of FIG. 4 may constitute a standard pattern and the modified pattern of FIG. 5 may constitute an inspection pattern in some embodiments.
[0040] The secondary electron signal profile (or waveform) displayed on the bottom of the scanning electron microscope picture indicates an intensity of the secondary electron signal achieved along the line MP of the picture. Two measurement points are placed on the line MP for measuring a line width.
[0041] To remove a noise element (to allow improved S/N ratio), signal processing can be applied to the secondary electron signal profile. For example, to allow improved S/N ratio, an arithmetic average, moving average, etc. can be applied. In the arithmetic average, a plurality of secondary electron signal profiles are acquired from a picture of the secondary scanning electron microscope and averaged to acquire a non-defective secondary electron signal profile.
[0042] To compute an average for a pattern of a contact hole, both measurement points for measuring a line width may be rotated around a center of the contact hole (the line MP is rotated around a center of the contact hole) and measured for several times to achieve an average value. Meanwhile, for a line pattern, both measurement points may be moved along a line pattern (the line MP is moved up and down along the line pattern) and measured for several times to determine an average value.
[0043] In the moving average, the secondary electron profile is flatted to improve the profile using a moving average with respect to the secondary electron signal profile. For example, when a signal of the nth pixel is S (n) and N number of pixels are moving averaged, the nth pixel signal S′(n) of which noise may be improved is given as follows:
[0000]
S
(
n
)
=
∑
i
=
-
L
i
=
+
L
S
(
n
+
i
)
N
(
where
L
=
(
N
-
1
)
/
2
)
.
Equation
(
1
)
[0044] Referring to FIGS. 2 , 3 , 4 and 5 , the scanning electron microscope pictures are somewhat different but the secondary electron signal profiles thereof are the same practically. Therefore, according to some embodiments of the present invention, both the scanning electron microscope pictures and the secondary electron signal profiles are used for a pattern matching.
[0045] First, pattern matching will be explained through a comparison of the scanning electron microscope pictures according to some embodiments of the present invention. Pixels comprising a picture of the scanning electron microscope with respect to the inspection pattern are compared with corresponding pixels comprising a standard scanning electron microscope picture to show the result as a score. As a result, if the score is higher than a preset threshold value, the inspection pattern is determined to be a non-defective pattern and if not, the inspection pattern is determined to be a defective pattern. The score dividing the similarity between the inspection pattern and the standard pattern may be acquired from a correlation coefficient calculated from Equation (2) using a normalized correlation between the pixels comprising the two scanning electron microscope pictures:
[0000]
r
(
X
,
Y
)
=
[
N
∑
i
.
j
P
ij
M
ij
-
(
∑
i
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j
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ij
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j
M
ij
)
]
[
N
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i
.
j
P
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2
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i
.
j
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ij
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2
]
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i
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M
ij
2
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(
∑
i
.
j
M
ij
2
)
2
]
.
Equation
(
2
)
[0046] In the above Equation (2), P ij refers to a concentration at pixel (i, j) of the picture of the inspection pattern (i.e., an intensity of secondary electrons), and M ij refers to a concentration at pixel (i, j) of the picture of the standard pattern.
[0047] When a correlation coefficient acquired from Equation (2) is r, the score (s) is given as follows:
[0000] s=1000r 2 . Equation (3)
[0048] When the score is 1000, the inspection pattern agrees with the standard pattern completely. As the score approaches 1000, the similarity between the two patterns increases. The inspection pattern is determined to be non-defective if the score is higher than a threshold value as a result of the matching, and defective if the score is less than the threshold value.
[0049] Next, pattern matching using a secondary electron signal profile will be explained with reference to FIG. 6 . FIG. 6 illustrates a schematic cross-section of the contact hole pattern and a secondary electron signal profile with respect to the cross-section of the contact hole pattern. As is well known, the secondary electron signal profile indicates a peak around an inclined edge of the inspection pattern. That is, the signal intensity of the secondary electron pattern is large around the edge of the pattern.
[0050] For example, in some embodiments of the present invention, the pattern matching using the secondary electron signal profile considers peak heights H p and distances D p between the peaks, or slant distances of peak S p and horizontal distances of a slant D s of the secondary electron signal profiles with respect to two patterns. In this case, the peak height H p means a vertical distance between a highest point and the lowest point. The highest point corresponds to an upper edge of the inspection pattern and the lowest point corresponds to a bottom edge of the inspection pattern. The slant distance of peak S p means a distance of the line connecting the highest and lowest points of the secondary electron profile. The horizontal distance of slant D s means a horizontal distance between the highest and lowest points of the secondary electron signal profile.
[0051] As the peak height H p becomes higher, the contact hole becomes deeper. In contrast, as the peak height H p becomes lower, the contact hole becomes shallower. In addition, as the slant distance S p and the horizontal distance D s become larger, the inclination of the contact hole becomes gentler.
[0052] According to some embodiments of the present invention, the peak height of the standard pattern is compared with the peak height of the inspection pattern to determine whether the inspection pattern is non-defective or defective. The result can be expressed as a score. When the peak height of standard pattern is R_Hp and the peak height of inspection pattern is S_Hp, the score s may be given by the following Equation (4):
[0000] s={ ( R — Hp−S — Hp )/ R — Hp}* 100. Equation (4)
[0053] If the score is smaller than a given value Tv (0<Tv<100), the inspection pattern is determined to be non-defective. As the given value becomes smaller, the pattern matching is more accurately performed.
[0054] Similarly, in some embodiments, the slant distance of the standard pattern and the slant distance of the inspection pattern, and the peak distance of standard pattern and the peak distance of the inspection pattern may be compared to perform a pattern matching.
[0055] In addition, in some embodiments, the horizontal distance of slant of the standard pattern is compared with the horizontal distance of slant of the inspection pattern to determine whether the inspection pattern is non-defective or defective.
[0056] According to pattern matching using the above-described scanning electron microscope, the modified patterns in FIGS. 3 and 5 can be determined to be defective. However, the secondary electron profiles with respect to the two pictures are closely similar, such that the modified patterns in FIGS. 3 and 5 are determined to be non-defective. Meanwhile, the non-defective patterns in FIGS. 2 and 4 may be determined to be non-defective by both pattern matching methods.
[0057] FIG. 7 is a flowchart of operations for measuring a line width of a fine pattern according to exemplary embodiments of the present invention using, for example, embodiments of FIG. 1 . Measuring a line width of a fine pattern formed in a semiconductor fabrication process will now be explained with reference to FIGS. 1 and 7 .
[0058] First, a sample with an inspection pattern is loaded on a stage 102 of the scanning electron microscope and a wafer is set on the stage 102 by an auto aligning operation at Block 701 .
[0059] The stage 102 and/or an electron beam 100 is transferred by auto aligning and/or auto addressing, so as to move an observation field of the scanning electron microscope to the inspection pattern formed on the wafer as shown in Block 703 . The auto aligning and auto addressing are controlled by the computer 118 .
[0060] The electron beam 100 is projected from an electron beam source, using a condenser lens 106 , a deflection coil 108 and an objective lens 110 , to impinge on the inspection pattern on the wafer 104 . In this case, secondary electrons 105 projected from the inspection pattern are detected by a detector 112 and converted to an electric signal. The converted electric signal is converted into a digital signal by an analog/digital converter 114 to form a picture with respect to an inspection pattern by an SEM picture forming unit 122 , as shown at Block 705 . The SEM picture may be shown on a screen of display unit 120 . Focus, magnification, etc. can be automatically controlled in forming the SEM picture.
[0061] Continuously, a secondary electron profile forming unit 124 acquires the secondary electron signal profile using the SEM picture as fully explained above, at Block 707 . The secondary electron signal profile may be displayed on the screen of display unit 120 and may be displayed overlapping the SEM picture acquired in Block 705 , as shown in FIGS. 2 through 5 .
[0062] The pattern matching unit 126 performs pattern matching using secondary electron signal profiles with respect to SEM pictures of a prepared standard pattern read by the computer 118 and an inspection pattern acquired from the secondary electron signal profile forming unit 124 , at Block 709 . The pattern matching may be performed as explained above.
[0063] If the pattern is determined to be non-defective (i.e., the pattern is in the range of permissible process modification), a line width measuring unit 128 measures the line width of the inspection pattern at Block 711 . Meanwhile, if the pattern is determined to be defective (i.e., the pattern is beyond the permissible process modification), the operation for measuring the line width is stopped at Block 713 . In this case, a proper treatment should follow because the pattern forming process may have a large error.
[0064] FIG. 8 is a flowchart of operations for measuring a line width according to other exemplary embodiments of the present invention. Blocks 701 through 707 illustrated in FIG. 7 are carried out as Blocks 801 through 807 in FIG. 8 .
[0065] Next, a pattern matching unit 126 compares the SEM picture of inspection pattern with the SEM picture of standard pattern to perform pattern matching, at Block 809 .
[0066] If the pattern is determined to be non-defective by the comparison of SEM pictures, a measuring unit 128 measures a line width of the inspection pattern at Block 811 . In contrast, if the pattern is determined to be defective as a result of the comparison of SEM pictures (even if the pattern is in a permissible error range), the pattern matching unit 126 performs the pattern matching again, so as to allow improved reliability of pattern matching. In this case, the secondary electron profile of the inspection pattern is compared with the secondary electron profile of a standard pattern to perform the pattern matching. If the pattern is determined to be non-defective, the measuring unit 128 measures a line width of the inspection pattern at Block 815 . If determined to be defective, the process is stopped at Block 817 . In this case, the process may have a large error, and a proper treatment should be carried out.
[0067] A method for measuring a line width by the measuring unit 128 will now be explained. The line width of the inspection pattern is measured using the secondary electron signal profile that is used in the pattern matching. In some embodiments, S/N ratio with respect to the secondary electron signal profile may be improved using the above explained arithmetic average, the moving average, etc.
[0068] A secondary electron signal of a non-defective profile is acquired and then a line width of the inspection pattern is measured. Two measuring points are decided on the secondary electron signal profile so as to measure the line width. Then, a distance between the two measuring points is measured. A technique for deciding the two measuring points includes a well-known threshold method, a peak detecting method, a function modeling, etc.
[0069] According to some embodiments of the present invention, the inspection pattern is determined to be non-defective or defective finally using the secondary electron signal profile. Therefore, a modified pattern in a permissible error range can be determined to be non-defective instead of being treated as defective, which may stop a fabrication process. Therefore, reliable line width measuring can be provided.
[0070] In the drawings and specification, there have been disclosed embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims. | A pattern is inspected by acquiring a scanning electron microscope picture of an inspection pattern, and acquiring a scanning electron microscope secondary electron signal profile of the inspection pattern. A determination is made as to whether the inspection pattern is defective by comparing the scanning electron microscope picture of the inspection pattern to a scanning electron microscope picture of a sample pattern, and by comparing the scanning electron microscope secondary electron signal profile of the inspection pattern to a scanning electron microscope secondary electron signal profile of a sample pattern. | 6 |
[0001] This application claims priority from Provisional U.S. Patent Application Ser. No. 60/670,360, filed Apr. 12, 2005 and from Provisional U.S. Patent Application Ser. No. 60/681,623, filed May 17, 2005.
TECHNICAL FIELD
[0002] The present invention relates to hydraulic valve mechanisms for activating valves in response to rotation of a camshaft in an internal combustion engine; more particularly, to such mechanisms having a locking mechanism for selectively engaging and disengaging such activation; and most particularly, to such a deactivating hydraulic valve mechanism having a vented internal lost motion spring and oil supply to the hydraulic element assembly that bypasses the lost motion spring chamber to minimize oil pumping by the mechanism while in deactivation mode.
BACKGROUND OF THE INVENTION
[0003] It is well known that overall fuel efficiency in a multiple-cylinder internal combustion engine can be increased by selective deactivation of one or more of the engine valves, especially the intake valves, under certain engine load conditions. For a cam-in-block pushrod engine, a known approach to providing selective deactivation is to equip the hydraulic lifters for those valves with a locking mechanism whereby the lifters may be rendered incapable of transferring the cyclic motion of engine cams into reciprocal motion of the associated pushrods. Typically, a deactivating hydraulic valve lifter (DHVL) includes, in addition to the conventional hydraulic lash compensation element, an outer body and a concentric locking pin housing disposed inside the outer body. The inner locking pin housing and outer body are mechanically connected to the pushrod and to the cam lobe, respectively, and may be selectively latched and unlatched hydromechanically to each other, typically by the selective engagement of one or more locking pins by pressurized engine oil.
[0004] U.S. Pat. No. 6,497,207 discloses such a DHVL wherein a lost motion coil spring is disposed between the lifter body and a tower extension of the inner pin housing. The tower extension is hollow and open at the outer end to admit an engine pushrod. This arrangement is functionally satisfactory for many but not all engine designs. In particular, the tower results in a relatively long overall length of the DHVL and, in order for the pushrod to clear the outer edge of the tower extension, the pushrod must be aligned nearly coaxial with the DHVL. Thus, this arrangement may be incompatible with engines having limited axial space for the added length DHVL, or for engines having relatively large pushrod engagement angles.
[0005] It is known in the art to shorten the operative length of a body and locking pin housing assembly by packaging the lost motion (LM) spring between the adjacent walls of the outer lifter body and the inner pin housing, thereby obviating the need for a tower and its concomitant length. U.S. Pat. No. 6,321,704 B1 (“the '704 patent”) discloses a hydraulic lash adjuster for valve deactivation in a cam-in-head roller finger follower engine having an outer body and an inner locking pin housing wherein the LM spring is disposed in an annular spring chamber between the walls of the body and locking pin housing.
[0006] A significant shortcoming of disposing the LM spring between the outer body and inner locking pin housing, as shown in the '704 patent, is that oil being supplied to the hydraulic element assembly (HEA) must pass through the LM spring chamber. Thus the chamber is always filled with oil, which must be pumped out of the chamber with every stroke of the lifter body in deactivation mode. Pumping oil reduces engine efficiency, as during at least part of the pumping stroke the oil pressure generated in the LM chamber opposes the engine's own oil pressure, and may cause valve train stability issues, wear, and noise due to induced air bubbles or cavitations. Still further, juxtaposition of the oil passages in the outer body and inner locking pin housing under certain lash conditions can allow for a low oil drawdown (drainage) level in the lash adjuster reservoir during engine shutdown, resulting in significant engine noise at restart.
[0007] In addition, the disclosure fails to account for mechanical lash in the deactivation mechanism resulting from inherent manufacturing variability in the deactivation components. The entire assembly is held together by a standard stop clip which is full-fitting in a groove in the outer body member. Thus, the amount of lash between the latching member and the latching surface after assembly, resulting from manufacturing variability in the components, cannot be compensated or adjusted in individual lifter or lash adjuster assemblies.
[0008] What is needed in the art is a deactivation lifter or lash adjuster assembly wherein the LM spring chamber is not in communication with the engine oil being supplied to the HEA.
[0009] What is further needed in the art is a deactivation lifter or deactivation lash adjuster assembly wherein mechanical lash within the lifter or lash adjuster may be readily set by appropriate shimming during assembly.
[0010] It is a principal object of the present invention to provide improved valve deactivation without pumping of deactivation oil in an LM spring chamber in engines requiring short overall length and large pushrod angle capability in a deactivation lifter or deactivation lash adjuster.
SUMMARY OF THE INVENTION
[0011] Briefly described, a deactivating hydraulic valve lifter or deactivating hydraulic lash adjuster, hereinafter referred to as a deactivation mechanism or DHVL, in accordance with the invention includes a conventional hydraulic lash adjustment element, also referred to herein as a hydraulic element assembly (HEA), disposed between a plunger and a cup member. The plunger and cup member are, in turn, disposed in a pin housing that is slidably disposed within an axial bore in a body. A transverse bore in the pin housing contains at least one locking pin that engages a locking feature such as a circumferential groove including a locking surface in the body whereby the body and the pin housing are locked together for mutual actuation by rotary motion of the cam lobe to produce reciprocal motion of an engine pushrod disposed against the hydraulic lash adjustment element.
[0012] A lost motion coil spring is disposed in an annular chamber formed within the envelope of the deactivation mechanism between the body and the pin housing. A vent of the annular chamber permits ready discharge of any accumulated oil from the chamber on the first lost-motion stroke of the body and thereafter.
[0013] An oil passage is provided from an engine gallery to the hydraulic element assembly, at the interface between the cup member and pin housing thereby bypassing the lost motion annular chamber.
[0014] An expansion ring holds the assembly together and also functions to set the mechanical lash in the deactivation mechanism. The ring may be provided as a two-part ring, the first part being a standard-thickness ring and the second part being a shim having a thickness selected to provided a predetermined amount of mechanical lash in the assembled mechanism to ensure facile engagement and disengagement of the locking pins in the body. The ring may also be provided as a one piece ring, its thickness being selected to set mechanical lash.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] These and other features and advantages of the invention will be more fully understood and appreciated from the following description of certain exemplary embodiments of the invention taken together with the accompanying drawings, in which:
[0016] FIG. 1 is an elevational cross-sectional view of a deactivating hydraulic lash adjuster for use as a roller finger follower pivot in an overhead cam engine, substantially as disclosed in U.S. Pat. No. 6,321,704 B1;
[0017] FIG. 2 is an elevational view of a first embodiment of a deactivating hydraulic valve lifter in accordance with the invention for use in a pushrod internal combustion engine;
[0018] FIG. 3 is a plan view of the lifter shown in FIG. 2 , shown rotated 90° counterclockwise;
[0019] FIG. 4 is a first elevational cross-sectional view taken along line 4 - 4 in FIG. 2 ;
[0020] FIG. 5 is a second elevational cross-sectional view taken along line 5 - 5 in FIG. 3 , this view being orthogonal to the view shown in FIG. 4 ;
[0021] FIG. 6 is a cross-sectional elevational view showing the lifter shown in FIG. 4 disposed in an engine block adjacent a cam, the lifter being on the base circle portion of the cam lobe; and
[0022] FIG. 7 is a view like that shown in FIG. 6 , but with the lifter in deactivation (lost motion) mode and the lifter being on the eccentric portion of the cam lobe, showing that the lifter body stays outside of the desired cone of activity for an associated pushrod.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Referring to FIG. 1 , a deactivating hydraulic lash adjuster 10 is substantially as disclosed in U.S. Pat. No. 6,321,704 B1. Lash adjuster 10 has a generally cylindrical adjuster body 12 . A pin housing 14 is slidably disposed within a first axial bore 16 in adjuster body 12 . Pin housing 14 itself has a second axial bore 18 for slidably receiving a plunger 20 having a domed end 22 for receiving a socket end (not shown) of a roller finger follower in an overhead-cam engine valve train.
[0024] Pin housing 14 has a transverse bore 24 slidably receivable of two opposed locking pins 26 separated by a pin-locking spring 28 disposed in compression therebetween. First axial bore 16 in adjuster body 12 is provided with a circumferential groove 30 for receiving the outer ends of locking pins 26 , thrust outwards by spring 28 when pins 26 are axially aligned with groove 30 . In such configuration, lash adjuster 10 is in valve-activation mode. (As shown in FIG. 1 , lash adjuster 10 is in valve-deactivation mode.)
[0025] Upper end 32 of pin housing 14 defines a first seat for a loss-of-motion (LM) return spring 34 disposed within an annular spring chamber 35 formed between bore 16 and pin housing 14 . LM spring 34 finds a second seat at an annular stop 37 in bore 16 .
[0026] Groove 30 further defines a reservoir for providing high pressure oil against the outer ends 36 of locking pins 26 to overcome spring 28 and retract the locking pins into bore 24 , thereby unlocking the pin housing from the adjuster body to deactivate the adjuster. Groove 30 is in communication via at least one port 38 with an oil gallery (not shown) in an engine 40 , which in turn is supplied with high pressure oil by an engine control module (not shown) under predetermined engine parameters in which deactivation of valves is desired.
[0027] Plunger 20 includes check valve components 42 lodged at an inner end thereof. The arrangement of the components and operation of feature 42 has been well known in the prior art for many years. Check valve components 42 include a spring loaded check ball 44 lodged against a seat 46 formed in plunger 20 separating a low-pressure oil reservoir 48 from a high-pressure chamber 50 . Oil is supplied to annular chamber 35 from an engine oil gallery (not shown) via port 54 in adjuster body 12 . Chamber 35 is also in communication with reservoir 48 via port 56 and annular groove 58 in pin housing 14 and annular groove 60 and port 62 in plunger 20 . Oil may be supplied from reservoir 48 to an associated roller finger follower (not shown) via port 52 in the outer end 22 of plunger 20 .
[0028] In operation, lash adjuster 10 is disposed in a bore in engine 40 such that housing 12 remains stationary. When the associated cam and rocker arm (not shown) exert force on plunger end 22 , in lost motion (valve-deactivation) mode, plunger 20 and pin housing 14 are forced into adjuster body 12 in a lost-motion stroke, compressing LM spring 34 . A serious operational problem exists with the arrangement shown for lash adjuster 10 . As spring 34 is compressed and the volume of chamber 35 is diminished, oil within chamber 35 must be pumped out, to the detriment of the mechanism and engine performance as described hereinabove.
[0029] A DHVL (not shown) having an internal LM spring arrangement similar to lash adjuster 10 is known in the art. Such a lifter performs for a pushrod engine the same LM function as does lash adjuster 10 for an overhead-cam engine. In operation during valve-deactivation mode, of course, it is the plunger and pin housing that remain stationary against a valve pushrod while the lifter body reciprocates past the pin housing, compressing the LM spring and diminishing the volume of the annular spring chamber. Such a prior art DHVL suffers from the same shortcomings as lash adjuster 10 , the pumping of oil in the LM chamber during operation in deactivation mode.
[0030] What is needed in the art, for deactivating hydraulic lash adjusters as well as for DHVLs, is a mechanism whereby oil is supplied to a central reservoir in the lifter or adjuster from an engine oil gallery without passing through an internal lost-motion chamber.
[0031] Referring now to FIGS. 2 through 5 , a first embodiment 110 of an improved DHVL in accordance with the invention comprises many components identical or analogous to those described hereinabove for lash adjuster 10 , which components bear the same identification numbers plus 100. Components which are different or significantly modified bear new numbers in the 100 and 200 series.
[0032] DHVL 110 has a generally cylindrical body 112 . A pin housing 114 is slidably disposed within a stepped first axial bore 116 in body 112 . Pin housing 114 itself has a second axial bore 118 for receiving a cup member 119 which in turn slidably receives a plunger 120 supporting a pushrod seat 122 for receiving a ball end 123 of a pushrod in an engine valve train.
[0033] Pin housing 114 has a transverse bore 124 slidably receivable of two opposed locking pins 126 separated by a pin-locking spring 128 disposed in compression therebetween. First axial bore 116 in body 112 is provided with a locking feature such as, for example, circumferential groove 130 for receiving the outer ends of locking pins 126 , thrust outwards by spring 128 when pins 126 are axially aligned with groove 130 . In such configuration, DHVL 110 is in valve-activation mode. (As shown in FIGS. 4 and 5 , DHVL 110 is in valve-activation mode.)
[0034] Upper end 132 of pin housing 114 defines a first seat for a loss-of-motion (LM) return spring 134 disposed within an annular spring chamber 135 formed between stepped bore 116 and pin housing 114 . LM spring 134 finds a second seat at annular step 137 in bore 116 .
[0035] Groove 130 further defines a reservoir for providing high pressure oil against the outer ends 136 of locking pins 126 to overcome spring 128 and retract the locking pins into bore 124 , thereby unlocking the pin housing from the lifter body to deactivate the lifter. Groove 130 is in communication via at least one port 138 with a first oil gallery 131 ( FIGS. 6 and 7 ) in an engine 140 , which in turn is supplied with high pressure oil by an engine control module (not shown) under predetermined engine parameters in which deactivation of valves is desired.
[0036] Plunger 120 includes check valve components 142 lodged at an inner end thereof which, like check valve components 42 of lash adjuster 10 , has been well known in the prior art for many years. Components 142 comprises a spring loaded check ball 144 lodged against a seat 146 formed in plunger 120 separating a low-pressure oil reservoir 148 from a high-pressure chamber 150 .
[0037] DHVL 110 includes a conventional cam follower roller assembly 111 that is well known in the prior art and need not be further elaborated here. Roller assembly 111 is recited solely for completion of disclosure and forms no part of the novelty of the present invention.
[0038] The oil passage 147 by which oil is supplied to reservoir 148 is an improved and distinguishing feature of DHVL 110 over lash adjuster 10 . Oil is supplied to reservoir 148 from a non-switched second engine oil gallery 170 ( FIGS. 6 and 7 ) via port 154 in lifter body 12 circumventing LM spring chamber 135 , as follows:
[0039] Oil from second gallery 170 is fed through body port 154 , thence through an annular oil distribution groove 172 formed in bore 116 , thence through port 157 in pin housing 114 , thence through an axially-extending passage 174 , such as a groove, formed in the outer surface of cup member 119 and leading around LM spring chamber 135 , thence through an adjacent headspace 178 beyond the end of cup member 119 , and thence through a transverse groove 180 formed in the underside of pushrod seat 122 and into reservoir 148 . Note that this oil path provides a high drainback residual oil level in reservoir 148 compared to the level in prior art plunger 20 which is fixed by the level of port 62 . Note also that any oil from oil passage 147 that may undesirably be trapped in an area beneath the cup member 119 is vented away through pin housing 114 to the outside of the DHVL via vent passages 149 a and b formed in the bottom of pin housing 114 .
[0040] Cup member 119 is a novel element over a prior art valve-deactivation lifter or lash adjuster, and is necessitated as follows. Note that reservoir 148 is contained fully within the axial extent of LM chamber 135 and is therefore not directly accessible in a radial direction for an oil supply passage except undesirably through chamber 135 as disclosed in the prior art shown in FIG. 1 . Ergo, supply port 154 must be located beyond the axial limit of chamber 135 ; however, inspection shows that a port at that axial location, absent intervening cup member 119 , intersects high pressure chamber 150 , which is clearly infeasible. Thus, intervening cup member 119 is necessitated. An additional benefit of cup member 119 is that it provides a ready bed for axial passage 174 and thereby provides means for conveying oil desirably to the upper end of plunger 120 for entry into reservoir 148 , resulting in a maximally high drainback level in reservoir 148 .
[0041] Passage 174 is shown in FIG. 4 as being an axial groove formed in the outer surface of cup member 119 . Of course, passage 174 may be formed alternately as an axial groove on the inside surface of pin housing 114 .
[0042] Further, transverse groove 180 is shown as being formed in pushrod seat 122 . Of course, alternatively oil may be supplied from headspace 178 to reservoir 148 via other means which will occur to those of ordinary skill in the art, for example, a notch in the end of plunger 120 mating with seat 122 or a bore through plunger 120 near seat 122 . All such alternative passage means are fully contemplated by the invention.
[0043] Referring now to FIGS. 6 and 7 , in operation, DHVL 110 is disposed in a bore 182 in engine 140 such that body 112 is slidably disposed therein. When the associated cam 184 exerts valve-opening force on roller follower assembly 111 in lost motion (valve-deactivation) mode ( FIG. 7 ), body 112 is forced past plunger 120 , cup member 119 , and pin housing 114 (which are prevented from moving by a pushrod and associated valve spring, not shown) in a lost-motion stroke, compressing LM spring 134 . As spring 134 is compressed and the volume of chamber 135 is diminished, there is no oil systematically provided within chamber 135 to be pumped out, as in the prior art. Further, a vent port 186 is provided in lifter body 112 which overlaps an axial passage 188 formed in engine 140 to permit venting and refilling of chamber 135 with air as the lifter body reciprocates past the stationary pin housing and engine, thereby minimizing the non-productive work required by HDVL 110 .
[0044] An important feature of an DHVL in accordance with the invention is that a wide range of pushrod angles may be accommodated in a relatively short assembly. Cone 190 represents the cone of operation available for pushrods, which in the example shown is a full cone angle of 22°, accommodating pushrod angles from the lifter axis 192 of up to 11°. At the extreme of the lost motion stroke ( FIG. 7 ), the outer end 196 of body 112 does not extend into cone 190 . Another noteworthy feature is that the outer diameter of pushrod seat 122 is larger than the sealing diameter of plunger 120 , that is, to some extent, the pushrod seat overhangs the plunger. This feature is important because the pushrod seat is a sealing type relying on the close fit between its outer diameter and the inside diameter of the pin housing to direct oil from passage 147 into reservoir 148 . Thus, any wear or deformation of the bottom face of the pushrod seat caused by contacting the plunger will be contained on the bottom face and not be translated to the sealing diameter (outer diameter) of the pushrod seat.
[0045] Referring again to FIGS. 4 and 5 , it is yet another important feature of a DHVL in accordance with the invention that each DHVL unit as manufactured may be adjusted to provide a desired amount of internal mechanical axial lash to ensure ready locking and unlocking of the latching pins. Such lash is defined as the clearance between locking surface 197 and pin face 198 when the DHVL is assembled and the pins are therefore in locking position. Sufficient clearance is needed to permit the pins to lock and unlock easily and reliably, but additional clearance creates clatter and accelerated wear in operation of the DHVL. Because of inherent variability in components of a DHVL as manufactured, variations in lash must occur in the mechanism shown in FIG. 1 wherein a single retaining ring is employed. See, for example, axial stop 37 in lash adjuster 10 which governs the stroke of pin housing 14 by engaging flange 15 when lock pin housing 14 is in its up-most position and thus positioning pins 26 for engagement into bores 30 . As can be seen in lash adjuster 10 , a change in the thickness of stop 37 has no affect on lash. In contrast, in an assembly in accordance with the invention, groove 130 is formed having a length in the axial direction greater than the axial length of locking pins 126 . After assembly of any one DHVL using a standard ring 202 having a thickness intended to yield excessive mechanical lash between the locking surface and locking pin, the resulting lash can be measured directly, and a shim ring 204 of a thickness selected to provide optimum lash may be subsequently installed adjacent to ring 202 . Alternately, the resulting accumulated lash of a particular DHVL may be measured and a one piece ring of a desired thickness may be installed to achieve the desired mechanical lash.
[0046] Referring again to FIG. 3 , body 112 preferably is provided with a single off-center flat 113 for antirotation and error-proofing of DHVL installation into engine 140 to ensure that the oil ports are correctly aligned with their respective feed galleries. Preferably, a guide plate (not shown) is employed during installation of a DHVL into an engine block. The guide plate includes asymmetric features such as bolt holes or a mating recess in the engine block such that the guide plate cannot be installed over the DHVL, or mated to the engine, unless the DHVL is properly oriented to the engine. In a V-6 application, typically all lifters in one engine bank are DHVLs.
[0047] While the text of the specification relates this invention to a deactivating hydraulic valve lifter (DHVL), it is understood that the invention is equally applicable to other valve deactivating devices such as deactivating roller hydraulic valve lifters (DRHVL) as shown in FIGS. 2-7 and to deactivating hydraulic lash adjusters (DHLA) as shown in FIG. 1 .
[0048] While the invention has been described by reference to various specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the described embodiments, but will have full scope defined by the language of the following claims. | A deactivating hydraulic valve mechanism includes a hydraulic element assembly disposed within cup within a pin housing slidably disposed within a bore in a body. A transverse bore in the pin housing contains selectively-retractable locking pins that engage a locking feature in the body to selectively lock together the body and the pin housing. A lost motion spring is disposed in a vented annular chamber between the body and the pin housing. An oil passage from an engine gallery to the hydraulic element assembly includes an axial component formed in the cup and bypasses the lost motion chamber. A ring holds the lifter assembly together and also sets mechanical lash. The ring may combine a standard-thickness ring and a shim selected to provided a predetermined amount of mechanical lash in the assembled mechanism to ensure facile engagement and disengagement of the locking pins in the body. | 5 |
BACKGROUND OF THE INVENTION
Aqueous emulsion explosives of the water-in-oil type are well known, as in U.S. Pat. Nos. 3,161,551; 3,164,503 and 3,447,978. U.S. Pat No. 4,248,644 teaches non-aqueous melt-in-fuel emulsion technology wherein essentially anhydrous molten salts are emulsified with an immiscible hydrocarbon fuel. The hydrocarbon fuel forms the continuous phase and the molten oxidizer forms the discontinuous phase. A fuel-continuous emulsion in obtained which is grease-like or extrudable at ambient temperatures.
Until recently, developments in non-aqueous melt-in-fuel emulsion explosives have been directed toward soft or pumpable explosives for commercial blasting operations. However, U.S. patent applications Ser. Nos. 578,177; 578,178; 578,179; 597,415 and 597,416 teach unstable melt-in-fuel emulsions which are castable. These emulsions are formulated so as to be unstable; that is, when cooled, the continuous phase is disrupted as the discontinuous droplets of molten oxidizer crystallize and knit together, forming a rigid structure.
Such compositions derived from unstable emulsions suffer from several disadvantages: The carefully regulated intimacy of fuel and oxidizer mixing achieved during process refinement is subject to the disruptive effects of oxidizer crystal growth and interknitting with potentially adverse effects on performance, sensitivity and storage life of the product. Further, the disruption of the fuel continuum increases the exposure of the oxidizer salts to the effect of moisture which also adversely affects both storage life and performance.
It has not been apparent heretofore that castable energetic compositions can be made from stable non-aqueous emulsions which retain oxidizer phase discontinuity during solidification of the individual oxidizer cells. In contrast to cast compositions made from unstable emulsions, the compositions of the present invention become solid, rigid or firm following cooling without significant disruption of the fuel phase continuum or substantial interknitting of the separate oxidizer cells. As expolsives, the shear sensitivity of the compositions may be reduced and the safety enhanced through internal lubrication by the fuel continuum. As propellants, elastomeric properties may be achieved superior to those of compositions exhibiting the more brittle, interknit crystalline structure resulting from unstable emulsions. In all such castable compositions made from stable emulsions, whether explosives, propellants, flares or gas generators, a high degree of fuel and oxidizer intimacy is maintained on solidification; and superior water resistance and shelf life result from preservation of the fuel continuum.
It is the principal objective of this invention to obtain solid, rigid or firm energetic compositions from stabe non-aqueous emulsions such that the fuel continuous geometry and intimacy of ingredients characteristic of the fluid emulsion is maintained in the final solid product. It is another objective to formulate the compositions in a manner which will permit continuous processing, cooling, optional admixing of additives, and loading or packaging, before solidification. Another objective is to achieve supercooling to or near to ambient temperatures before solidification in order to reduce cast defects resulting from thermal shrinkage. A further objective is to achieve water resistance in the compositions. Other objectives are to achieve internal lubrication and reduced shear sensitivity in explosive compositions and substantially to prevent interknitting of oxidizer crystals so as to achieve improved elastomeric properties in propellants and plastic bonded explosives.
Because the oxidizer cells in the final product are typically sub-micron in certain dimensions, the products are referred to as microcellular composite energetic materials.
Since the discontinuous phase of the fluid emulsion as first formed remains substantially discontinuous in the final solidified product, and since the continuous phase remains substantially continuous in the final solidified product, microcellular composite formulations can also be referred to as solid emulsions. This term is intended to include those microcellular formulations which have solidified as a result of either or both phases having become solid.
SUMMARY OF THE INVENTION
This invention relates to essentially anhydrous energetic compositions, including explosives, propellants, flares and gas generators. The compositions are initially formed at process temperatures above the solidification temperature of contained oxidizer salts as stable, essentially anhydrous emulsions having a continuous fuel phase and a discontinuous molten oxidizer phase. By means of selected surfactants and the degree and duration of shear imparted during mixing, emulsion stability is retained during solidification. The choice of surfactants and the extent of shear also influence the degree to which the material supercools, typically to or near to ambient temperature, before solidification. Upon hardening the compositions retain general fuel phase continuity and oxidizer phase discontinuity. The final product is a firm or solid composition characterized by an intimate dispersion of discrete solid oxidizer cells within a substantially continuous fuel phase. Structural rigidity results from the high ratios of solid oxidizers to fuels and the consequent close packing of the non-spherical oxidizer cells. Experimentation has shown that such structural rigidity occurs regardless of whether the oxidizer cells are crystalline or amorphous in the final solid state. The use of polymeric fuels may also contribute to the structural rigidity and integrity of the final product.
The methods disclosed in the invention permit the manufacturing of numerous formulations from separate non-hazardous components on a continuous basis. Such continuous processing minimizes both the quantity of neat energetic material in process and the residence time of the material at elevated manufacturing temperatures. Safety is greatly enhanced since only small quantities are in process at a given time. Microcellular formulations can therefore employ molten oxidizers having melting temperatures considerably in excess of those considered practical for conventional melt-cast operations. It has been found practical to make microcellular composites involving oxidizers with melt temperatures as high as 250° C. Nevertheless, supercooling has been achieved to ambient or near ambient temperature before solidification takes place.
It will be apparent from the foregoing that a wide variety of ingredients may be used in microcellular compositions, including many which hitherto have been regarded as impractical or unsafe, as well as a variety of low cost ingredients (which can typically be selected to form the bulk of the composition with significant cost savings).
Oxidizer salts which may be used in microcellular compositions, singly or in combination, include the nitrite, nitrate, chlorate and perchlorate salts of lithium, sodium, potassium, magnesium, calcium, strontium, barium, copper, zinc, manganese, lead and the ammonium counterparts. Particularly attractive for ease and safety of handling are combinations of such oxidizer salts which form melts at temperatures below the melting points of the individual salts present. Many such combinations have been found which reduce melting temperatures to levels convenient for processing.
The oxidizer melt may be comprised of soluble ingredients in addition to the molten inorganic oxidizer salts, including soluble self-explosives such as the nitrate or perchlorate adducts of ethanolamine, ethylenediamine and higher homologs; aliphatic amides such as formamide, acetamide and urea; urea nitrate and urea perchlorate; nitroguanidine, guanidine nitrate and perchlorate, and triaminoguanidine nitrate and perchlorate; polyols such as ethylene glycol, glycerol, and higher homologs; ammonium and metal salts of carboxylic acids such as formic and acetic and higher acids; sulfur containing compounds such as dimethylsulfoxide; and mixtures of the above.
These added ingredients may be selected to take advantage of their properties as secondary fuels or oxidizers and as melting point depressants, thus enabling supplementary means for achieving a suitable oxygen balance in the final product, typically from +5% to -50% relative to carbon dioxide, and suitably low melting points, typically within the range from 70° C. to 200° C., preferably from 70° C. to 140° C.
A wide variety of fuels, used separately and in combination, is similarly applicable to microcellular compositions. Almost any organic material can be used to constitute the fuel phase of the emulsion, so long as it is liquid at processing temperatures. Aliphatic fuels are suitable, including waxes and oils, as are nonaliphatic fuels. Both monomeric and polymeric materials are suitable for use, depending upon their physical and chemical properties. Particulate metallic fuels and soluble and insoluble self-explosive fuels may be added before or after emulsification. In all cases the oxygen balance of the composition is easily adjusted, and the fuel phase typically falls within the range from 2 to 25 percent by weight, preferably from 3 to 15 percent by weight, of the composition.
Microcellular formulations lend themselves particularly to the use of polymeric fuels, crosslinkable polymers, and polymerizable fuels. Microcellular formulations which make use of polymeric fuels are especially applicable to plastic bonded explosives, rocket propellants and gas generators, all of which require resiliency in the final product. Many polymer families and polymerization routes are available.
Polymers that are thermoplastic are useful as fuels in compounding microcellular compositions. The elastomer is heated until molten and is then blended with the molten oxidizer to form an emulsion. Upon cooling, either or both of the fuel and oxidizer phases may be solid in the final microcellular product. Various low melting point polyethylenes have been used with success and impart a range of mechanical properties to the final products, which are highly water resistant. Microcellular materials made in this way require no separate curing reaction.
Prepolymers are also suitable as fuels. The prepolymer and crosslinker are introduced in the fuel phase, and after emulsification of the material and dispersion of the discrete oxidizer cells has occured, the curing reaction proceeds to a completely cross-linked structure with favorable elastomeric properties and a high degree of storage and dimensional stability.
The ultimate stability of energetic composite materials is largely controlled by the fuel phase. Thermal stability can be enhanced by choosing the oil phase from the silicone, perfluorinated or other synthetic oils. These are useful in compounding formulations with specially desired properties that would not be available otherwise.
A wide variety of surfactants, including emulsifiers and crystal habit modifiers, is applicable. Surfactants are selected to be chemically compatible with the other ingredients in the composition, thermally stable, and effective in producing stable emulsions of the fuel and oxidizer phases. Surfactants which are effective in producing emulsions which supercool and remain stable during solidification can be selected from the groups consisting of (a) cationic surfactants, such as, oleylamine, cocoamine, stearylamine, dodecylamine, hexylamine, oleylamine acetate, oleyl-N-propylamine acetate, dodecylamine acetate, octadecylamine acetate, oleylamine linoleate, soyaamine linoleate and oleyloxazoline derivatives; (b) anionic surfactants, such as, sodium oleate, sodium lauryl sulfate, sodium dodecylbenzene sulfonate, sodium dimethylnaphthalene sulfonate, stearic acid, linoleic acid, polyethoxylated fatty acids, alkylaryl sulfonic acids, sodium dioctyl sulfosuccinate, and potassium alphaolefin sulfonate; (c) non-ionic surfactants, such as, sorbitan monooleate, sorbitan monopalmitate, sorbitan sesquioleate, lecithin, and alkylphenoxypolyethoxyethanols; and (d) amphoteric surfactants, such as, N-coco-3-aminobutanoic acid, the dodecylamine salt of dodecylbenzene sulfonic acid, and mixtures of the above.
In the case of surfactants containing straight-chain moieties, such as the aliphatic amines, RNH 2 , The R-groups may contain 6 or more carbon atoms, preferably 12 to 20 carbon atoms. Emulsifiers containing saturated or unsaturated hydrocarbon chains can be used, as can emulsifiers selected from the group consisting of aromatic or alkylaryl hydrocarbons.
Surfactants which also function as crystal habit modifiers are helpful because of their added influence upon nucleation and crystal growth. Those selected from the dialkylnaphthalene sulfonates are particularly useful for inhibiting dendritic crystal growth.
Other ingredients may be added for density control or sensitization, such as, microballoons, perlite, fumed silica, entrained gas or gas generated in situ.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In general, microcellular compositions are formed by first preparing a melt of inorganic oxidizer salts, with or without added soluble ingredients. The molten oxidizer phase ingredients are then mechanically blended with molten fuel phase ingredients, and the mixture is subjected to vigorous, high shear agitation until a uniform, stable, oil-continuous emulsion is formed in which discrete molten oxidizer cells constitute the discontinuous phase. Solid particulate fuels or sensitizing materials such as self-explosives, may be added before or after the emulsion is formed. By proper selection of ingredients and processing conditions the molten oxidizer cells can be made to supercool before solidification as crystalline or amorphous solids. While still fluid the mixture is castable, that is, it can be poured or pumped into containers where subsequent solidification takes place resulting in a hard, rigid or firm product.
Examples of microcellular composite explosives are presented in Table I. The compositions in the table were prepared, as described above, in 300 g. batches at temperatures not less than 10° C. above the melting point of the combined salts. The molten oxidizer was added to the heated fuel, and the ingredients were stirred with a stainless steel impeller at speeds between 1000 and 3000 rpm until an oil-continuous emulsion was formed. The emulsion was then further refined to reduce the size of the individual cells of the oxidizer phase to the desired dimensions. Microcellular compositions have also been made by adding the heated fuel to the molten oxidizer. In all cases the fuel-phase continuity of the original emulsion was substantially preserved during the hardening process, as was the oxidizer-phase discontinuity.
The solid final product has been studied by means of scanning electron microscopy at high magnifications. These photographs show the discrete nature of the solidified oxidizer cells and the extremely intimate relationship between fuels and oxidizers. The final products are characterized by closely packed, discrete, irregular microcells with rounded corners and edges, separated from each other by a thin film of the fuel-phase continuum. Comparisons of the size and shape of the microcells before and after solidification show no substantial changes in geometry.
The examples in Table I illustrate the broad range of ingredients which can be used in microcellular compositions. Formulations that are nitrate based, perchlorate based and based on mixtures of nitrates, perchlorates and other ingredients are presented.
Example 1 illustrates the use of an oxidizer miscible fuel and melting point depressant (urea) in combination with ammonium nitrate, sodium nitrate and potassium perchlorate as the oxidizer phase.
Example 2 is an all perchlorate eutectic combination of ammonium perchlorate and lithium perchlorate. Both examples illustrate sensitization by means of density control using microballoons.
Examples 3 and 4 illustrate eutectic combinations of ammonium nitrate with nitroguanidine and guanidine nitrate, with and without granular cyclotrimethylenetrinitramine (RDX) as a sensitizer.
Example 5 employs a single oxidizer salt, lithium perchlorate, as the oxidizer and illustrates the high temperatures at which certain microcellular composites can be made (236° C.).
Examples 6 and 7 employ eutectic combinations of ammonium nitrate and sodium perchlorate; the former containing only an immiscible fuel (mineral oil), the latter a melt-soluble fuel (glycerine) in addition to mineral oil. Example 8 also employs glycerine in the oxidizer phase and makes use of a ternary combination of oxidizer salts, namely ammonium nitrate, sodium nitrate and potassium perchlorate.
Examples 9 and 10 contain powdered aluminum as a secondary fuel. Both contain soluble molecular explosives made in situ (monoethanolamine nitrate and monoethanolamine perchlorate, respectively). Example 9 also contains granular RDX.
Examples 11, 12, 13 and 14 are combinations of ammonium nitrate with a perchlorate salt and a soluble compound explosive. Ethylenediamine dinitrate is used in mix numbers 11, 12 and 13, while monoethanolamine nitrate is used in number 14. Mix 12 contains cyclotetramethylenetetranitramine (HMX) and mix 13 RDX as sensitizers while mix 14 is sensitized with microballoons.
Examples 15, 16, 17 and 18 contain, respectively, polyethylene, a synthetic oil, a silicone oil, and a halogenated oil as fuels. These different fuels impart distinctly different physical properties to the final products. For example, the use of a thermoplastic elastomer, such as polyethylene, imparts an elastomeric property to the final product. The use of a polysiloxane as the fuel imparts a rubbery consistency to the final product. Elastomeric properties are mandatory in many explosive, propellant and gas generator applications.
Example 19 contains a eutectic mixture of potassium nitrite and lithium nitrate as the oxidizer phase with a combination of mineral oil and wax as the fuel. Example 20 contains a eutectic combination of lithium nitrate, sodium chlorate and potassium chlorate as the oxidizer phase with mineral oil as the fuel.
GLOSSARY OF TERMS USED IN TABLE I
Alk T=Alkaterge T (an oleyloxazoline derivative)
AE-O=Oleylamine
OAL=Oleylamine linoleate
AC-18D=Octadecylamine acetate
AC-HT=Hydrogenated tallow amine acetate
AE-12D=Dodecylamine (distilled)
SMO=Sorbitan monooleate
Petro AG=Sodium dimethylnaphthalene sulfonate
AE-SD=Soyaamine (distilled)
AC-T=Tallowamine acetate
TA=Tallow amine
MEAN=Monoethanolamine nitrate
MEAP=Monoethanolamine perchlorate
EDDN=Ethylenediamine dinitrate
NQ=Nitroguanidine
GN=Guanidine nitrate
L=Length
D=Diameter
VOD=Velocity of Detonation
TABLE 1__________________________________________________________________________Microcellular Compositions__________________________________________________________________________ Mix No. 1 2 3 4 5 6 7 8 9 10__________________________________________________________________________Ingredients (wt %)NH.sub.4 NO.sub.3 63.5 66.2 53.0 67.7 67.5 69.5 35.8NaNO.sub.3 9.0 13.9KNO.sub.3LiNO.sub.3NH.sub.4 ClO.sub.4 24.0 19.6NaClO.sub.4 19.4 19.3 6.5KClO.sub.4 7.0 5.0LiClO.sub.4 57.5 82.0 48.0NaClO.sub.3LiClO.sub.3KNO.sub.2AlkTAE-O 3.0 1.2OAL 12.0 0.5AC-18D 1.0 0.8AC-HT 8.5 2.0AE12D 1.0 0.8SMO 0.5Petro AG 2.0 0.5AE-SDAC-TTAPetroleum JellyMineral Oil 7.0 4.0 3.2 6.9 1.2 1.3 1.9 4.0Wax 6.0 8.5Silicone Oil.sup.1Halogenated Oil.sup.2Synthetic Oil.sup.3Polyethylene.sup.4Powdered Al 18.0 20.0Urea 9.0Glycerine 9.7 8.8MEAN 16.6MEAP 6.4EDDNNQ 14.4 11.5GN 14.4 11.5Microballoons 1.5 0.5 1.0 3.0 1.0 0.5RDX 20.0 20.0HMXDensity (g/cm.sup.3) 1.20 1.65 1.38 1.50 1.30 1.20 1.32 1.48 1.74 2.07Melting point. 104 180 101 101 236 118 104 111 93 165Oxydizer Phase (°C.)Charge dimensions, 10/6.4 8/3.8 10/6.4 10/6.4 10/6.4 8/3.8 8/3.8 10/6.4 48/7.9 48/7.9L/D (cm/cm)Iniator (Cap No) 8 8 8 8 8 8 8 8 8 8Booster 30 g 30 g 15 g 100 g 100 g PETN Comp C-4 Comp C-4 Comp Comp BResults: VOD (ka/sec) 7.05 8.38Plate dent.sup.5 Pos Pos Neg Pos Pos Pos Pos Pos__________________________________________________________________________ Mix No. 11 12 13 14 15 16 17 18 19 20__________________________________________________________________________Ingredients (wt %)NH.sub.4 No.sub.3 41.1 30.8 28.8 59.2 65.8 65.8 62.3 60.6NaNO.sub.3 18.6 18.6 17.7 17.2KNO.sub.3LiNO.sub.3 30.5 31.6NH.sub.4 ClO.sub.4NaClO.sub.4 10.6KClO.sub.4 7.3 5.5 5.1 7.6 7.6 7.2 7.0LiClO.sub.4NaClO.sub.3 40.6LiClO.sub.3 13.1KNO.sub.2 56.4AlkTAE-O 1.7 1.3 1.2 0.4OALAC-18DAC-HTAE12DSMOPetro AGAE-SD 2.0 5.1 3.3 3.6AC-T 2.0TA 5.9Petroleum Jelly 5.0Mineral Oil 3.3 2.5 2.3 1.1 1.0 3.3 11.1Wax 6.5Silicone Oil.sup.1 5.9Halogenated Oil.sup.2 10.1Synthetic Oil.sup.3 6.0Polyethylene.sup.4 1.0Powdered AlUreaGlycerineMEAN 27.6MEAPEDDN 46.6 34.9 32.6NQGNMicroballoons 1.1RDX 30.0HMX 25.0Density (g/cm.sup.3) 1.62 1.61 1.64 1.42 1.54 1.51 1.50 1.51 1.40 1.72Melting point, 104.5 104.5 104.5 95 112 112 112 112 108 114Oxydizer Phase (°C.)Charge dimensions, 48/7.9 48/7.9 48/7.9 25/7.9 10/6.4 10/6.4 10/6.4 10/6.4 10/6.4 10/6.4L/D (cm/cm)Initiator (Cap No) 8 8 8 8 8 8 8 8 8 8Booster 100 g 100 g 100 g 100 gr/ft 50 g 50 g 50 g 50 g 50 g 50 g Comp B Comp B Comp B det cord RDX RDX RDX RDX RDX RDXResults: VOD (km/sec) 3.34 8.48 7.80 6.70Plate dent.sup.5 Pos Pos Pos Pos Pos Pos__________________________________________________________________________ Notes: .sup.1 General Electric, Silicone Fluid SF9620, Lot No. KC552. .sup.2 Halocarbon Products Corporation, Series 56 Halocarbon Oil, Batch 8430. .sup.3 Gulf Oil, Synthetic Base Fluid, Synfluid 4cSt PAD (Polyalphaolefins). .sup.4 Allied Corporation, Ethylene Homopolymer, Grade 617. .sup.5 Plate Dent: Pos = Dent in or perforation of one half inch thich mild steel plate. Neg = No dent in or perforation of one half inch thick mild steel plate. | Essentially anhydrous energetic compositions, including explosives, propellants, flares, and gas generators, are initially formed at process temperatures above the solidification temperature of contained oxidizer salts as stable, melt-in-fuel emulsions having a continuous fuel phase and a discontinuous molten oxidizer phase. Surfactants are employed which cause the compositions to retain general fuel phase continuity and oxidizer phase discontinuity upon solidification. The final product is a firm or solid emulsion generally characterized by an intimate dispersion of discrete solid oxidizer cells in a fuel continuum, the product having excellent storage stability and water resistance. | 2 |
BACKGROUND AND FIELD
[0001] This application relates to the use of sacrificial agents in cementitious mixtures containing ash including fly ash concrete, and to the resulting mixtures and compositions. More particularly, this application relates to sacrificial agents that reduce or eliminate the detrimental effects of ash such as fly ash on the air entrainment properties of cementitious mixtures.
[0002] The partial replacement of portland cement by fly ash is growing rapidly, driven simultaneously by more demanding performance specifications on the properties of concrete and by increasing environmental pressures to reduce portland cement consumption. Fly ash can impart many beneficial properties to concrete such as improved rheology, reduced permeability and increased later-age strength; however, it also may have a negative influence on bleed characteristics, setting time and early strength development. Many of these issues can be managed by adjusting mixture proportions and materials, and by altering concrete placement and finishing practices. However, other challenging problems encountered when using certain fly ash are not always easily resolved. The most important difficulties experienced when using fly ash are most often related to air entrainment in concrete.
[0003] Air entrained concrete has been utilized in the United States since the 1930's. Air is purposely entrained in concrete, mortars and grouts as a protective measure against expansive forces that can develop in the cement paste associated with an increase in volume resulting from water freezing and converting to ice. Adequately distributed microscopic air voids provide a means for relieving internal pressures and ensuring concrete durability and long term performance in freezing and thawing environments. Air volumes (volume fraction) sufficient to provide protective air void systems are commonly specified by Building Codes and Standard Design Practices for concrete which may be exposed to freezing and thawing environments. Entrained air is to be distinguished from entrapped air (air that may develop in concrete systems as a result of mixing or the additions of certain chemicals). Entrained air provides an air void system capable of protecting against freeze/thaw cycles, while entrapped air provide no protection against such phenomena.
[0004] Air is also often purposely entrained in concrete and other cementitious systems because of the properties it can impart to the fresh mixtures. These can include: improved fluidity, cohesiveness, improved workability and reduce bleeding.
[0005] The air void systems are generated in concrete, mortar, or paste mixtures by introducing air entrainment admixtures (referred to as air entrainment agents or air-entraining agents) which are a class of specialty surfactants. When using fly ash, the difficulties in producing air-entrained concrete are related to the disruptive influence that some fly ashes have on the generation of sufficient air volumes and adequate air void systems. The primary influencing factor is the occurrence of residual carbon, or carbonaceous materials (hereafter designated as fly ash-carbon), which can be detected as a discrete phase in the fly ash, or can be intimately bound to the fly ash particles. Detrimental effects on air entrainment by other fly ash components may also occur, and indeed air entrainment problems are sometimes encountered with fly ash containing very low amounts of residual carbon.
[0006] Fly ash-carbon, a residue of incomplete coal or other hydrocarbon combustion, is in many ways similar to an “activated carbon.” For example, like activated carbon, fly ash-carbon can adsorb organic molecules in aqueous environments. In cement paste containing organic chemical admixtures, the fly ash-carbon can thus adsorb part of the admixture, interfering with the function and performance of the admixture. The consequences of this adsorption process are found to be particularly troublesome with air entrainment admixtures (air entrainment agents) which are commonly used in only very low dosages. In the presence of significant carbon contents (e.g. >2 wt %), or in the presence of low contents of highly reactive carbon or other detrimental fly ash components, the air entrainment agents may be adsorbed, interfering with the air void formation and stability; this leads to tremendous complications in consistently obtaining and maintaining specified concrete air contents.
[0007] To minimize concrete air entrainment problems, ASTM guidelines have limited the fly ash carbon content to less than 6 wt %. Other institutions such as AASHTO and state departments of transportation have more stringent limitations. Industry experience indicates that, in the case of highly active carbon (for example, high specific surface area), major interferences and problems can still be encountered, even with carbon contents lower than 1 wt %.
[0008] Furthermore, recent studies indicate that, while fly ash carbon content, as measured by loss on ignition (LOI) values, provides a primary indicator of fly ash behavior with respect to air entrainment, it does not reliably predict the impact that a fly ash will have on air entrainment in concrete. Therefore, there currently exist no means, suitable for field quality control, capable of reliably predicting the influence that a particular fly ash sample will have on air entrainment, relative to another fly ash sample with differing LOI'S, sources, or chemistries. In practice, the inability to predict fly ash behavior translates into erratic concrete air contents, which is currently the most important problem in fly ash-containing concrete.
[0009] Variations in fly ash performance are important, not only because of their potential impact on air entrainment and resistance to freeze thaw conditions, but also because of their effects related to concrete strength. Just as concrete is designed according to building standards for a particular environment, specifications are also provided for physical performance requirements. A common performance requirement is compressive strength. An increase in entrained air content can result in a reduction in compressive strength of 3-6% for each additional percentage of entrained air. Obviously, variations in fly ash-carbon, which would lead to erratic variations in air contents, can have serious negative consequences on the concrete strength.
[0010] The fly ash-carbon air entrainment problem is an on-going issue that has been of concern since fly ash was first used nearly 75 years ago. Over the past ten years, these issues have been further exacerbated by regulations on environmental emissions which impose combustion conditions yielding fly ash with higher carbon contents. This situation threatens to make an increasingly larger portion of the available fly ash materials unsuitable for use in concrete. Considering the economic impact of such a trend, it is imperative to develop practical corrective schemes that will allow the use, with minimal inconvenience, of fly ash with high carbon contents (e.g., up to 10 wt %) in air-entrained concrete.
[0011] Air entrainment in fly ash-concrete may become yet more complicated by pending regulations that will require utilities to reduce current mercury (Hg) emissions by 70-90%. One of the demonstrated technologies for achieving the Hg reduction is the injection of activated carbon into the flue gas stream after combustion so that volatile Hg is condensed on the high surface area carbon particles and discarded with the fly ash. Current practices are designed such that the added activated carbon is generally less than 1% by mass of the fly ash, but preliminary testing indicates this is disastrous when using the modified fly ash in air-entrained concrete.
[0012] The origin of air entrainment problems in fly ash concrete, and potential approaches to their solution, have been the subject of numerous investigations. Most of these investigations focused on the “physical” elimination of the carbon by either combustion processes, froth floatation, or electrostatic separation. To date, the proposed fly ash treatment approaches have found limited application due to their inherent limitations (e.g., separation techniques have limited efficiency in low carbon fly ash; secondary combustion processes are most suitable for very high carbon contents), or due to their associated costs.
[0013] “Chemical” approaches have also been proposed to alleviate carbon-related problems in concrete air entrainment, for example through the development of alternative specialty surfactants for air entrainment agents such as polyoxyethylene-sorbitan oleate as an air entrainment agent (U.S. Pat. No. 4,453,978). Various other chemical additives or fly ash chemical treatments have been proposed, namely:
the addition of inorganic additives such as calcium oxide or magnesium oxide (U.S. Pat. No. 4,257,815); this patent prescribes the use of inorganic additives which may influence other properties of fresh mortars or concrete, for example, rate of slump loss and setting time; the addition of C8 fatty acid salts (U.S. Pat. No. 5,110,362); the octanoate salt is itself a surfactant, and it is said to “stabilize the entrained air and lower the rate of air loss” (Claim 1 of U.S. Pat. No. 5,110,362); the use of a mixture of high-polymer protein, polyvinyl alcohol and soap gel (U.S. Pat. No. 5,654,352); this discloses the use of protein and polyvinyl alcohol, and optionally a colloid (for example, bentonite) to formulate air entrainment admixtures; treatment with ozone (U.S. Pat. No. 6,136,089); the ozone oxidizes fly ash-carbon, reducing its absorption capacity for surfactants and thus making the fly ash more suitable for use in air entrained systems.
[0018] None of these proposed solutions have found significant acceptance in the industry, either because of their complexity and cost, or because of their limited performance in actual use. For example, a clear limitation to the addition of a second surfactant (e.g., C8 fatty acid salt), to compensate for the adsorption of the air entrainment agents surfactant, simply shifts the problem to controlling air content with a combination of surfactants instead of a single one. The problem of under- or over-dosage of a surfactant mixture is then the same as the problem discussed above with conventional air entrainment agents.
[0019] Hence, a practical solution is needed for efficiently relieving air entrainment problems for a wide variety of fly ash materials and for other ashes, in ready mix facilities or in the field.
SUMMARY
[0020] The methods and compositions described herein facilitate the formation of cementitious mixtures containing fly ash and other combustion ashes, and solid products derived therefrom. Further, these methods and compositions facilitate air entrainment into such mixtures in a reliable and predictable fashion.
[0021] According to some embodiments, there is provided a method of reducing or eliminating the effect of fly ash or other combustion ashes on air-entrainment in an air-entraining cementitious mixture containing fly ash or another combustion ash, comprising the steps of: forming a cementitious mixture comprising water, cement, fly ash or another combustion ash, (and optionally other cementitious components, sand, aggregate, etc.) and an air entrainment agent (and optionally other concrete chemical admixtures); and entraining air in the mixture; wherein an amount of at least one sacrificial agent is also included in the cementitious mixture in at least an amount necessary to neutralize the detrimental effects of components of said fly ash or other combustion ash on air entrainment activity, the sacrificial agent comprising a material or mixture of materials that, when present in the same cementitious mixture without fly ash or the other combustion ash in said amount, causes less than 2 vol. % additional air content in the cementitious mixture.
[0022] The amount of the sacrificial agent used in the cementitious mixture can, in some embodiments, exceed the amount necessary to neutralize the detrimental effects of the components of the fly ash or other combustion ash. Thus, if the fly ash varies in content of the detrimental components from a minimum content to a maximum content according to the source or batch of the fly ash or other combustion ash, the amount of the at least one sacrificial agent can exceed the amount necessary to neutralize the detrimental effects of the components of the fly ash when present at their maximum content.
[0023] The sacrificial agent is a primary amine, secondary amine, or tertiary amine compound, or any combination thereof. The sacrificial agent can be a compound selected from the group consisting of the structure NR 1 R 2 R 3 . R 1 is substituted or unsubstituted non-alkoxylated C 5-22 alkyl, substituted or unsubstituted non-alkoxylated C 5-22 alkenyl, substituted or unsubstituted non-alkoxylated C 5-22 alkynyl, substituted or unsubstituted C 2-22 alkoxylated alkyl, substituted or unsubstituted C 2-22 alkoxylated alkenyl, or substituted or unsubstituted C 2-22 alkoxylated alkynyl. R 2 and R 3 are each independently selected from hydrogen, substituted or unsubstituted C 1-22 alkyl, substituted or unsubstituted C 2-22 alkenyl, or substituted or unsubstituted C 2-22 alkynyl. R 2 and R 3 can be optionally alkoxylated. One or more of R 1 , R 2 , or R 3 can be an alkoxylated or non-alkoxylated, substituted or unsubstituted, fatty acid residue. The fatty acid residues can be saturated fatty acid residues, monounsaturated fatty acid residues, polyunsaturated fatty acid residues, or mixtures thereof. In some embodiments, one or more of R 1 , R 2 , and R 3 can be amino-substituted including NR 4 R 5 as a substituent. For example, the sacrificial agent can be polyoxypropylenediamine or triethyleneglycol diamine. In some embodiments, the sacrificial agent is an alcoholamine. In some embodiments, the sacrificial agent is a mixture of two or more compounds. In some embodiments, the HLB value of the sacrificial agent or the mixture of sacrificial agents is in the range of 5 to 20 (e.g., 4 to 18). In some embodiments, the Log K ow for the sacrificial agent can be in the range of −3 to +2 (e.g. −2 to +2).
[0024] In some embodiments, the sacrificial agent is a compound selected from tridodecylamine, dodecyldimethylamine, octadecyldimethylamine, cocoalkyldimethylamine, hydrogenated tallowalkyldimethylamines, oleyldimethylamine, dicocoalkylmethylamine, N-oleyl-1,1′-iminobis-2-propanol, N-tallowalkyl-1,1′-iminobis-2-propanol, polyoxypropylenediamine, triethyleneglycol diamine, and mixtures thereof. In some embodiments, the sacrificial agent includes dodecyldimethylamine. In some embodiments, the sacrificial agent includes one or more compounds selected from N-oleyl-1,1′-iminobis-2-propanol and N-tallowalkyl-1,1′-iminobis-2-propanol. In some embodiments, the sacrificial agent includes a polyetheramine.
[0025] The dosage, or amount, of the sacrificial agent can vary from 0.005% to 5% by weight based on the weight of the fly ash or other combustion ash. In some embodiments, the amount is from 0.01 to 2%, 0.02-1% and 0.05-0.5% (e.g. 0.1-0.3%) by weight based on the weight of the fly ash or other combustion ash. The sacrificial agent can be added directly to the fly ash by pre-treating the fly ash or can be added to the cementitious composition or with other components of the cementitious composition.
[0026] Typically, the fly ash or other combustion ash is provided in the cementitious composition in an amount of from 5% to 55% by weight of the total amount of cementitious materials in the cementitious composition (cement and fly ash or other combustion ash), depending on the type and composition of the fly ash or other combustion ash. In some embodiments, the amount of fly ash or other combustion ash is from 10% to 50% or 15% to 30% by weight (e.g. 25% by weight) of the total amount of cementitious materials in the cementitious composition.
[0027] The sacrificial agent can be mixed with the air entrainment agent prior to mixing the sacrificial agent and air entrainment agent with the fly ash or other combustion ash, cement, and water. Alternatively, the sacrificial agent can be mixed with the fly ash or other combustion ash prior to mixing the sacrificial agent and the fly ash or other combustion ash with the cement, water, and the air entrainment agent. In the latter case, the sacrificial agent can be added to the fly ash or other combustion ash by spraying a liquid containing the sacrificial agent onto the fly ash or other combustion ash, or by mixing a spray-dried solid sacrificial agent formulation with the fly ash or other combustion ash. Suitable methods are described in published U.S. Patent Application No. US 2004/0144287, which is hereby incorporated by reference in its entirety. Alternatively, the sacrificial agent can be added after the fly ash or other combustion ash, cement, water, and air entrainment agent have been mixed together. In some embodiments, an additional material selected from sand, aggregate, concrete modifier, and combinations thereof, can be incorporated into the mixture.
[0028] In some embodiments, the cementitious mixture can be formed by mixing an amount of the sacrificial agent with the fly ash or other combustion ash to form a pre-treated fly ash or other combustion ash, and then mixing the pre-treated fly ash or other combustion ash with the water, air entrainment agent and cement. In some embodiments, the cementitious mixture is formed by mixing the air entrainment agent and the sacrificial agent to form a component mixture, and then mixing the component mixture with the water, fly ash or other combustion ash and cement, and entraining the air in the mixture. In some embodiments, water, cement, fly ash or other combustion ash, air entrainment agent and sacrificial agent are mixed together simultaneously while entraining the air in the mixture. In some embodiments, the sacrificial agent is mixed with the water, cement and fly ash or other combustion ash before the air entrainment agent is added. In some embodiments, the sacrificial agent is mixed with the water, cement, and fly ash or other combustion ash at the same time as the air entrainment agent.
[0029] In some embodiments, the fly ash or other combustion ash consists essentially of fly ash. In some embodiments, the fly ash or other combustion ash comprises a blend of fly and another combustion ash. In some embodiments, the sacrificial agent, when present in the same cementitious mixture without fly ash or the other combustion ash in the appropriate amount causes less than 1 vol. % additional air content in the cementitious mixture.
[0030] In some embodiments, the method further includes the step of selecting a sacrificial agent including a material or mixture of materials to reduce or eliminate the effect of fly ash or another combustion ash on air entrainment in a cementitious mixture and selecting an amount of the sacrificial agent such that the amount is at least an amount necessary to neutralize the detrimental effects of components of the fly ash on air entrainment activity and the amount of sacrificial agent causes less than 2 vol. % additional air content in the same cementitious mixture without fly ash or the other combustion ash. In some embodiments, the fly ash or other combustion ash has a predetermined maximum carbon content and the amount of sacrificial agent exceeds the amount necessary to neutralize the maximum carbon content in the fly ash or other combustion ash. In some embodiments, the sacrificial agent amount used does not result in a substantial increase in air entrainment compared to providing the sacrificial agent in an amount necessary to neutralize the detrimental effects of components of the fly ash on air entrainment activity. In some embodiments, the sacrificial agent causes less than 2 vol. % additional air content in the cementitious mixture without fly ash. In some embodiments, the components to be neutralized are carbon content.
[0031] There is also provided a method of reducing or eliminating the effect of fly ash on air entrainment in an air-entraining cementitious mixture, comprising the steps of: forming a cementitious mixture comprising water, cement, fly ash, and an air entrainment agent, and entraining air in the mixture; wherein a sacrificial agent is also included in the cementitious mixture in at least the amount necessary to neutralize the detrimental effects of the carbon content of said fly ash on air entrainment activity, the sacrificial agent comprising a material or mixture of materials that, when present in the same cementitious mixture without fly ash in said amount causes less than 2 vol. % additional air content in the cementitious mixture.
[0032] There is further provided a method of addressing the variance of carbon content in fly ash used in cementitious compositions to provide a cementitious composition with a substantially constant level of air entrainment, comprising: forming a cementitious mixture comprising water, cement, fly ash, an air entrainment agent, and a sacrificial agent and entraining air in the mixture, wherein the fly ash has a maximum carbon content; and selecting a sacrificial agent for the cementitious mixture and an amount of the sacrificial agent such that the amount of the sacrificial agent exceeds the amount necessary to neutralize the maximum carbon content in the fly ash, wherein the sacrificial agent comprises a material or mixture of materials that, when present in the same cementitious mixture without fly ash in said amount causes less than 2 vol. % additional air content in the cementitious mixture.
[0033] Furthermore, a method of pre-treating fly ash or another combustion ash to reduce or eliminate the effect the fly ash or the other combustion ash has on air entrainment in an air-entraining cementitious mixture comprising the fly ash or other combustible fly ash and an air-entraining agent is provided, the method comprising: mixing a sacrificial agent with fly ash or another combustion ash to form a pre-treated ash, wherein the sacrificial agent is combined with the fly ash or the other combustion ash in at least an amount necessary to neutralize the detrimental effects of components of the fly ash or the other combustion ash on air entrainment activity in the air-entraining cementitious mixture, the sacrificial agent comprising a material or mixture of materials that, when present in a cementitious mixture without fly ash or another combustion ash in said amount causes less than 2 vol. % additional air content in the cementitious mixture.
[0034] There is also provided a method of addressing the variance of carbon content in fly ash used in cementitious compositions to provide a cementitious composition with a substantially constant level of air entrainment, comprising: selecting a sacrificial agent and an amount of the sacrificial agent such that the amount of the sacrificial agent exceeds the amount necessary to neutralize the maximum carbon content in the fly ash, mixing the sacrificial agent with fly ash or another combustion ash to form a pre-treated ash, wherein the sacrificial agent is combined with the fly ash or the other combustion ash in at least an amount necessary to neutralize the detrimental effects of components of the fly ash or the other combustion ash on air entrainment activity in the air-entraining cementitious mixture, the sacrificial agent comprising a material or mixture of materials that, when present in a cementitious mixture without fly ash or another combustion ash in said amount causes less than 2 vol. % additional air content in the cementitious mixture
[0035] Also provided herein is a composition comprising fly ash or another combustion ash that reduces or eliminates the effect the fly ash or the other combustion ash has on air entrainment in an air-entraining cementitious mixture comprising the fly ash or the other combustion ash and an air-entraining agent, the composition comprising fly ash or another combustion ash and a sacrificial agent, the sacrificial agent present in at least an amount necessary to neutralize the detrimental effects of components of the fly ash or the other combustion ash on air entrainment activity in the air-entraining cementitious mixture, the sacrificial agent comprising a material or mixture of materials that, when present in a cementitious mixture without fly ash or another combustion ash in said amount causes less than 2 vol. % additional air content in the cementitious mixture.
[0036] Also provided herein is a composition that addresses the variance of carbon content in fly ash or another combustion ash used in cementitious compositions to provide a cementitious composition with a substantially constant level of air entrainment, comprising fly ash or another combustion ash and a sacrificial agent, the sacrificial agent present in at least an amount necessary to neutralize the detrimental effects of components of the fly ash or the other combustion ash on air entrainment activity in the air-entraining cementitious mixture, the sacrificial agent comprising a material or mixture of materials that, when present in a cementitious mixture without fly ash or another combustion ash in said amount causes less than 2 vol. % additional air content in the cementitious mixture.
[0037] Also provided herein is an air-entraining cementitious mixture comprising fly ash or another combustion ash that reduces or eliminates the effect the fly ash or other combustion ash has on air entrainment in the air-entraining cementitious mixture; the air-entraining cementitious mixture comprising air, water, cement, fly ash, an air entrainment agent and a sacrificial agent, wherein the sacrificial agent is present in at least an amount necessary to neutralize the detrimental effects of components of the fly ash or the other combustion ash on air entrainment activity in the air-entraining cementitious mixture, the sacrificial agent comprising a material or mixture of materials that, when present in a cementitious mixture without fly ash or another combustion ash in said amount causes less than 2 vol. % additional air content in the cementitious mixture.
[0038] Further provided herein is an air-entraining cementitious mixture comprising fly ash or another combustion ash that addresses the variance of carbon content in fly ash used in cementitious compositions to provide a cementitious composition with a substantially constant level of air entrainment, the air-entraining cementitious mixture comprising air, water, cement, fly ash, an air entrainment agent and a sacrificial agent, wherein the sacrificial agent is present in at least an amount necessary to neutralize the detrimental effects of components of the fly ash or the other combustion ash on air entrainment activity in the air-entraining cementitious mixture, the sacrificial agent comprising a material or mixture of materials that, when present in a cementitious mixture without fly ash or another combustion ash in said amount causes less than 2 vol. % additional air content in the cementitious mixture, wherein the sacrificial agent is present in at least an amount necessary to neutralize the detrimental effects of components of the fly ash or the other combustion ash on air entrainment activity in the air-entraining cementitious mixture, the sacrificial agent comprising a material or mixture of materials that, when present in a cementitious mixture without fly ash or another combustion ash in said amount causes less than 2 vol. % additional air content in the cementitious mixture.
[0039] Also provided herein is an air-entrained hardened cementitious mass comprising fly ash or another combustion ash that reduces or eliminates the effect the fly ash or other combustion ash has on air entrainment in the air-entrained hardened cementitious mass, the air-entrained hardened cementitious mass comprising air, cement, fly ash, an air entrainment agent and an amount of a sacrificial agent, wherein the sacrificial agent is present in at least an amount necessary to neutralize the detrimental effects of components of the fly ash or the other combustion ash on air entrainment activity in the air-entraining cementitious mixture, the sacrificial agent comprising a material or mixture of materials that, when present in a cementitious mixture without fly ash or another combustion ash in said amount causes less than 2 vol. % additional air content in the cementitious mixture.
[0040] As described herein, the sacrificial agents can be used to eliminate or drastically reduce air entrainment problems encountered in concrete containing fly ash. Such additives, or combinations of such additives, can be added before (e.g. in the fly ash material), during, or after the concrete mixing operation. The use of these materials can have the following advantages. They:
enable adequate levels (typically 5-8 vol %) of gas, normally air, to be entrained in concrete or other cementitious products, with dosages of conventional air entrainment agents that are more typical of those required when no fly ash, or fly ash with low carbon content, is used; confer predictable air entrainment behavior onto fly ash-concrete regardless of the variability in the fly ash material, such as the source, carbon content, chemical composition; do not interfere with cement hydration and concrete set time; do not alter other physical and durability properties of concrete; do not significantly alter their action in the presence of other concrete chemical admixtures, for example, water reducers, superplasticizers and set accelerators; and do not cause detrimental effects when added in excessive dosages, such as excessive air contents, extended set times, or strength reduction.
[0047] The acceptability of “overdosage” of these sacrificial agents is advantageous in some embodiments, since large fluctuations in fly ash properties (carbon content, reactivity, etc.) can be accommodated by introducing a moderate excess of these sacrificial agents without causing other problems. This provides operators with a substantial trouble-free range or comfort zone.
[0048] The cementitious mixtures can contain conventional ingredients such as sand and aggregate, as well as specific known additives.
Definitions
[0049] The term “fly ash”, as defined by ASTM C 618 (Coal Fly Ash or Calcined Natural Pozzolan For Use in Concrete) refers to a by product of coal combustion. However, other combustion ashes can be employed which are fine ashes or flue dusts resulting from co-firing various fuels with coal, or resulting from the combustion of other fuels that produce an ash having pozzolanic qualities (the ability to form a solid when mixed with water and an activator such ash lime or alkalis) or hydraulic qualities (the ability to form a solid when mixed with water and set). The ash itself has pozzolanic/hydraulic activity and can be used as a cementitious material to replace a portion of portland cement in the preparation of concrete, mortars, and the like. The term “fly ash and other combustion ash” as used herein includes:
1) Ash produced by co-firing fuels including industrial gases, petroleum coke, petroleum products, municipal solid waste, paper sludge, wood, sawdust, refuse derived fuels, switchgrass or other biomass material, either alone or in combination with coal. 2) Coal ash and/or alternative fuel ash plus inorganic process additions such as soda ash or trona (native sodium carbonate/bicarbonate used by utilities). 3) Coal ash and/or alternative fuel ash plus organic process additives such as activated carbon, or other carbonaceous materials, for mercury emission control. 4) Coal ash and/or alternative fuel ash plus combustion additives such as borax. 5) Coal ash and/or alternative fuel gases plus flue gas or fly ash conditioning agents such as ammonia, sulfur trioxide, phosphoric acid, etc.
[0055] The term “fly ash concrete” means concrete containing fly ash and portland cement in any proportions, but optionally additionally containing other cementitious materials such as blast furnace slag, silica fume, or fillers such as limestone, etc.
[0056] The term “surfactants” is also well understood in the art to mean surface active agents. These are compounds that have an affinity for both fats (hydrophobic) and water (hydrophilic) and so act as foaming agents (although some surfactants are non-foaming, e.g. phosphates), dispersants, emulsifiers, and the like, e.g. soaps.
[0057] The term “air entrainment agent” (AEA) means a material that results in a satisfactory amount of air being entrained into a cementitious mixture, e.g. 5-9 vol % air, when added to a cementitious formulation. Generally, air entrainment agents are surfactants (i.e. they reduce the surface tension when added to aqueous mixtures), and are often materials considered to be soaps.
[0058] The mode of action of air entrainment agents, and the mechanism of air void formation in cementitious mixtures are only poorly understood. Because of their influence on the surface tension of the solution phase, the surfactant molecules are believed to facilitate the formation of small air cavities or voids in the cementitious paste, by analogy to formation of air ‘bubbles’. It is also believed that the wall of these voids are further stabilized through various effects, such as incorporation into the interfacial paste/air layer of insoluble calcium salts of the surfactants, or of colloidal particles.
[0059] The performance of surfactants as concrete air entrainment admixture depends on the composition of the surfactant: the type of hydrophilic group (cationic, anionic, zwitterionic, or non-ionic), the importance of its hydrophobic residue (number of carbon groups, molecular weight), the chemical nature of this residue (aliphatic, aromatic) and the structure of the residue (linear, branched, cyclic), and on the balance between the hydrophilic and lipophilic portions of the surfactant molecule (HLB). Cationic and non-ionic surfactants are reported to entrain more air than anionic surfactants because the latter are often precipitated as insoluble calcium salts in the paste solution; however, the stability of the air void has also been reported to be greater with anionic surfactant than with cationic or non-ionic surfactants. Typical examples of compounds used as surface active agents are sodium salts of naturally occurring fatty acid such as tall oil fatty acid, and sodium salts of synthetic n-alkylbenzene sulfonic acid. Common concrete air entrainment (or air-entraining) agents include those derived from the following anionic surfactants: neutralized wood resins, fatty acids salts, alkyl-aryl sulfonates, and alkyl sulfates.
[0060] The term “sacrificial agent” (SA) means a material, or a mixture of materials, that interacts with (and/or neutralizes the detrimental effects of) components of fly ash that would otherwise interact with an air entrainment agent and reduce the effectiveness of the air entrainment agent to incorporate air (or other gas) into the cementitious mixture. The sacrificial agents are not “air entrainment agents” as they are understood in the art and, in the amounts used in the cementitious mixture, do not cause more than 2 vol % additional air content (or even less than 1 vol % additional air content) into the same mixture containing no fly ash. In some embodiments, the sacrificial agent, in the amounts employed in fly ash-containing mixtures, is responsible for introducing less than 0.5 vol % or even substantially no additional air content into the same mixture containing no fly ash. In some embodiments, the sacrificial agent neither promotes nor inhibits the functioning of the air entrainment agent compared with its functioning in a similar mixture containing no fly ash.
[0061] The term “cementitious mixture” means a mixture such as concrete mix, mortar, paste, grout, etc., that is still in castable form and that, upon setting, develops into a hardened mass suitable for building and construction purposes. Likewise, the term “cement” means a product (other than fly ash) that is capable of acting as the principal hardenable ingredient in a cementitious mixture. In some embodiments, the cement is portland cement, but at least a portion can include blast furnace slag, gypsum, and the like.
[0062] The term “percent” or “%” as used herein in connection with a component of a composition means percent by weight based on the cementitious components (cement and fly ash) of a cementitious mixture (unless otherwise stated). When referring to air content, the term % means percent by volume or vol %.
[0063] The terms “alkyl”, “alkenyl”, and “alkynyl” as used herein can include straight-chain and branched monovalent substituents. Examples include methyl, ethyl, isobutyl, 2-propenyl, 3-butynyl, and the like.
[0064] The term “substituted” as used herein indicates the main substituent has attached to it one or more additional components, such as, for example, amino, hydroxyl, carbonyl, or halogen groups. The term “unsubstituted” indicates that the main substituent has a full compliment of hydrogens, i.e., commensurate with its saturation level, with no substitutions, e.g., linear decane (—(CH 2 ) 9 —CH 3 ).
[0065] The term “alkoxylated” as used herein is an adjective referring to a compound having an “alkoxyl” linkage having the formula —(OR) n — wherein R can be an alkyl, alkenyl, or alkynyl group. Examples of suitable “R” groups include ethyl (ethoxylate), propyl (propoxylate), or butyl (butoxylate)groups. The value for n is an average value and can vary for the sacrificial agent (where alkoxylation is present) from 1 to 10, 1.5 to 9 or 2 to 8.
Abbreviations
[0066]
[0000]
Fly Ash
FA
Portland cement A
PCA
Portland cement C
PCC
Sacrificial agent
SA
Air entrainment agents or admixtures
AEA
Relative to cementitious materials (CM)
wt %
Amount of air entrained
vol %
Average of Air Entrained
Aver (%)
Relative Standard Deviation
RSD (%)
HLB
Hydrophilic Lipophilic Balance
K ow
Ratio of solubility in oil
(octanol) and in water
LogK ow
Logarithm of K ow
LOI
Loss on ignition
BRIEF DESCRIPTION OF THE DRAWINGS
[0067] FIG. 1 is a graph illustrating the competitive absorption by activated carbon with various sacrificial agents at saturated concentrations.
[0068] FIG. 2 is a graph illustrating the percentage of air in concrete with increasing concentrations of an air entrainment agent with various activated carbon samples at varying amounts.
[0069] FIG. 3 is a graph illustrating the dosage of an air entrainment agent at 6% air in concrete with increasing amounts of carbon contents.
[0070] FIG. 4 is a graph illustrating the percentage of air in concrete with increasing concentrations of an air entrainment agent with various amounts of activated carbon.
[0071] FIG. 5 is a graph illustrating the percentage of air in concrete with increasing concentrations of an air entrainment agent with sacrificial agents and activated carbon.
[0072] FIG. 6 is a graph illustrating the percentage of air in concrete with increasing concentrations of an air entrainment agent with sacrificial agent-treated fly ash combined with activated carbon.
[0073] FIG. 7 is a graph illustrating the percentage of air in concrete with increasing concentrations of an air entrainment agent with sacrificial agent-treated fly ash with and without activated carbon.
[0074] FIG. 8 is a graph illustrating the percentage of air in concrete with increasing percentages of activated carbon in the presence of an air entrainment agent and with and without sacrificial agents.
[0075] FIG. 9 is a graph illustrating the percentage of air in concrete with increasing concentrations of an air entrainment agent with and without sacrificial agents.
[0076] FIG. 10 is a graph illustrating the percentage of air in concrete with increasing concentrations of an air entrainment agent with concrete friendly activated carbon and varying quality fly ash samples.
[0077] FIG. 11 is a graph illustrating the percentage of air in concrete with increasing concentrations of an air entrainment agent with high and poor quality fly ash , concrete friendly activated carbon, and sacrificial agents.
DETAILED DESCRIPTION
[0078] In the following description, reference is made to air entrainment in concrete and cementitious mixtures. It will be realized by persons skilled in the art that other inert gases, such as nitrogen, that act in the same way as air, can be entrained in concrete and cementitious mixtures. The use of air rather than other gases is naturally most frequently carried out for reasons of simplicity and economy. Techniques for entraining air in cementitious mixtures using air-entraining agents are well known to persons skilled in the art. Generally, when an air entrainment agent is used, sufficient air is entrained when the ingredients of the mixture are simply mixed together and agitated in conventional ways, such as stirring or tumbling sufficient to cause thorough mixing of the ingredients.
[0079] As noted earlier, air entrainment problems in fly ash concrete have been traced to undesirable components contained in the fly ash materials, particularly residual carbon. These fly ash components can adsorb and/or react or interact with the air entrainment agent (surface active compounds, e.g. soaps) used for entrainment air in concrete, thereby neutralizing or diminishing the functionality of such agents and consequently reducing the uptake of air. Up to the present, the industrial approach to dealing with these air entrainment problems consisted in adding higher dosages of the air entrainment agents in order to overwhelm the deleterious processes. Because the quantities of detrimental components in fly ash can vary greatly among fly ashes from different sources, or for a fly ash from any particular source at different times, the current practices lead to other complications, namely in assessing the adequate dosage of air entrainment agents to achieve a specified air content, in maintaining the specified air content over adequate time periods, in guarding against excessive entrained air contents that would detrimentally impact concrete strength and durability, in obtaining specified air void parameters, etc. In particular, the fact that excessive dosages of the air entrainment agent can result in excess air entrainment and subsequent reduction in concrete compressive strength, is particularly serious and a major disadvantage of the prior approach.
[0080] The issues with the components of fly ash and other combustion ash and the effects of these components on air entrainment are further complicated by the addition of activated carbon to fly ash and other combustion ashes. Specifically, mercury (Hg) is present as a trace element in coal that becomes a contaminant in fly ash from coal-fired power plants and other coal fired furnaces. As a result, processes have been developed to capture Hg contained in fly ash. For example, one process that has been developed injects activated carbon in fly ash to absorb Hg. Unfortunately, activated carbon is expensive and thus its use for Hg removal adds significantly to overall costs. Fly ash without activated carbon may be used as a partial replacement for portland cement in concrete if it meets certain specifications (such as those found in ASTM C618-05 “Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete”). The most common reason fly ash without activated carbon cannot be used in concrete is excess unburned carbon content in the ash. Excess unburned carbon is not allowed because it absorbs additives used in concrete making and makes them ineffective. However, after addition of activated carbon for Hg capture, ash is generally unusable even if it meets the unburned carbon specifications. This is because the activated carbon absorbs the concrete additives to a much large degree than the unburned carbon normally found in fly ash. Therefore, adding activated carbon to fly ash to capture Hg requires additional thermal beneficiation to make the resulting fly ash usable. The inventors have found that adding an amine sacrificial agent can make fly ash concrete including activated carbon useful without employing the expensive treatment methods associated with activated carbon.
[0081] To address the above problems, an amine sacrificial agent is used to neutralize or eliminate the effect of the harmful components of fly ash on the air entrainment agent. Typically, the sacrificial agent acts preferentially (i.e. when present at the same time as the air entrainment agent, or even after the contact of the air entrainment agent with the fly ash, the sacrificial agent interacts with the fly ash), does not itself entrain air in significant amounts, and does not harm the setting action or properties of the cementitious material in the amounts employed. The inventors have now found certain amines capable of “neutralizing” the detrimental fly ash components, while having little or no influence on the air entrainment process provided by conventional air entrainment agents and having no adverse effects on the properties of the concrete mix and hardened concrete product. These amine sacrificial agents, introduced into the mixture at an appropriate time, render fly ash concrete comparable to normal concrete with respect to air entrainment. The finding of economically viable chemical additives of this type, as well as practical processes for their introduction into concrete systems, constitutes a major advantage for fly ash concrete technologies.
[0082] It has been found that primary, secondary, and tertiary non-aromatic amines are the most suitable as sacrificial agents, namely compounds selected from the group consisting of the structure NR 1 R 2 R 3 , wherein R 1 is substituted or unsubstituted non-alkoxylated C 5-22 alkyl, substituted or unsubstituted non-alkoxylated C 5-22 alkenyl, substituted or unsubstituted non-alkoxylated C 5-22 alkynyl, substituted or unsubstituted C 2-22 alkoxylated alkyl, substituted or unsubstituted C 2-22 alkoxylated alkenyl, or substituted or unsubstituted C 2-22 alkoxylated alkynyl. R 2 and R 3 are each independently selected from hydrogen, substituted or unsubstituted C 1-22 alkyl, substituted or unsubstituted C 2-22 alkenyl, or substituted or unsubstituted C 2-22 alkynyl. In some embodiments, the Log K ow is in the range of −3 to +2 (e.g., −2 to +2) and/or the HLB value is in the range of 5 to 20 (e.g., 4 to 18). The alkyl, alkenyl or alkynyl chains can be branched or straight chains. R 2 and R 3 can be optionally alkoxylated. The R 1 , R 2 and R 3 can be substituted with groups such as halogen, carbonyl, hydroxyl, amine, and the like. In some embodiments, these compounds are used in pure or substantially pure form.
[0083] In some embodiments, one or more of R 1 , R 2 , and R 3 is independently an alkoxylated or non-alkoxylated, substituted or unsubstituted fatty acid residue. In some embodiments, R 1 , R 2 , and R 3 can be selected from the group consisting of saturated fatty acids, monounsaturated fatty acids, polyunsaturated fatty acids, and mixtures thereof.
[0084] In some embodiments, R 1 is a higher alkyl, alkenyl or alkynyl group having 7 or more carbon atoms (e.g, C8-C25 or C10-C20) and is generally an alkyl or alkenyl group. The R 2 and R 3 groups can also be a higher alkyl, alkenyl or alkynyl group although, in some embodiments, are lower alkyl, alkenyl or alkenyl groups (e.g. C1-C5) such as C1-C3 alkyl or hydrogen. Exemplary compounds include tridodecylamine, dodecyldimethylamine, octadecyldimethylamine, cocoalkyldimethylamines, hydrogenated tallowalkyldimethylamines, oleyldimethylamine, dicocoalkylmethylamine, and mixtures thereof. The compounds can also be polyetheramines including the groups for R 1 , R 2 and R 3 described above and further being alkoxylated to the levels described herein.
[0085] In some embodiments, one or more of R 1 , R 2 , and R 3 is independently amino-substituted (e.g. with a NR 4 R 5 group where R 4 and R 5 are H or substituted or unsubstituted, alkoxylated or non-alkoxylated, alkyl, alkenyl or alkynyl groups). For example, the amine sacrificial agent can be a diamine compound wherein R 1 is amino-substituted. Exemplary diamines include polyetherdiamines (such as polyoxypropylenediamines and polyoxyethylene diamines) wherein the average level of alkoxylation is from 1 to 10, from 1.5 to 9 or from 2 to 8. Suitable alkoxylated diamines can have the formula NH 2 —R—(R 1 O) x —NH 2 wherein R is C1-C5 alkyl, R 1 is C2-C4 alkyl, and x is the level of alkoxylation. For example, polyoxypropylenediamines are commercially available as Jeffamine D 400 and Jeffamine D 230; and triethyleneglycol diamine is commercially available as Jeffamine EDR 148, all from Huntsman International LLC. In some embodiments, the diamines are non-alkoxylated wherein x is 0 and R can be C5 or greater (e.g. C8-C25 or C10-C20). In some embodiments, the diamines are alkoxylated and have the formula R 3 ((R 4 O) w H)N—R 2 —N((R 5 O) y H)((R 6 O) z H) wherein R 2 is C1-C5 alkyl, R 3 is C1-C25 alkyl, alkenyl or alkynyl, R 4 , R 5 and R 6 are independently C2-C4 alkyl, one or more of x, y and z is greater than 0, and the total level of alkoxylation (w+y+z) is 1 to 10, 1.5 to 9 or 2 to 8. In some embodiments, R 3 is C5-C25 alkyl, alkenyl, or alkynyl (e.g. C8-C25 or C10-C20 alkyl). Exemplary alkoxylated diamines include N-oleyl-1,1′-iminobis-2-propanol and N-tallowalkyl-1,1′-iminobis-2-propanol. One commercially available example is N-tallowalkyl-1,1′-iminobis-2-propanol available from Akzo Nobel as Ethoduomeen T/13N. In some embodiments, the diamines can be non-alkoxylated (w+y+z)=0 and R 2 can be C5 or greater (e.g. C8-C25 or C10-C20).
[0086] In some embodiments, the amine is hydroxyl substituted (e.g. at one, two or three of R 1 , R 2 and R 3 ) and is an alcoholamine. In some embodiments, R 1 is higher alkyl as described above and can be optionally substituted with a carbonyl group and one or more of R 2 and R 3 are hydroxyl substituted. For example, Amadol 1017 commercially available from Akzo Nobel and having the formula CH 3 (CH 2 ) 10 C(═O)N(CH 2 CH 2 OH) 2 can be used. Alternatively, R 1 and one or more of R 2 and R 3 can be hydroxyl substituted.
[0087] In some embodiments, the amine sacrificial agent has a particular “Hydrophilic Lipophilic Balance” (HLB) rating, or oil/water (or octanol/water) partition coefficients (K OW ). These terms are understood in the art and are described, for example, in U.S. Pat. No. 7,485,184, which is hereby incorporated by reference in its entirety. In some embodiments, the HLB value of the sacrificial agent or the mixture of sacrificial agents is in the range of S to 20 (e.g., 4 to 18). In some embodiments, the Log Kow for the sacrificial agent can be in the range of −3 to +2 (e.g. −2 to +2).
[0088] Combinations of these amine sacrificial agents can be used as the sacrificial agent composition. For example, in some embodiments, dodecyldimethylamine, polyoxypropylenediamine, triethyleneglycol diamine, and mixtures thereof are used as the sacrificial agent. In some embodiments, the sacrificial agent can two or more amine sacrificial agents in weight a ratio of 1:1-1:50 wherein the total sacrificial agent is as described herein. For example, the sacrificial agent can include a first component having a compound A from the group of tridodecylamine, dodecyldimethylamine, octadecyldimethylamine, cocoalkyldimethylamines, hydrogenated tallowalkyldimethylamines, oleyldimethylamine, dicocoalkylmethylamine, and mixtures thereof (e.g. dodecyldimethylamine), and a second compound B from the group of polyetheramines, diamines, alcoholamines, all as described above, and mixtures thereof (e.g. polyoxypropylenediamine), wherein the weight ratio of compound A to compound B is 2:1 to 1:50, 1.25:1 to 1:25, or 1:1 to 1:5. In some cases, it can be advantageous to mix a sacrificial agent having different HLB values (e.g. high and low values) to produce a combined sacrificial agent mixture that is approximately neutral in its effect on the entrainment of air in the mixture. In this way, it is possible to use highly active sacrificial agents that would otherwise interfere too much with the entrainment of air.
[0089] In some embodiments, the amounts of such sacrificial agents are sufficient to neutralize the harmful components of the fly ash that adsorb or react with the air entrainment agents. The required minimum dosage can be determined experimentally through air entrainment protocols since, as discussed earlier and shown below, the deleterious effects of fly ash components are not necessarily directly related to their carbon content or LOI. In some embodiments, the sacrificial agents can be used in reasonable excess over the neutralizing amounts without entrainment of excess air (or reduction of such entrainment) or harming the concrete mixture or the subsequent setting action or properties of the hardened concrete. This means that an amount can be determined which exceeds the neutralizing amount required for a fly ash containing the highest amount of the harmful components likely to be encountered, and this amount can then be safely used with any fly ash cement mixture.
[0090] The amine sacrificial agents can be used in combination with one or more sacrificial agents described in U.S. Pat. No. 7,485,184, which is incorporated by reference herein in its entirety. For example, additional sacrificial agents can include sodium naphthoate, sodium naphthalene sulfonate, sodium diisopropyl naphthalene sulfonate, sodium cumene sulfonate, sodium dibutyl naphthalene sulfonate, ethylene glycol phenyl ether, ethylene glycol methyl ether, butoxyethanol, diethylene glycol butyl ether, dipropylene glycol methyl ether, polyethylene glycol and phenyl propylene glycol and combinations thereof In addition, In some embodiments, sodium diisopropyl naphthalene sulfonate is included with the amine sacrificial agent in the sacrificial agent composition. The additional sacrificial agent can be included at a weight ratio of non-amine sacrificial agent to amine sacrificial agent of 1:2 to 1:150, or 1:5 to 1:100, or 1:10 to 1:75.
[0091] In some embodiments, the amine sacrificial agents can be used in combination with a water reducer. For example, lignosulfonates and polynaphthalene sulfonates have been found to particularly enhance the properties of the amine sacrificial agents. The water reducer can be included in a weight ratio of water reducer to amine sacrificial agent of 40:1 to 1:1.25 or 15:1 to 2:1.
[0092] The sacrificial agents can be added at any time during the preparation of the concrete mix. In some embodiments, they are added before or at the same time as the air entrainment agents so that they can interact with the fly ash before the air entrainment agents have an opportunity to do so. The mixing in this way can be carried out at ambient temperature, or at elevated or reduced temperatures if such temperatures are otherwise required for particular concrete mixes. The sacrificial agents can also be premixed with the fly ash or with the air entrainment agent.
[0093] It is particularly convenient to premix the sacrificial agent with the fly ash because the sacrificial agent can commence the interaction with the harmful components of the fly ash even before the cementitious mixture is formed. The sacrificial agent can simply be sprayed or otherwise added in liquid form onto a conventional fly ash and left to be absorbed by the fly ash and thus to dry. If necessary, the sacrificial agent can be dissolved in a volatile solvent to facilitate the spraying procedure. Fly ash treated in this way can be prepared and sold as an ingredient for forming fly ash cement and fly ash concrete.
[0094] Surprisingly, it has also been found that the sacrificial agent is even effective when added after the mixing of the other components of the cementitious mixture (including the air entrainment agent). Although not wishing to be bound by a particular theory, it appears that the sacrificial agent can reverse any preliminary deactivation of the air entrainment agent caused by contact with the fly ash, and thus reactivate the air entrainment agent for further air entrainment. It is observed, however, that the beneficial effect of the sacrificial agents is somewhat lower when added at this stage rather than when added before or during the mixing of the other components.
[0095] As noted above, in some embodiments, the chemical additives used as sacrificial agents are not effective air entrainment agents in the amounts employed, so that they do not contribute directly to air entrainment and can thus also be used in normal concrete containing no fly ash. This confers on the sacrificial agents the particularly important feature that these sacrificial agents can be introduced at dosages higher than the minimum dosage required to restore normal air entrainment without leading to erratic air entrainment and excessive air entrained levels. If one of the sacrificial agents used in a combination of sacrificial agents exhibits some surfactant (air entrainment) properties, it can be proportioned in such a way that the combination of sacrificial agents will entrain less than 2% air (or less than 1% air, or substantially no air), above the control values, in normal concrete without any fly ash. That is to say, when a concrete formulation is produced without fly ash, but with an air entrainment agent, the extra amount of air entrained when a sacrificial agent is added represents the extra air entrained by the sacrificial agent. The amount of air entrained in a cementitious mixture can be measured by determination of specific gravity of the mixture, or other methods prescribed in ASTM procedures (ASTM C231, C 173, and C138—the most recent disclosures of which are incorporated herein by reference in their entirety).
[0096] Typical concrete air entrainment agents are n-dodecylbenzene sulfonate salts (referred to as Air 30) and tall oil fatty acid salts (referred to as Air 40). The typical dosage range of these ingredients in portland cement concrete mixes is 0.002 to 0.008 wt % of the cementitious components. The targeted air entrainment for the cementitious composition is typically 6-8 vol % air.
[0097] Other components of the cementitious mixtures are water, cement and fly ash. These can be used in proportions that depend on the type of material desired (e.g., pastes, grouts, mortars, concrete) and on the required fresh and hardened properties of the finished material. Such systems and their composition, as well as equipment and protocols for their preparation, are well known in the art; for mortars and concrete, these are adequately described in standard reference texts, such as ASTM Cement and Concrete (e.g., 4.01, 4.02); Design and Control of Concrete Mixtures—Portland Cement Association; and American Concrete Institute—Manual of Concrete Practice (the disclosures of which are incorporated herein by reference). For pastes, the composition and preparation equipment and protocols will be described in detail in following sections. In practice, the content of various ingredients in a cementitious mixture are often reported as weight ratios with respect to the cement or to the total cementitious materials when other cementitious materials such as fly ash, slag, etc., are present. These ratios are well known to persons skilled in the art.
[0098] Once formed, the cementitious mixture can be used in any conventional way, e.g. poured into a form and allowed to harden and set. The hardened product will contain fly ash and entrained air, but no excess of air entrainment agent that could adversely affect the air content and properties of the hardened product.
[0099] The cementitious mixtures can include other standard or specialized concrete ingredients known to persons skilled in the art.
[0100] The following examples are provided to more fully illustrate some of the embodiments of the present 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 inventors to function well in the practice of the invention, and thus can be considered to constitute exemplary 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 that are disclosed and still obtain a like or similar result without departing from the spirit and scope of the invention. Parts and percentages are provided on a per weight basis except as otherwise indicated.
EXAMPLES
Example 1
PACT Formulation:
[0101] A sacrificial agent formulation (PACT) is prepared by mixing polyoxypropylenediamine, dodecyldimethylamine, and optionally sodium diisopropylnapthalenesulfonate. For the following examples, PACT was formulated as follows: 0.05% dodecyldimethylamine and 0. 15% polyoxypropylenediamine, by weight of fly ash.
Composition Preparation:
[0102] To prepare the composition, the aggregate is mixed with partial water followed by the portland cement. Fly ash combined with activated carbon is then added followed by the PACT formulation and the air entrainment agent. Alternatively, the PACT formulation can be added directly to the fly ash. Additional water is added to obtain a 4-6 inch slump. The composition is then mixed using a rotary mixer, and tested for volume percentage of air using a pressure meter according to the ASTM C 231 method.
[0103] Activated carbon for the following examples was obtained from three sources:
[0104] PAC-A: Norit HgLH (Norit Americas Inc., Marshall, Tex.)
[0105] PAC-B: ADA-ES (ADA Environmental Solutions, Littleton, Colo.)
[0106] PAC-C: Calgon MC Plus (Calgon Carbon, Pittsburgh, Pa.)
[0107] The air entrainment agent used in the following examples was MB-AE 90 (BASF Construction Chemicals, Shakopee, Minn.) and is labeled as AEA-1.
Example 2
[0108] The competitive absorption by PAC-C with various sacrificial agents at saturated concentrations was determined ( FIG. 1 ). The trace labeled Model AEA (DDBS) displays the absorption of an air entrainment agent (dodecylbenzenesulfonate (DDBS)) by MC activated carbon without the presence of a sacrificial agent. The trace labeled DDBS (with SA-A2) displays the absorption of DDBS by PAC-C and Jeffamine EDR-148. The trace labeled DDBS (with SA-C) displays the absorption of DDBS by MC activated carbon and Jeffamine 230. The trace labeled DDBS (with SA-J4) displays the absorption of DDBS by MC activated carbon and Jeffamine 400.
Example 3
[0109] The percentage of air in concrete with increasing concentrations of air entraining agent AEA-1 with varying amounts of activated carbon samples PAC-A, PAC-B, and PAC-C was determined. The amounts tested for each activated carbon sample include 0.75% and 1.5% ( FIG. 2 ). Cement and fly ash cement independently served as controls. All activated carbon samples increased the air entraining agent demand.
Example 4
[0110] The dosage of an air entrainment agent for 6% air in concrete with increasing amounts of carbon content with activated carbon samples PAC-A, PAC-B, and PAC-C was determined ( FIG. 3 ). Fly ash served as the control.
Example 5
[0111] The percentage of air in concrete with increasing concentrations of an air entrainment agent (AEA-1) with varying amounts of activated carbon (PAC-A) was determined ( FIG. 4 ). Fly ash served as the control. The presence of activated carbon caused the air entraining admixture demand to reach unacceptable levels.
Example 6
[0112] The percentage of air in concrete with increasing concentrations of an air entrainment agent (AEA-1) with varying amounts of activated carbon (PAC-A) with and without PACT (as formed in Example 1) was determined ( FIG. 5 ). The amounts tested include 0.75% PAC, 2% PAC, 3% PAC, 0.75% PAC with PACT, 2% PAC with PACT, and 3% PAC with PACT. Fly ash served as the control. The inclusion of PACT in the activated carbon formulations reduced the air entraining admixture demand to acceptable levels.
Example 7
[0113] The percentage of air in concrete with increasing concentrations of an air entrainment agent (AEA-1) with fly ash treated with activated carbon (PAC-A) in the presence of PACT was determined ( FIG. 6 ). The amounts tested included fly ash treated with 1.5% activated carbon and fly ash treated with 3% activated carbon. The PACT was present in constant, high dosage. Untreated fly ash served as the control. Increasing the dosage of PACT resulted in a performance comparable to that of untreated fly ash.
Example 8
[0114] The percentage of air in concrete with increasing concentrations of an air entrainment agent (AEA-1) with PACT treated fly ash in the presence and absence of 3% activated carbon (PAC-A) was determined ( FIG. 7 ). Both the PACT treated fly ash that contained activated carbon and the PACT treated fly ash that did not contain activated carbon displayed similar entraining properties.
Example 9
[0115] The percentage of air in concrete with varying amounts of activated carbon (PAC-A) with a constant concentration (1 oz/cwt) of an air entrainment agent (AEA-1) was determined ( FIG. 8 ). The air entrainment agent was treated with PACT. Untreated AEA-1 served as the control. PACT treatment was shown to minimize air fluctuations over a broad range of PAC contamination levels.
Example 10
[0116] The percentage of air in concrete with increasing concentrations of air entrainment agent (AEA-1) was determined for untreated activated carbon and activated carbon treated with PACT ( FIG. 9 ). The activated carbon samples were obtained from three different sources (PAC-A, PAC-B, and PAC-C). PACT was effective for all of the PAC samples tested; however, in some cases, it may be better to adjust the formulation depending upon the PAC source.
Example 11
[0117] The percentage of air in concrete with increasing concentrations of air entrainment agent (AEA-1) was determined for high quality fly ash having a LOI of about 1% and a low quality fly ash having a LOI of about 2.5% with or without the addition of CF PAC-C activated carbon, a concrete friendly activated carbon available from Calgon Corp. and present in an amount of 3% ( FIG. 10 ). The concrete friendly activated carbon influenced air entrainment, but did not compensate for underlying ash quality issues related to high or varying native carbon content.
Example 12
[0118] The percentage of air in concrete with increasing concentrations of air entrainment agent (AEA-1) was determined for the same high quality and low quality fly ashes from Example 11 with or without the addition of CF PAC-C activated carbon and/or PACT ( FIG. 11 ). PACT effectively decreased the negative influence of carbon. | A method of producing cementitious mixtures containing fly ash as one of the cementitious components, under air entrainment conditions is described. The method involves forming a mixture comprising water, cement, fly ash, optionally other cementitious materials, aggregate, conventional chemical admixtures, and an air entrainment agent and agitating the mixture to entrain air therein. Additionally, at least one amine sacrificial agent is included in the mixture. The cementitious mixtures and hardened concretes resulting from the method and fly ash treated with sacrificial agent, or air entrainment agent/sacrificial agent combinations, are also described. | 8 |
BACKGROUND OF THE INVENTION
The invention relates to a method for reducing the surface tack of EPDM and related elastomers and to an EPDM elastomer having its surfaces coated with cellulose.
Uncured EPDM elastomers usually exhibit a sufficient degree of tack that if two surfaces of the uncured EPDM elastomer are brought into direct contact with each other, they will strongly adhere together. Thus, for example, if two sheets of uncured EPDM elastomer are brought into contact with each other, of if a sheet of uncured elastomer is wound up into a roll and the elastomer surfaces are permitted to remain in contact with each other for any significant period of time, it will be extremely difficult if not impossible to separate the sheets or unwind the roll. Such a problem is greatly magnified if the sheets or roll of elastomer are subjected to a curing procedure since the bond between the elastomer surfaces is greatly strengthened by curing.
In order to overcome the problem of EPDM elastomer surfaces adhering to each other during handling or after curing, it is necessary to apply a coating of an anti-sticking or lubricating agent to the elastomer surfaces. A number of such anti-sticking agents are known in the elastomer or polymer arts including talc, mica, starch and metal stearates. The most common anti-sticking agents used for elastomers are talc and mica. These materials effectively reduce the surface tension of the elastomer thereby reducing the tendency of the surfaces to stick together. Talc and mica strongly adhere to the elastomer surfaces but due to their lamellar structures permit the surfaces to slide past each other without sticking together.
As indicated, talc and mica are effective anti-sticking agents for EPDM elastomer surfaces. However, these materials exhibit a major disadvantage in certain EPDM elastomer applications. This disadvantage is particularly apparent in EPDM elastomers which are utilized for flat roofing applications. In such applications, it is usually necessary to splice two or more sheets of cured EPDM elastomer together with a contact adhesive in order to provide for complete coverage of the roof. However, talc and mica have been found to exert a negative effect on the peel adhesion of the splice or seam when a contact adhesive is used to splice the sheets of cured EPDM together. Thus, in order to achieve maximum lap splice strength it is necessary to completely remove the talc or mica from those portions of the elastomer surfaces which are to be spliced together. However, removal of the talc or mica is difficult and time consuming since these materials adhere strongly to the elastomer surfaces. As will be evident, the application of sheets of cured EPDM elastomer to flat roofs is a labor intensive operation. Accordingly, the necessity of completely removing the talc or mica is a significant disadvantage.
In view of the foregoing, the discovery of an anti-sticking agent which does not adversely affect the peel adhesion of EPDM splices, and therefore need not be removed or at least completely removed, would be a major achievement.
SUMMARY OF THE INVENTION
In accordance with the present invention, a method for reducing the tack of EPDM elastomer surfaces comprises coating the surfaces of the EPDM elastomer with particulate cellulose. The resultant cellulose coated EPDM elastomer can be subjected to various handling and curing operations without encountering surface sticking problems. Sheets of cellulose coated cured EPDM elastomer can be spliced together with a contact adhesive without the necessity for first removing the cellulose coating.
DETAILED DESCRIPTION OF THE INVENTION
The term "EPDM" as employed throughout the specification and claims is used in the sense of its definition as found in ASTM-D-1418-64 and is intended to mean a terpolymer of ethylene, propylene and a diene monomer.
EPDM terpolymers and illustrative methods for their preparation are described in various patents including U.S. Pat. No. 3,280,082 and British Pat. No. 1,030,289, the disclosures of which are incorporated herein by reference. The preferred terpolymers are those derived from a monomer mixture consisting of from about 40 to about 80 weight percent ethylene and from about 1 to about 10 weight percent of the diene monomer with the balance being propylene. Diene monomers which may be utilized in forming the terpolymers are preferably non-conjugated dienes. Illustrative examples of non-conjugated dienes which may be employed are dicyclopentadiene, alkyl dicyclopentadiene, 1,4-pentadiene, 1,4-hexadiene, 1,5-hexadiene, 1,4-heptadiene, 2-methyl-1,5-hexadiene, cyclooctadiene, 1,4-octadiene, 1,7-octadiene, 5-ethylidene-2-norbornene, 5-n-propylidene-2-norbornene, 5-(2-methyl-2-butenyl)-2-norbornene and the like.
A number of the above-described EPDM elastomers are commercially available. A typical commercial EPDM elastomer is Vistalon 2504, a terpolymer of 50 weight percent ethylene, 45 weight percent propylene and 5 weight percent 5-ethylidene-2-norbornene having a number average molecular weight (M n ) as measured by GPC of about 47,000; a weight average molecular weight (M w ) as measured by GPC of about 174,000 and a Mooney Viscosity (ML, 1+8, 100° C.) of about 40, available from Exxon Chemical Company. Another typical commercial EPDM elastomer is Nordel 1070, an ethylene/propylene/1,4-hexadiene terpolymer having an M n of 87,000 and an M w of 188,000 as determined by GPC, available from duPont.
As indicated, the surface tack of EPDM elastomers can be reduced in accordance with the method of the invention by coating the elastomer surfaces with particulate cellulose. Unlike talc and mica, cellulose has an amorphous structure and does not strongly adhere to itself or an elastomer surface except by entrapment. Accordingly, any excess cellulose applied to elastomer surfaces to prevent surface sticking during handling of the elastomer and during curing can be removed if desired by light brushing or other light mechanical action. Moreover, as mentioned heretofore it is not necessary to remove the cellulose coating during splicing of two elastomer surfaces together using a contact adhesive since cellulose does not adversely affect peel adhesion. Virtually any particulate cellulose can be employed to prevent sticking of the EPDM elastomer surfaces together. A preferred particulate cellulose is one having a particle size which will enable it to pass through a number 200 mesh screen.
The coating of particulate cellulose can be applied to the EPDM surfaces by any convenient method. Thus, for example, the particulate cellulose may be applied by dusting or brushing. Alternatively and often preferably, the particulate cellulose can be applied to the EPDM elastomer surfaces by passing a sheet of the elastomer through a suitable container (e.g., a trough) filled with particulate cellulose.
The following examples are submitted for the purpose of further illustrating the nature of the present invention and are not to be regarded as a limitation on the scope thereof.
In the examples, a series of trial runs were conducted to evaluate the effect of cellulose in preventing sticking of EPDM elastomer surfaces to each other or to other substrates during processing and curing. The effect of cellulose on the peel adhesion of splices formed by bonding cellulose coated EPDM elastomer surfaces together using a contact adhesive was also evaluated. For comparative purposes, in some of the examples talc was subjected to the same tests.
RUN #1
Two (2) uncured sheets of EPDM elastomer of the Nordel type, 6"×6"×0.060" were coated on each side with #200 mesh cellulose using a brush. The amount of cellulose coated on each side was about 1-2 grams per square foot. The cellulose coated sheets of EPDM were then placed in a 6"×6"×0.060" steel mold and cured for four (4) hours at 300°-320° F. The mold was then cooled, opened and the cellulose coated cured EPDM sheets were removed. There was no sticking of the elastomer surfaces to the surfaces of the steel mold.
RUN #2
A trial run was conducted by passing an 0.060" thick sheet of an EPDM elastomer of the Nordel type through a V-shaped trough containing #200 mesh particulate cellulose in two passes to apply a coating of cellulose to each surface of the EPDM sheet. The EPDM sheet was coated with cellulose on both sides at a level of about 1 gram of cellulose per square foot of sheeting. The cellulose coated EPDM sheet was then rolled onto a mandrel, placed in a large autoclave and cured for four (4) hours at 300°-320° F. The roll of cellulose coated cured EPDM sheet was then unrolled to evaluate the effectiveness of cellulose in preventing sticking together of the elastomer surfaces. On unrolling, the EPDM sheet showed no evidence of sticking or adhering of the elastomer surfaces.
A similar run was conducted using talc instead of cellulose to obtain a material to serve as a control for peel adhesion testing.
Peel Adhesion of Talc Coated Cured EPDM Sheets Vs. Cellulose Coated Cured EPDM Sheets
In this comparative evaluation, the peel adhesion of lap splices formed by bonding two (2) 6"×6"×0.060" sheets of talc coated cured EPDM using a contact adhesive was compared to the peel adhesion of lap splices formed by bonding two (2) 6"×6"×0.060" sheets of cellulose coated cured EPDM using the same contact adhesive. Test samples were prepared without prior removal of the talc or cellulose coatings and also with pretreatments of the elastomer surfaces to remove the coating using various solvents and mechanical removal procedures.
The peel adhesion strips were generally prepared by applying a coating of contact adhesive over a 3"×4" area of the surface of each cured EPDM sheet to be bonded using a 1" wide paint brush. The adhesive coated surfaces were then allowed to dry until they were just tacky to the touch. The adhesive coated surfaces were then brought into contact with each other and manually pressed together. Then, pressure was applied to the test strip by rolling the lap splice with a 2"×2" diameter steel roller. The test strips were then allowed to age for various periods of time at various temperatures before testing for peel adhesion. It should be noted that in those cases where an attempt was made to remove the talc or cellulose coating, this was done before application of the contact adhesive.
The contact adhesive employed in the evaluation was a composition composed of a neutralized zinc sulfonated EPDM elastomer having from about 10 to about 100 milliequivalents of neutralized sulfonate groups per 100 grams of terpolymer, an organic hydrocarbon solvent or mixture of an organic hydrocarbon solvent and an aliphatic alcohol, a para-alkylated phenol formaldehyde and an alkylphenol or ethoxylated alkylphenol. The contact adhesive is described in copending application Ser. No. 431,403, now U.S. Pat. No. 4,450,252, of J. W. Fieldhouse, filed Sept. 30, 1982, commonly assigned to the assignee herein, the disclosure of which is incorporated herein by reference.
Peel adhesion, reported in pounds per linear inch (PLI), was conducted at room temperature (i.e., 22° C.) on test strips aged for seven (7) days at various temperatures. Peel adhesion was performed on an Instron tester operating at 2" per minute using the T peel adhesion test described in ASTM D-413. Identification of the surface coating used on the elastomer surfaces bonded together to form the test strip, surface preparation for removal of the surface coating if any and peel adhesion conditions and results are shown in the Table.
TABLE______________________________________ Peel Adhesion, PLI @ 22° C.Surface Surface After Aging 7 Days @ °C.Test # Coating Preparation 22 50 70 120______________________________________1 talc none 1-2 -- -- --2 talc gasoline 3 5 3.5 2.5 only3 talc gasoline + 6.5 8 4 1.5 sand blasting4 cellu- none 7.5 7.5 6.0 4.0 lose5 cellu- gasoline + 10.5 14.0 13.0 9.0 lose nylon brush______________________________________ | A method for reducing the surface tack of EPDM and related elastomers is provided. The method involves coating the surfaces of the elastomer with particulate cellulose. Sheets of cellulose coated elastomer can be subjected to rolling up and curing operations without encountering surface sticking problems. In addition, the cellulose coated surfaces of the elastomer can be bonded together for the purpose of forming splices or seams without the necessity for first removing the cellulose coating. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 60/427,678, filed Nov. 19, 2002, entitled CENTER CAP FOR VEHICLE WHEEL.
BACKGROUND OF THE INVENTION
The present invention relates to a center cap for a vehicle wheel, and in particular to the connection of a decorative wheel center cap to a vehicle wheel assembly.
Ornamental outer coverings have been employed for providing a decorative surface to the exposed surface of wheels for many years. These outer coverings offer design flexibility in that various configurations may be used to cover a single style wheel. One aspect of some of these outer coverings has been the utilization of a center cap to cover the central hub aperture of an associated wheel. These center caps 2 , as shown in FIGS. 1 and 2 , have been held in connection with the wheel by various means, one of which incorporates a plurality of connecting tabs 4 . Typically, the tabs 4 of the shown design include sharp corners 6 that contact the associated wheel during the assembly of the center cap with the wheel. As these components are assembled, the sharp corners 6 of the tabs 4 dig into the surface of the wheel proximate the central hub, thereby increasing the force required to be exerted on the center cap 2 to assemble the cap 2 with the wheel, resulting in degradation to the corrosion barrier finish and a destruction of the aesthetic finish on the wheel. These problems are magnified when the wheel cap is constructed of a material that is significantly harder than the associated wheel, such as when the wheel cap is covered with a chrome finish and the wheel is constructed from aluminum and the like.
A central cap is desired that reduces the force required to assemble the cap with an associated wheel, and that does not adversely effect the protective and aesthetic finish of the wheel during assembly.
SUMMARY OF THE INVENTION
One aspect of the present invention is to provide a wheel having an outer surface and a centrally located aperture extending through the wheel, and a wheel cap having a body portion and a plurality of flexibly resilient fingers extending substantially orthogonal to the body portion, wherein each finger has a pair of side walls and an integrally formed outer wall, and wherein the outer wall includes a centrally located portion and rounded abutment portions located proximate the side walls.
Another aspect of the present invention is to provide a wheel center cap for a vehicle wheel that includes a substantially planar body portion, and a plurality of flexibly resilient fingers extending substantially orthogonal to the body portion and adapted to be received within a central aperture of a wheel. Each finger includes a pair of side walls and an integrally formed outer wall including a centrally located portion defining a first radius of curvature, and rounded abutment portions located proximate the side walls and having a second radius of curvature that is less than the first radius of curvature.
Yet another aspect of the present invention is to provide a method of assembling a wheel cap with a vehicle wheel that includes providing a wheel assembly having an outer surface and a centrally located hub aperture extending through the wheel assembly, wherein the hub aperture has a first radius, and providing a wheel cap having a body portion and a plurality of flexibly resilient fingers extending substantially orthogonal to the body portion, wherein each finger has a pair of side walls and an integrally formed outer wall including a centrally located portion having a second radius and rounded abutment portions located proximate the side walls and each having a third radius, wherein the third radius is less than the second radius. The method also includes aligning the fingers of the wheel cap with the hub aperture with the wheel, and providing an inwardly directed force to the body portion of the wheel cap, thereby forcing the legs to flex inwardly until the rounded abutment portions of the fingers abut the hub aperture of the wheel assembly.
The present inventive center cap for vehicle wheels is efficient in use, economical to manufacture, easily assembled with an associated wheel assembly without the use of tools, results in a decrease in the force required to assemble the center cap with the associated wheel assembly, reduces the adverse effects of assembling the center cap with the associated wheel and is particularly well adapted for the proposed use.
These and other advantages of the invention will be further understood and appreciated by those skilled in the art by reference to the following written specification, claims and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a rear elevational view of a prior art wheel center cap;
FIG. 2 is a side elevational view of the prior art wheel center cap;
FIG. 3 is a rear elevational view of a wheel center cap embodying the present invention;
FIG. 4 is a side elevational view of the wheel center cap embodying the present invention;
FIG. 5 is a perspective view of a vehicle wheel assembly; and
FIG. 6 is an enlarged rear elevational view of a finger of the wheel center cap.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in FIGS. 3 and 4 . However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
The reference numeral 10 ( FIGS. 3 and 4 ) generally designates a wheel center cap embodying the present invention. In the illustrated example, the center cap 10 is connectable to a vehicle wheel assembly 12 ( FIG. 2 ). As illustrated, the wheel assembly 12 includes a wheel 14 , however, the wheel assembly 12 may also include a decorative wheel cladding (not shown) such as those disclosed in U.S. Pat. Nos. 5,564,791; 5,577,809; 5,597,213; 5,630,654; 5,636,906; 5,845,973; and 6,085,829, the disclosures of which are incorporated herein by reference. The wheel 14 has an outer surface 16 and a centrally located hub aperture 18 extending through the wheel 14 . The center cap 10 includes a body portion 20 and a plurality of flexibly resilient fingers 22 extending substantially orthogonal to the body portion 20 . Each finger 22 ( FIG. 6 ) has a pair of side walls 24 and an integrally formed outer wall 26 having a centrally located portion 28 and rounded abutment portions 30 located proximate the side walls 24 .
The wheel 14 of wheel assembly 12 is made of aluminum, magnesium, steel, or other material conventionally used for manufacturing vehicle wheels. The cladding (not shown) may be bonded to the wheel 14 via an adhesive. The cladding is injection molded of a polymeric material, such as a combination of polycarbonate and ABS. The polcarbonate to ABS ratio ranges from about 60% to about 70% polycarbonate and about 40% to about 30% ABS, respectively. Other polymeric materials or composite polymeric materials may be also used. An outer decorative surface of the cladding is covered with a bright (highly reflective) or satin finished metal plating such as chrome as described in U.S. patent application Ser. No. 09/707,866, filed Nov. 7, 2000 and entitled METHOD AND COMPOSITION FOR METALLIC FINISHES, now U.S. Pat. No. 6,749,946, the disclosure of which is incorporated herein by reference. The outer surface 16 of wheel 14 and the outer surface of the cladding can also be painted, textured or otherwise finished for a particularly desired appearance. The hub aperture 18 of the wheel 14 defines an interior or aperture wall 32 . A locking ring 36 extends circumferentially about the hub aperture 18 and inwardly from the aperture wall 32 .
The wheel assembly 12 also includes a plurality of exposed lug nut apertures 38 arranged in a circular pattern and spaced for the particular vehicle on which the wheel assembly 12 is to be employed. The lug nuts (not shown) as associated with the wheel assembly 12 are typically exposed once the wheel 14 is mounted to a vehicle.
The body portion 20 of the center cap 10 is substantially planar having an outer surface 39 , and extends radially outward beyond the fingers 22 , thereby creating a rim or lip 40 having an inner surface 42 . Each finger is resiliently inwardly flexible in a direction as indicated by directional arrow 44 , between an unflexed position A, a flexed assembly position B, and a flexed assembled position C, as discussed below. Each finger 22 includes a raised nub 46 located along the length thereof, and that is adapted to abut the locking ring 36 of the wheel 14 as described below. The center cap 10 is preferably constructed of similar materials and with similar methods as the cladding as discussed above, including the bright (highly reflective) or satin finish metal plating such as chrome. The center cap 10 further includes a flexibly resilient biasing ring 48 located on the middle of and abutting an inner surface 50 of each of the fingers 22 , and biasing the fingers 22 outwardly in direction as indicated and represented by arrow 51 .
In assembly, the cap 10 is placed within the hub aperture 18 of the wheel 14 by aligning the fingers 22 of the cap 10 with the hub aperture 18 and exerting a force to the outer surface 39 of the cap in a direction as indicated and represented by directional arrow 52 . As the fingers 22 are forced within the hub aperture 18 , a force is exerted on each finger 22 by the aperture wall 32 , thereby forcing the fingers to flex in an inward direction 44 until the nub 46 of each finger 22 is aligned with the locking ring 36 of the wheel 14 , and the fingers 22 are each located in the assembly position B. At this position the rounded abutment portions 30 of each finger 22 is in contact with the locking ring 36 . The force 52 is continued until the nub 46 of each finger 22 is located behind the locking ring 36 of the wheel 14 , and the fingers 22 are each located in the assembled position C. It should be noted that the fingers 22 are inwardly flexed when in the assembled position C and, therefore, continue to exert a force against the aperture wall 32 of the hub aperture 18 .
The present inventive center cap for vehicle wheels is efficient in use, economical to manufacture, easily assembled with an associated wheel assembly without the use of tools, results in a decrease in the force required to assemble the center cap with the associated wheel assembly, reduces the adverse effects of assembling the center cap with the associated wheel and is particularly well adapted for the proposed use.
In the foregoing description, it will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed herein. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise. | A wheel center cap for a vehicle wheel includes a substantially planar body portion, and a plurality of flexibly resilient fingers extending substantially orthogonal to the body portion and adapted to be received within a central aperture of a wheel. Each finger includes a pair of sidewalls and an integrally formed outer wall, wherein the outer wall includes a centrally-located portion defining a first radius of curvature, and rounded abutment portions located proximate the sidewalls and having a second radius of curvature that is less than the first radius of curvature. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is related to, and claims the benefit of, the provisional patent application entitled “Elastic Grip Handle for a Baseball/Softball Bat”, filed Jan. 14, 2003, bearing U.S. Ser. No. 60/439,906 and naming Roberto Estape and Frank Acosta, the named inventors herein, as sole and joint inventors, the contents of which is specifically incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to baseball/softball equipment. In particular, it relates to an elastomeric grip/handle which attaches to the knob of a baseball/softball bat and allows the batter to swing the bat while holding the bat knob without interference with the batter's wrist motion, which results in reduced likelihood of injuries to the batter, which results in improved comfort for the batter while manipulating the bat, and which results in higher bat velocity and increased ball flight distance when the ball is struck by the bat.
2. Background
The games of baseball and softball have been played for many years. Originally, baseball was played with a simple stick and a ball having a relatively simple construction. Over time, numerous improvements were made to both the bat and the ball. Usually, these improvements were made to increase in ball flight distance and to increase the usability of the bat.
For ease of discussion, the terms “baseball bat,” “softball bat,” and “bat” may be used interchangeably herein to describe both baseball bats (e.g., which uses a smaller hard ball) and softball bats (e.g., which uses a larger ball). An early problem which became apparent in regard to the use of baseball/softball bats, was a loss of control of the bat which occasionally slipped out of the batter's hand while swinging and created a potential risk of injury to other players. To avoid this safety hazard, the proximal end of the bat, adjacent to the batter's hands, were equipped with a knob whose function was to prevent the bat from slipping from batter's hands when swinging. This simple use of a knob on the proximal end of the bat substantially reduced the number of times a batter lost control of a bat and flung it while swinging the bat. While addressing the loss of control problem, the knob on the proximal end of the bat created several new problems.
For example, many individuals who play baseball or softball do not own their own bats. Quite often, a team will own several bats which are shared by the players. One problem created by this situation is that each player is different in terms of physical size, strength, arm length, finger length, etc. Since multiple batters may share the same bat, the bat which is the perfect size for one batter may have a bat knob or shaft that is too thick or too small for another batter. In the case where a batter is using the bat which is too long, a variety of devices have been developed to help the batter to “shorten up” a bat. The term shorten up refers to gripping the bat on its handle away from its proximal end.
A number of devices have been developed to assist the batter in shortening up the batter's grip. Typically, they involve the use of flexible pads which are installed onto a baseball/softball bat adjacent to the knob. When a batter grasps the bat, the batter's hand rests against the flexible pads rather than the knob of the baseball/softball bat. By varying the number of pads, the batter can adjust where on the bat handle the bat is to be gripped. These types of spacing devices actually reduce the speed at which the bat strikes a baseball because the effective length of the bat is shortened and leverage is reduced. As a result, a batter using this type of device will experience reduced distance and power when a baseball or softball is struck.
Another approach to this problem has been the development of specialized gripping surfaces which are attached to the narrow end of the bat above its proximal end where the knob is located. They are not designed to allow a batter to hold the bat by the knob. It would be desirable to have the ability to grasp the bat by the knob, thereby improving freedom of movement while at the same time improving leverage when swinging a conventional bat.
Another issue related to prior art bats is the potential injury to a batter's hand from repetitious swinging of a baseball/softball bat. The prior art has also attempted to address this issue by providing pads which fit on the knob of a baseball/softball bat. These knobs intervene between the batter's hand and the knob of the baseball/softball bat to reduce impact and friction injuries to the batter's hand. These devices also have the adverse effect of reducing leverage because the hand is moved away from the proximal end of the bat.
While the prior art has provided several devices designed to provide a more secure grip on the baseball/softball bat and to reduce potential injury to the hand of the batter caused by repetitive swinging, the prior art has not provided a method of improving the freedom of motion of the batter's wrist. In addition, the prior art has not provided a method of allowing a batter to take advantage of the entire length of the bat by allowing the batter to grasp the knob of the baseball/softball bat with only a few fingers secured the bat knob in the palm of the batter's hand. Of course, the prior art has failed to provide a device which simultaneously achieves all of these goals.
SUMMARY OF THE INVENTION
The present invention provides a resilient elastic baseball/softball bat grip or knob cover which allows the batter to make use of the entire length of the baseball/softball bat, which increases the batter's leverage, which increases the speed at which a bat can be swung, and which reduces the potential for injury to a batter's hand, fingers, and/or wrist. The elastic grip is stretched over the knob at the end of the bat handle. It can be temporarily attached to the end of the baseball/softball bat and either secured by elastic pressure, or permanently attached to the bat by adhesives, tape, or any other suitable securing means. An upper ridge is provided which increases safety by increasing finger hold on the bat. The increased finger hold reduces the chance that the batter will lose control of the bat. Below the ridge, the side of the elastic grip forms a rounded, curved, or oblong outer surface which is designed to ergonomically fit into the wedge of the thumb and the crease of the palm, thereby increasing the surface area of contact with the batter's hand and increasing bat control. The increased surface area, the upper ridge and a rough textured coating provide greater friction and surface tension throughout the swing thereby increasing safety and control of the bat.
The rough textured surface also allows the batter to safely secure the bat with less hand pressure. As a result, the batter's hand can be more relaxed. A rounded base allows for a single, double or triple finger drop which increases bat speed and reduces wrist rigidity. The reduced number of fingers grasping the elastic grip increases the maneuverability of the wrist therefore allowing greater bat speed and whipping motion, which in turn results in increased power and ball flight distance when the ball is hit. The dropped fingers also provide added support to the base of the bat for better control of the head of the bat during the swing as it passes through the power zone.
The grip not only enhances greater bat speed, distance and control for all ages, it also provides greater safety and prevents soft tissue injury during batting practice or continued use. The elastic grip provides extra gripping surface tension and pliability for greater gripping force with less hand and finger contraction while enhancing comfort and providing injury protection. In addition, the resilient elastic material from which the grip is made also provides reverberation dampening to further reduce the possibility of injury to the batter's hand or wrist.
The grip to be fabricated from a variety of resilient elastic materials. As used herein, the term “resilient elastic materials” includes any suitable material which can be used to fabricate the grip, including materials such as thermal plastic rubber, Kraton(tm), sanopreme, or any other thermal plastic or thermal set rubber, elastomer or any silicone based material or polyvinyl chloride material that attaches to baseball and softball bats of wood or metal to assist with grip, form, hand placement, safety, injury prevention, wrist mobility, control and bat speed.
In addition to the foregoing resilient elastic materials, it has been found that the addition of a filler to resilient elastic materials can further improve the batter's control of the bat by further reducing the chance of slippage when swinging. Those skilled in the art will recognize that the filler can be made from any number of materials which are mixed with the resilient elastic materials to provide a surface with greater friction. The only requirement is that the material used to create the filler must be suitable for combination with the particular resilient elastic materials used to fabricate the grip.
One such filler is fiberglass which has been found to be a suitable material that can be combined with the resilient elastic materials during the fabrication process to provide a grip that will provide an improved level of surface friction. Of course, as noted above, a variety of other materials can also be used as fillers, in addition to fiberglass, so long as they are compatible with the elastic materials and produce the desired increase in surface friction. The increased surface friction in turn improves the batter's control of the grip.
In the preferred embodiment, the filler is envisioned as a small amount of fiberglass, on the order of ten percent (10%), that is added to the resilient elastic materials. However, those skilled in the art will realize that the amount of fiberglass added to the resilient elastic materials is not critical and can vary. In fact, the amount of fiberglass that is used can be varied to increase or decrease the relative surface friction level of the grip. For example, an increase from ten percent to twenty or twenty-five percent in the total amount of fiberglass used would create an increase in the relative surface friction level of the grip. Likewise, a reduction to a reduced level of fiberglass, such as one percent, will result in a corresponding reduction in relative surface friction.
Another advantage of fillers is that in addition to increasing the batter's control of the bat, fillers may also increase the durability of the grip. The fiberglass filler discussed above is one such example of a filler that can increase the durability of a grip. Of course, the type of filler selected will vary in terms of its durability.
In addition to its use as a grip during an actual ball game, the grip can also be used as a training tool for proper hand placement, finger placement, and body mechanics. Likewise, it can be made of any color or design, i.e. silver, blue, team logos, etc. In fact, it can have substantial value as a method of displaying commercial logos or messages.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side cutaway view of a preferred embodiment of the elastic grip handle.
FIG. 2 illustrates the knob of a bat being inserted into a preferred embodiment of the elastic grip handle.
FIG. 3 illustrates the knob of a bat after insertion into a preferred embodiment of the elastic grip handle.
FIG. 4 is a side view of the elastic grip handle after attachment to a bat.
FIG. 5 illustrates a preferred embodiment of the elastic grip handle being held by the batter with three fingers.
FIG. 6 illustrates a preferred embodiment of the elastic grip handle being held by the batter with four fingers.
FIG. 7 illustrates a preferred embodiment of the elastic grip handle being held by the batter with five fingers.
FIG. 8 illustrates a preferred embodiment of the elastic grip handle being held by the batter with a thumb and one finger.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Prior to a detailed discussion of the figures, a general overview of the system will be presented. The invention provides an elastic grip handle which attaches to the knob of a baseball/softball bat. The elastic grip handle is designed to be flexible enough to allow it to be stretched over the knob of a baseball/softball bat. The elastic grip handle further has an internal cavity shaped like the knob of the baseball/softball bat which, when the knob of the bat is inserted into the cavity, secures the elastic grip handle to the baseball/softball bat.
Elastic grip handle has a generally rounded shape which is sized to fit within the palm of a batter. The elastic grip handle also has a ridge at its distal end which provides a gripping surface for one or more of the batter's fingers. The gripping surface is intended to insure that the batter does not lose control of the bat. In addition, the rounded shape which fits within the batter's palm allows the batter to hold the bat with the batter's thumb and one or more fingers. The remaining fingers typically will rest the proximal end the elastic grip handle and provide further control when the batter is swinging the bat.
Because the elastic grip handle allows the batter to control the bat with two or more fingers, the bat can be held at its proximal end. By holding the bat at its end, the batter can take advantage of the entire length of the bat, which provides increased leverage that in turn results in increased bat speed and therefore power when the ball is hit. In addition, since the elastic grip handle allows the batter to hold the bat at a high location in the batter's hand, the knob of the bat does not interfere with movement of the batter's wrist. This provides unimpeded wrist movement. The improved freedom of motion of the batter's wrists results in higher velocity bat swings which in turn improves ball flight distance and batting power. An additional benefit associated with the improved freedom of wrist motion is an improvement in safety since potential injuries caused by knob/wrist/finger/hand contact are reduced.
Having discussed the features and advantages of the invention in general, we turn now to a more detailed discussion of the figures.
FIG. 1 illustrates a cutaway side view of a preferred embodiment of the elastic grip handle 1 . This embodiment illustrates a generally rounded external shape of the elastic grip handle 1 . A handle aperture 2 provides access to a knob cavity 7 inside the elastic grip handle 1 . The knob cavity 7 is sized to snugly fit the knob 10 of the baseball/softball bat 9 (shown in FIG. 2 ). When the bat 9 is inserted into the elastic grip 1 , the protrusion 6 in knob cavity 7 will rest against the upper surface of the knob 10 (shown in FIG. 2 ) of the bat and secure the knob in place. Internal walls 5 in the elastic grip handle 1 define a channel which accepts the handle of bat 1 above the knob 10 . The channel is also sized to snugly fit the bat handle.
Also shown in this figure is a ridge 3 which provides a gripping surface at the distal end of the elastic grip handle 1 . When swinging the bat, the batter would typically have one finger resting on the ridge 3 . This provides the batter with better control by preventing the bat from slipping from the batter's hand when swinging the bat 9 . The rounded bulge 4 towards the proximal end of the elastic grip handle 1 is designed to fit in the crease between the batter's thumb and the palm of the batter's hand. This increased surface contact provides additional control over the handle by increasing the amount of surface in contact with the batter's hand when the bat 9 is swung. The proximal end 8 provides a surface where one or more fingers may rest when the bat 9 is swung. Placement of the figures in this location also helps to control the bat's motion and stability.
Those skilled in the art will recognize that different types of bats 9 (e.g., wood, metal, as well as baseball bats, softball bats, etc.) may vary in shape and size. As a result, the dimensions of the elastic grip handle 1 may also vary to suit to a particular type of bat 9 .
The elastic grip handle 1 can be fabricated from any suitable material. The requirements for the material used to fabricate the elastic grip handle 1 are that it be elastic enough so that it can be stretched to insert the knob 10 of a bat 9 . A number of commercially available materials are suitable for fabrication of the elastic grip handle 1 . For example, a thermal plastic rubber such as Kraton(™), or sanopreme, or any other thermal plastic or thermal set rubber, elastomer or any silicone based material or polyvinyl chloride material can be used.
In addition to the wide range of materials used to fabricate the elastic grip handle 1 , numerous decorative features such as colors, team logos, etc. can also be incorporated into the elastic grip handle 1 for a wide variety of aesthetic and/or commercial purposes.
FIG. 2 illustrates a side cutaway view of a bat 9 being inserted into a preferred embodiment of the elastic grip handle 1 . As can be seen from this illustration, the material used to fabricate the elastic grip handle 1 must be able to stretch sufficiently to allow the knob 10 of baseball/softball bat to be inserted into the channel.
FIG. 3 illustrates a side cutaway view of a bat 9 which has been inserted into the elastic grip handle 1 . In this preferred embodiment, the bat knob 10 as well as the bat 9 are snugly fit within the channel and knob cavity of the elastic grip handle 1 . The protrusions 6 rest against the distal surface of the bat knob 10 to secure it firmly in place. In the preferred embodiment, the elastic grip handle 1 can be removably attached to the bat knob 10 . However, those skilled in the art will recognize that the elastic grip handle 1 can be permanently attached to the bat knob 10 via adhesive, etc.
FIG. 4 illustrates an external side view of the elastic grip handle 1 installed onto the proximal end of a baseball/softball bat 9 . This view illustrates the ridge 3 which provides a surface for resting one of the batter's fingers. By placing a finger on the ridge 3 , the batter is able to provide greater resistance to prevent the bat 9 from slipping out of the batter's hand. Also shown are rounded sides 4 to which are designed to provide comfortably fit the palm of the batter's hand when it is secured by the batter's thumb.
In the preferred embodiment, the surface of the elastic grip handle 1 has a nonslip surface texture. This provides greater control of the bat 9 , and prevents slippage.
In FIG. 5 , a side view of a preferred embodiment of the elastic grip handle 1 is shown being held by a batter. In this view, the forefinger 12 of the batter rests on the ridge 3 to prevent slippage. The thumb 11 secures the elastic grip handle 1 in position with the rounded side 4 resting against the crease 14 between the batter's thumb and the palm of the batter's hand. In this illustration, the index finger 13 is shown wrapped around the elastic grip handle 1 . However, the index FIG. 13 can also be moved to the proximal end of the elastic grip handle 1 where the other fingers 15 , 16 are shown. The fingers 15 , 16 provide extra stability and support when the bat 9 is swung.
As can be seen from this illustration, the elastic grip handle 1 allows a batter to hold the bat 9 such that the batter effectively is holding the bat at a location which is approximately equal to the location of the knob 10 . This effectively allows the batter to use the entire length of the bat which results in increased leverage. Also, by gripping elastic grip handle 1 in the palm of the batter's hand, the knob 10 of the bat 9 no longer interferes with wrist movement. This helps avoid injuries, and also, it improves freedom of motion of the batter's wrist which results in greater bat speed and greater power when the bat 9 strikes the ball.
FIG. 6 illustrates another method of holding the elastic grip handle 1 . In this figure, the elastic grip handle 1 is held with the batter's thumb and three fingers 12 , 13 , 15 .
FIG. 7 illustrates another method of holding the elastic grip handle 1 . In this figure, the elastic grip handle 1 is held with the batter's thumb and four fingers 12 , 13 , 15 , 16 .
FIG. 8 illustrates another method of holding the elastic grip handle 1 . In this figure, the elastic grip handle 1 is held with the batter's thumb and one finger 12 .
While the invention has been described with respect to a preferred embodiment thereof, it will be understood by those skilled in the art that various changes in detail may be made therein without departing from the spirit, scope, and teaching of the invention. For example, the elastic grip handle can be fabricated from any suitable material, the size and shape of the cavity can vary to suit differences in bat sizes, and the size of the elastic grip handle can also vary to suit variances in the size of the batter's hands. Accordingly, the invention herein disclosed is to be limited only as specified in the following claims. | A resilient elastic bat grip for baseball and softball bats that covers the knob on the bat handle. The grip has a bulbous shape which is wider then the knob of the baseball bat, and fits snugly in the batter's palm such that the bat is controlled by one or more fingers and swung with the batter's wrist below the end of the bat. The grip does not require all five fingers to hold the bat, and as a result, increases the maneuverability of the wrist which allows greater bat speed and whipping motion. A rounded base enables a single, double or triple finger drop for more bat speed and less wrist rigidity. This also allows added finger support for better control of the head of the bat during the swing as it passes through the power zone. | 0 |
RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 11/780,876, titled IMMOBILIZATION OF DYES AND ANTIMICROBIAL AGENTS ON A MEDICAL DEVICE, filed Jul. 20, 2007, and assigned to the assignee of the present application, the entire contents of which are hereby incorporated by reference and relied upon; this application is also a continuation-in-part of U.S. patent application Ser. No. 11/780,917, entitled MEDICAL FLUID ACCESS DEVICE WITH ANTISEPTIC INDICATOR, also filed on Jul. 20, 2007, and assigned to the assignee of the present application, the entire contents of which are hereby incorporated by reference and relied upon.
BACKGROUND
The present disclosure relates generally to methods of immobilizing dyes and antimicrobial agents on a surface, especially a surface of a medical device. In particular, the disclosure relates to methods of treating a polymer surface for better attachment of antimicrobial agents onto the surface, and for the attachment of dyes to the surface. The dyes will change from a first color or appearance to a second color or appearance when they are swabbed with a disinfecting fluid, such as isopropyl alcohol (IPA) or a solution of water and IPA, especially a solution of 70% water/30% IPA.
Infections acquired at hospitals or other health care sites, nosocomial infections, are an undesirable source of distress to patients. The advent of ever-more resistant bacteria and bacteria that are resistant to multiplicities of drugs only exacerabates the problem and makes the eradication of these infections even more important. An example of one cause of such infections is a biofilm, an aggregate of microbes with a distinct architecture. A biofilm is similar to a small city with a great abundance of microbial cells, each only a micrometer or two in length. The microbes form towers that can be hundreds of micrometers high, with the “streets” between the towers being fluid filled channels that supply nutrients, oxygen, and other necessities to the biofilm communities.
Such biofilms can form on the surfaces of medical devices, especially implants, such as contact lenses, catheters or other access devices, pacemakers, and other surgical implants. The U.S. Centers for Disease Control (CDC) estimates that over 65% of nosocomial infections are caused by biofilms. Bacteria growing in a biofilm can be highly resistant to antibiotics, up to a thousand times more resistant than the same bacterium not growing in a biofilm. It would be desirable if the surfaces of these medical devices were resistant to biofilm formation and bacterial growth.
Polymers are used to make many of the diagnostic or therapeutic medical devices that are subject to biofilm formation. For example, connectors for kidney dialysis, such as peritoneal dialysis and hemodialysis may be made of polymers. Dialysate fluid containers, access ports, pigtail connectors, spikes, and so forth, are all made from plastics or elastomers. Therapeutic devices such as catheters, drug vial spikes, vascular access devices such as luer access devices, prosthetics, and infusion pumps, are made from polymers. Medical fluid access devices are commonly used in association with medical fluid containers and medical fluid flow systems that are connected to patients or other subjects undergoing diagnostic, therapeutic or other medical procedures. Other diagnostic devices made from polymers, or with significant polymer content meant for contact with tissues of a patient, include stethoscopes, endoscopes, bronchoscopes, and the like. It is important that these devices be sterile when they are to be used in intimate contact with a patient.
Typical of these devices is a vascular access device that allows for the introduction of medication, antibiotics, chemotherapeutic agents, or a myriad of other fluids, to a previously established IV fluid flow system. Alternatively, the access device may be used for withdrawing fluid from the subject for testing or other purposes. The presence of one or more access devices in the IV tubing sets eliminates the need for phlebotomizing the subject repeatedly and allows for immediate administration of medication or other fluids directly into the subject.
Several different types of access devices are well known in the medical field. Although varying in the details of their construction, these devices usually include an access site for introduction or withdrawal of medical fluids through the access device. For instance, such devices can include a housing that defines an access opening for the introduction or withdrawal of medical fluids through the housing, and a resilient valve member or gland that normally closes the access site. Beyond those common features, the design of access sites varies considerably. For example, the valve member may be a solid rubber or latex septum or be made of other elastomeric material that is pierceable by a needle, so that fluid can be injected into or withdrawn from the access device. Alternatively, the valve member may comprise a septum or the like with a preformed but normally closed aperture or slit that is adapted to receive a specially designed blunt cannula therethrough. Other types of access devices are designed for use with connecting apparatus employing standard male luers. Such an access device is commonly referred to as a “luer access device” or “luer-activated device,” or “LAD.” LADS of various forms or designs are illustrated in U.S. Pat. Nos. 6,682,509, 6,669,681, 6,039,302, 5,782,816, 5,730,418, 5,360,413, and 5,242,432, and U.S. Patent Application Publications Nos. 2003/0208165 and 2003/0141477, all of which are hereby incorporated by reference herein.
Before an access device is actually used to introduce or withdraw liquid from a container or a medical fluid flow system or other structure or system, good medical practice dictates that the access site and surrounding area be contacted, usually by wiping or swabbing, with a disinfectant or sterilizing agent such as isopropyl alcohol or the like to reduce the potential for contaminating the fluid flow path and harming the patient. It will be appreciated that a medical fluid flow system, such as an IV administration set, provides a direct avenue into a patient's vascular system. Without proper aseptic techniques by the physician, nurse or other clinician, microbes, bacteria or other pathogens found on the surface of the access device could be introduced into the IV tubing and thus into the patient when fluid is introduced into or withdrawn through the access device. Accordingly, care is required to assure that proper aseptic techniques are used by the healthcare practitioner. This warning applies to many medical devices, especially those in contact with the patient, and especially so for access devices that, like catheters or infusion pumps, access the patient's bodily orifices, especially those of the vascular system. Other devices that are subject to multiple touches include device covers and housings, and especially touch-screens, key pads, and user controls, such as switches, handles, and knobs.
As described more fully below, the methods for attaching antimicrobial agents and dyes that indicate that proper aseptic techniques have been used, are believed to represent important advances in the safe and efficient administration of health care to patients.
SUMMARY
One embodiment is a method for providing a cover or housing for a medical device. The method includes steps of providing a medical device cover or a housing made from a polymer, the polymer optionally including a porous surface. The method also includes steps of treating a surface of the cover or housing with a plurality of functional groups, attaching a linking group to the functional groups, and attaching an antimicrobial agent to the functional group or to the linking group.
Another embodiment is a method of treating a medical device. The method includes steps of treating a surface or porous surface of a polymeric cover or a polymeric housing for a medical device with a strong acid or plasma discharge to provide a plurality of functional groups on the surface. The method also includes steps of reacting the functional groups with a linking agent to form attachment sites, the linking agent selected from the group consisting of poly(N-succinimidyl acrylate) (PNSA), polyethyleneimine, polyallylimine, and polymers with an aldehyde functional group, and attaching a solvatochromic dye, an antimicrobial agent, or an alkyl-amino containing compound to the attachment sites.
Another embodiment is a polymeric cover or housing. The polymeric cover or housing includes a polymer in a form of a cover or a housing for a medical device, a plurality of attachment sites on an least an outer surface of the polymer, optionally, a plurality of functional groups attached to the attachment sites, and at least one of an antimicrobial compound and a solvatochromic dye, attached to the attachment sites or to the functional groups, wherein the outer surface is configured to reversibly change from a first appearance to a second appearance when the outer surface is swabbed with a disinfecting solution.
Another embodiment is a medical device. The medical device includes a porous polymeric surface or cover for a medical device, a plurality of attachment sites on the polymeric surface, optionally, a plurality of functional groups attached to the attachment sites, a solvatochromic dye, attached to the attachment sites or to the functional groups, wherein the porous polymeric surface is configured to reversibly change from a first appearance to a second appearance when the porous polymeric surface is swabbed with a disinfecting solution, and optionally an antimicrobial compound, attached to the attachment sites or to the functional groups, wherein the antimicrobial compound is configured to be cidal to, or to resist growth of, microorganisms on the polymeric surface.
Another embodiment is a medical device. The medical device includes a cover or housing for a medical device made from a polymer, a plurality of attachment sites on a surface of the cover or housing, optionally, a plurality of functional groups attached to the attachment sites, a solvatochromic dye, attached to the attachment sites or to the functional groups, wherein the surface is configured to reversibly change from a first appearance to a second appearance when the porous polymeric surface is swabbed with a disinfecting solution, and an amino-alkyl containing compound selected from the group consisting of peptides, proteins, Factor VIII or other anti-clotting Factor, polysaccharides, polymyxins, hyaluronic acid, heparin, condroitin sulfate, chitosan, and derivatives of each of these, to the attachment sites.
Additional features and advantages are described herein, and will be apparent from, the following Detailed Description and the figures.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective view of a medical device;
FIG. 2 is a cross-sectional view of a medical device; and
FIG. 3 is a perspective view of a medical housing and cover.
DETAILED DESCRIPTION
Immobilization of Dyes and Antimicrobial Agents on Polymer Surfaces
This section describes the experimental work that was done to prepare polymeric surfaces for direct attachment of dye molecules and antimicrobial agents. The substances used to prepare the surfaces function by reacting the surfaces and adding functional groups that will covalently bind the dye to the surface. Examples of dyes include Reichardt's dye and solvatochromic dyes. A solvatochromic dye changes color to alert a medical professional that the surface, such as an infusion pump housing or cover, has been swabbed and is momentarily clean. This technique is also effective in binding antimicrobial agents to the surface. Examples include chlorhexidine compounds and derivatives, such as chlorhexidine gluconate, and other antimicrobial agents bearing aminoalkyl groups. Examples also include chloroxyphenol, triclosan, triclocarban, and their derivatives, and quaternary ammonium compounds. Many other antimicrobial or oligodynamic substances may also be attached. These compounds are cidal to, or at least to inhibit the growth of harmful bacteria or other microorganisms on the surfaces to which they are applied, which is beneficial to the patient.
Materials known to have properties of resistance to such microorganisms are described and disclosed in U.S. Pat. No. 4,847,088, U.S. Pat. No. 6,663,877, and U.S. Pat. No. 6,776,824, all of which are hereby incorporated by reference in their entirety as though they were copied directly into this patent. For instance, quaternary ammonium compounds (frequently with organic or silicate side chains) are well-known for such properties, as are boric acid and many carboxylic acids, such as citric acid, benzoic acid, and maleic acid. Pyridinium and phosphonium salts may also be used. Besides organic compounds, certain non-organic materials and compounds are also known for their resistance to germs and organisms. Antimicrobial compounds are used in low concentrations, typically about from about 0.1% to 1% when incorporated into the material itself, e.g., a housing of a luer access device or other vascular access device. Antimicrobial compounds may also be used on many other medical devices, such as catheters, dialysis connects, such as those used in peritoneal dialysis, hemodialysis, or other types of dialysis treatment. They may also be applied to drug vial spikes, prosthetic devices, stethoscopes, endoscopes and similar diagnostic and therapeutic devices, and to infusion pumps and associated hardware and tubing. The use of antimicrobial compounds on these devices, among others, can help to prevent infection and to lessen the effect of infection.
Metals, especially heavy metals, and ionic compounds and salts of these metals, are known to be useful as antimicrobials even in very low concentrations or amounts. These substances are said to have an oligodynamic effect and are considered oligodynamic. The metals include silver, gold, zinc, copper, cerium, gallium, platinum, palladium, rhodium, iridium, ruthenium, osmium, bismuth, and others. Other metals with lower atomic weights also have an inhibiting or cidal effect on microorganisms in very low concentrations. These metals include aluminum, calcium, sodium, lithium, magnesium, potassium, and manganese, among others. For present purposes, all these metals are considered oligodynamic metals, and their compounds and ionic substances are oligodynamic substances. The metals and their compounds and ions, e.g., zinc oxide, silver acetate, silver nitrate, silver chloride, silver iodide, and many others, may inhibit the growth of microorganisms, such as bacteria, viruses, or fungi, or they may have cidal effects on microorganisms, such as bacteria, viruses, or fungi, in higher concentrations, such as biofilms. Because many of these compounds and salts are soluble, they may easily be placed into a solution or a coating, which may then be used to coat a medical device housing or cover, such as for a luer access device or an infusion pump. Silver has long been known to be an effective antimicrobial metal, and is now available in nanoparticle sizes, from companies such as Northern Nanotechnologies, Toronto, Ontario, Canada, and Purest Collids, Inc., Westampton, N.J., U.S.A. Other oligodynamic metals and compounds are also available from these companies.
Other materials, such as sulfanilamide and cephalosporins, are well-known for their resistance properties, including chlorhexidine and its derivatives, ethanol, benzyl alcohol, lysostaphin, benzoic acid analogs, lysine enzyme and metal salt, bacitracin, methicillin, cephalosporin, polymyxin, cefachlor, Cefadroxil, cefamandole nafate, cefazolin, cefime, cefinetazole, cefonioid, cefoperazone, ceforanide, cefotanme, cefotaxime, cefotetan, cefoxitin, cefpodoxime proxetil, cefiaxidime, ceftizomxime, cefirixzone, cefriaxone moxolactam, cefuroxime, cephalexin, cephalosporin C, cephalosporin C sodium salt, cephalothin, cephalothin sodium salt, cephapirin, cephradine, cefuroximeaxetil, dihvdracephaloghin, moxalactam, or loracarbef mafate. Microban, “Additive B,” 5-chloro-2-(2,4 dichloro-phenoxy)phenol is another such material.
Functional Groups
The following portion discusses a number of processes found to be effective in providing functional groups for the attachment of the above-mentioned solvatochromic dyes and antimicrobial agents. Functional groups may include an activated carboxyl group, an activated amine group, an aldehyde group, epoxy group or alkyl halide group. The desired dye or agent may then be directly attached, or an intermediate group may be used attach the desired substance. Certain polymers, such as nylon, polycarbonate, and polyester, e.g., polyethylene terephthalate (PET), are adaptable for attachment of such agents. These structural materials, among others, are useful in making housings or containers for medical instruments, such as infusion pump housings, dialysis cassettes, housings for viewing screens or monitors, printer bodies, keyboards, keypads, and the like. These structures are desirably not hospitable environments for microbes, biofilms, or any other pathogens. Antimicrobial treatments may more easily adhere to these surfaces when treated as discussed below.
Nylon Surfaces
In one example, a Whatman nylon-6,6 membrane, pore size 0.2 μm, 47 mm, Whatman Cat. No. 7402-004, was obtained from Whatman Inc., Florham Park, N.J., USA. Other membranes are also available from Whatman, including other nylons or polyamides, polytetrafluoroethylene (PTFE or Teflon®), polyester, polycarbonate, cellulose and polypropylene. The membranes were first washed thoroughly, successively with dichloromethane, acetone, methanol and water. The membranes were then washed several times with water to achieve a neutral pH. They were finally washed in methanol and dried under high vacuum. The membranes were then treated with 3M HCl at 45° C. for four hours to yield specimen NM-1. Without being bound by any particular theory, it is believed that this resulted in the creation of a number of amino groups on the membrane surface. The free amine concentration of the untreated nylon was calculated as 6.37×10 −7 moles/cm 2 , while the free amine concentration after acid treatment was calculated as 13.28×10 −7 moles/cm 2 . The concentration was calculated using the method of Lin et al., described in Biotech Bioeng ., vol. 83 (2), 168-173 (2003). Thus, the treatment appeared to double the concentration of free amine on the surface and available for binding.
The NM-1 membrane was then contacted with poly(N-succinimidyl acrylate) (PNSA) dissolved in dimethylformamide (DMF) by placing the membrane in a flask with the dissolved PNSA. It is expected that treatments with other polymers containing aldehyde groups, such as polyacrylaldehyde or polyacrolein, would also be effective. Triethylamine was then added to the flask, which was rotary shaken while under a continuous argon purge for about 6 hours. The treated nylon membrane was then thoroughly washed with DMF to produce N-succinimidyl carboxylate groups on the surface of the nylon, forming NM-2. The di(trifluoroacetate) salt of 4,6-dichloro-2-[2-(6-amino-hexyl-4-pyridinio)-vinyl] phenolate was dissolved in DMF and was converted by neutralization of the trifluoroacetate counter ions with triethylamine. The previously-treated membrane was added to the reaction flask and was rotary-shaken overnight. The resulting membrane, NM-3, with the salt of 4,6-dichloro-2-[2-(6-amino-hexyl-4-pyridinio)-vinyl]phenolate on its surface, was then thoroughly washed with DMF. The surface of the membrane was a light purple when dry. The same surface turned dark purple when swabbed with isopropyl alcohol, and turned a salmon color when swabbed with a mixture of isopropyl alcohol containing about 30% water.
It is believed that the NM-3 membrane had excess N-succinimidyl carboxylate on its surface. It is also believed that this excess would hydrolyze and protonate the dye at the phenolate position, rendering the dye colorless. A number of NM-3 membranes were treated with different amines to stabilize the carboxyl groups and also to discover what colors or other properties would result from the use of different amines. A series of membranes. NM-4 to NM-9 were treated with different amines, resulting in membranes with more stable surfaces but with only slightly different colors. The particular amine was dissolved in methanol, the membrane was added to the reaction flask, and the flask was rotary shaken overnight. The resulting membrane was then washed with acetone and dried under vacuum. Table 1 below summarizes the different used amines and the resulting properties. These results suggest that a number of amino and ammonium compounds may be used to provide attachment sites, including primary amines, ammonium hydroxide, amine (NH 2 )— terminated compounds and polymers, morpholine, and an aromatic primary amine.
The membranes had pores on the order of 0.2 μm, resulted in rapid color changes when swabbed, and returned to the dry color within a minute or two. As noted, it is believed that the NM-3 membrane had an excess of N-succinimidyl carboxylate groups on its surface. Therefore, an antimicrobial agent, chlorhexidine, was applied. Chlorhexidine was dissolved in methanol, the membrane was added to the reaction flask, and the flask was rotary shaken overnight. The membrane was thoroughly washed with acetone and dried under vacuum. It is believed that this membrane, NM-10, now contained both antimicrobial agent and dye. The membrane was tested. Its dry color was a moderate purple, turning to a dark purple in isopropyl alcohol (IPA) and to a moderate orange/red in 70% IPA.
TABLE 1 Amine Treatment of Nylon Membranes Color, Nylon Amine IPA + Membrane- dose, reagent Soln Color, 30% Number Amine used mmol. soln, ml pH Color, dry IPA water NM-4 2-methoxyethylamine 15 7.50 ml 11.5 Very, very Light Light DMF light pink brown/ brown/ pink pink NM-5 Hexylamine 15 7.50 ml 12 Very, very Light Light DMF light brown/ brown/ brown/pink pink pink NM-6 Benzylamine 15 7.50 ml 11.5 Very light Light Light DMF pink brown/ brown/ pink pink NM-7 Morpholine* 15 7.50 ml 10 Moderate Dark Salmon DMF purple purple NM-8 Ammonium hyroxide excess 20 ml ND** Moderate Dark Salmon NH 4 OH purple purple NM-9 3-aminopropyl- 3.51 10 ml 10 Light Moderate Moderate terminated poly- toluene purple purple salmon dimethylsiloxane *NM-7 had an additional 0.1 ml triethylamine added, with a final pH of 11- to 11.5. **The pH of the NM-8 solution was not determined.
Polycarbonate Surfaces
A second series of plastic surfaces was also tested. DE1-1D Makrofol® polycarbonate films, 0.005 inch thick, clear-gloss/gloss, were obtained from Bayer Polymers Division, Bayer Films Americas, Berlin, Conn., USA. The films were cut into 1 cm squares and were treated with 4 ml of a solution of 0.25 M chlorosulfonic acid in ethyl ether. The square and the solution were placed in a screw-cap vial and cooled to about 5° C. and rotary shaken for 1 hour. The resulting chlorosulfonated film was thoroughly washed with ethyl ether to yield membrane PC-1. It is believed that the amino end groups on the 4,6-dichloro-2-[2-(6-amino-hexyl-4-pyridinio)-vinyl] phenolate dye would react with the chlorosulfonyl groups which had been attached to the polycarbonate surface. A solution of the dye was prepared by dissolving 10 mmol in ethanol and treating with 0.22 mmol triethylamine. The resulting dye solution had a pH of 9.7. The PC-1 film was then added to a rotary flask containing the dye and was rotary shaken overnight and then washed thoroughly with methanol to yield film PC-2. The dry film had a moderately pinkish/purple color. When wetted with 70% IPA, it turned to a peach color.
Other films treated in the same manner, but with a four-hour chlorosulfonic acid treatment, had no color change activity. It is believed that the chlorosulfonyl moiety is a temporary transition product that converts to a more stable entity over time, and thus is not available for attachment of the dye. Other experiments included varying the time for dye attachment from 1 day to 5 days. The films treated for longer periods of time also had more intensely-colored surfaces. Due to the solubility of PC in other solvent, only ethyl ether was used for this experiment. The color change in the polycarbonate film, with very low porosity, was much slower than the color change in membranes, which have a high and regulated porosity. Treatment of polycarbonate surfaces with methacrylic acid or acrylic acid is expected to add carboxyl functional groups to the surface.
Polyester Surfaces
Polyester surfaces were also obtained and tested, e.g., Millipore polyethylene-terephthalate (PET) membranes were obtained, Cat. No. T6PN1426, from Millipore Corp., Billerica, Mass., USA. These membranes were 47 mm in diameter, 0.013 mm thick, with pores having a nominal diameter of 1.0 μm. The membranes were cut into 3 cm×3 cm squares and added to a solution of water and acetone in a screw-cap bottle. 7.5 mmol of methacrylic acid, followed by 0.090 mmol of benzoyl peroxide in 2 ml acetone, were added to the solution. The bottle was rotary shaken at 85 C for 4 hours. The resulting membrane was thoroughly washed several times with hot water, followed by acetone, and then dried under vacuum to yield membrane PET-1. Without being bound to any particular theory, it is believed that this treatment results in the grafting of poly(methacrylic acid) to benzene ring of PET. The membranes were tested, and treatment by methacrylic acid resulted in weight gains of 50-53 percent. It is also believed that the subsequent treatment with benzoyl peroxide results in attachment of poly(methacrylic acid) to the polyester or PET surface. At least some of the attachments may be of a polymeric rather than monomeric nature, i.e., the attachments may be at least short chains with multiple carboxyl terminations. The terminal amine groups of a solvato-chromic dye, 4,6-dichloro-2-[2-(6-amino-hexyl-4-pyridinio)vinyl]-phenolate dye, or of an antimicrobial agent, can then attach to the carboxyl groups, as amide linkages.
A solution of the was prepared as follows for the PET membranes. 0.25 mmol of the di(trifluoroacetate) salt was dissolved in 10 ml of DMF, to which was added 0.51 mmol of triethylamine. 0.30 mmol of EEDQ (2-ethoxy-1-ethoxycarbonyl-1,2 dihydroquinoline) coupling agent was added. The PET-1 membrane was added to this reaction solution and was rotary shaken overnight. The resulting membrane was thoroughly washed with methanol. This membrane had a light orange/red color. It is believed that the residual carboxyl groups may protonate the phenolate moiety of the dye, rendering it colorless. Therefore, the membrane was surface-treated with a 5% sodium bicarbonate solution to convert any remaining carboxyl groups to the sodium salt. The membrane was then washed with water, followed by methanol, and dried under vacuum to yield the PET-2 membrane. The dry film was orange/red. When wetted with 70% IPA, the membrane became a light salmon color, and changed to a salmon color when tested with IPA alone. In further experiments, it was found that increasing the treatment time of the membrane by the dye solution caused a more intense coloration of the membrane.
In addition to the treatments discussed above for specific structural plastics, other treatments may be used. For example, polycarbonate materials may be cleaned on their surface and then treated with polyethyleneimine or polyallylimine to prepare the surface by forming what is believed to be a polycarbonate/polyethyleneimine conjugate or linking group or a polycarbonate/polyallylimine conjugate or linking group. The material is then treated with an appropriate antimicrobial compound, a solvatochromic dye, or both.
The results of these tests demonstrate that several substrates are suitable for the attachment of solvatochromic dyes or antimicrobial agents or compounds, or may be treated so that the dyes or antimicrobials easily attach. In addition to the particular materials tested, urethane membranes and foams may be used, perhaps without any treatment because of the —NHCOO— functional groups inherent in urethanes. These results demonstrate that discrete, small rings or membranes, such as those cut from a sheet, may be used. Other polymeric surfaces useful in embodiments include thin films, cast films, molded or shaped parts, or even thin coatings intended for placement on another object, for example, a medical device housing or cover, such as a luer access device, an infusion pump, or a catheter.
Acrylic membranes or coatings may be used, at least for Reichardt's dye, without treatment. The presence of polyester-like RCOO— groups in acrylic polymers renders them suitable from the start for attachment of amine-containing dyes or antimicrobials, as well as other dyes. Urethane membranes or foams may be used as is, or they may be treated to make them even more suitable for dye or antimicrobial attachment. Polyimides may suitable if they are flame- or plasma treated, or if foamed polyimides are used. Melamines, maleic anhydride derivatives, blends and co-polymers may also be useful, as may blends, co-polymers and composites of any of these materials. Silicones are less amenable to treatment, however, foamed silicones may be used. For example, treating silicone with 5-10 M NaOH for several hours forms Si—OH (silanol) groups, which can then be used to form carboxyl or other functional group attachment sites.
Solvatochromic Dyes Useful as Antiseptic Indicators
The synthesis of a solvatochromic dye that has been found useful as an antiseptic indicator was previously disclosed in U.S. patent application Ser. No. 11/780,876, to which this patent claims priority and which is incorporated by reference in its entirety. The synthesis was carried out in a number of steps, resulting in compound 1 below:
Without being bound to any particular theory, the solvatochromic activity is believed to be due at least in part, to the portion of the molecule between the phenolate ring and the pyridine ring. Accordingly, it has been found that substitution of a hydrogen atom for the acrylamido group does not adversely affect the solvatochromic activity of the dye. The structure of the this molecule, 4,6-dichloro-2-[2-(6-aminohexyl-4-pyridinio)vinyl]phenolate compound 2, is shown below, after neutralization and removal of the trifluoroacetate counterions. In one sense, compound 2 below is compound 1 with a hydrogen substituting for the acryl group.
Compound 2 is more easily handled as a salt, which may be the HCl, HBr, HF, phosphate, sulfate, or other salt, so long as the species is not carboxylated, as described in the referenced document.
Other substitutes as shown below on compound 3, R1, on the amine group nitrogen atom include at least the halogens, chloride, bromide, fluoride, iodide, and alkyl mercapto. Alkyl mercapto groups, such as ethyl mercapto, and non-bending aromatic bridge groups, such as aromatic mercaptan, are also suitable. It is also possible that at least short chain alkoxy derivatives, such as C3 through C6, especially C3 and C6, are suitable. A hexyl group between the amine group and the pyridine ring worked well. Other short chain aliphatic molecules may also be used in these solvatochromic dyes, such as isohexyl, pentyl, isopentyl, butyl, isobutyl, and decyl and many others, up to C 20 , i.e., C 4 to C 20 aliphatic.
It is also believed that aliphatic species are required. Other molecules that will perform well as a solvatochromic dye include substitution of ethene group between the pyridine ring and the benzene ring by conjugated double bonds of butadiene, —C═C—C═C— or hexatriene, —C═C—C═C—C═C—. Other embodiments may include substitutions on the benzene ring, as shown below in structure 3. Either or both of the chlorides at R4, R6, may be replaced by iodide, bromide, or fluoride. The O − group in the 7-position could instead be placed in the 5-position between the chlorides. It is possible that nitrate, —NO 2 , alkoxy, such as methoxy, ethoxy, may also yield a solvatochromic dye. Note that a number of substations on the benzene ring are readily available. For example, several salicylaldehyde compounds with halogen atoms in the 3, 5 positions are readily available from manufactures, such as Sigma-Aldrich, St. Louis, Mo., USA. When the salicylaldehyde molecule reacts with its aldehyde functionality to the pyridine ring on structure 5, the 3, 5 positions on the salicylaldehyde molecule become the 4, 6 positions on the phenol/phenolate product formed. Of course, R1 may be amine or acrylamido, R2 is C4 to C20 aliphatic, R3 is ethene, butadiene, or hexatriene, R4 and R6 are as discussed above, and R5 may be one of hydrogen and O − and R7 may be the other of hydrogen and O − .
It is possible to incorporate the dye into a coating, preferably a permeable coating, which may be applied to luer access device (LAD) housings or other medical device housing or cover. LAD housings are typically made from polycarbonate (PC), but they may also be made from elastomers and other plastics, such as acrylic (e.g., PMMA), acrylonitrile butadiene styrene (ABS), methyl acrylonitrile butadiene styrene (MABS), polypropylene (PP), cyclic olefin copolymer (COC), polyurethane (PU), polyvinyl chloride (PVC), nylon, and polyester including polyethylene terephthalate) (PET). There are many coatings that will firmly adhere to the above mentioned plastics, including epoxies, polyesters, and acrylics. An example of a medical device, a vascular access device, is seen in FIG. 1 . Luer access device 10 includes a housing 12 , male luer connector threads 14 , a rim 16 , and a septum 18 . Rim 16 is porous and includes a swab-access dye, shown as a dotted surface 16 a . Rim 16 and rim surface 16 a have been treated so that antimicrobial compounds and dyes will attach to the outer surface 16 a.
FIG. 2 depicts a medical device 20 with housing 22 and a porous surface layer 24 . The pores are shown as narrow channels 25 in the surface layer 24 . The porous surface layer may include effective amounts of the dye 26 , about 0.1 to about 1.0% by weight, and may also include small amounts of antimicrobial or oligodynamic compounds 28. There are many ways to make compounds porous, e.g., by purchasing membranes with known pore size and density, by applying solvents in the well-known TIPS (thermal inversion phase separation) process, or by inducing surface crazing or cracking into the surface. Polycarbonate membranes with tailored pore sizes may be purchased from Osmonics Corp., Minnetonka, Minn., U.S.A., and polyethylene membranes may be purchased from DSM Solutech, Eindhoven, the Netherlands. Pore sizes may vary from 1 μm down, preferably 0.2 μm down. This small pore size, and smaller, is sufficient to allow permeability to antimicrobial swabbing solutions, but large enough to prevent access by many microorganisms, which tend to be larger than 0.2 μm diameter. Many of these techniques are described in the above-mentioned related patent applications, all of which were previously incorporated by reference.
It is also possible to incorporate the dye or the antimicrobial compound into onto a cover or housing for the device. For example, FIG. 3 depicts an infusion pump 30 , as described in U.S. Pat. No. 7,018,361, which is assigned to the assignee of the present patent, and which is hereby incorporated by reference in its entirety. Infusion pump 30 includes a housing 32 , a control panel 34 with a small keypad (note arrows), an output screen 36 and a handle 40 . Depicted in FIG. 3 is a thin, transparent outer cover 38 over substantially the control panel 34 and screen 36 . Also depicted is a second transparent cover 42 which covers a broader area of the surface of infusion pump 30 . Cover 42 also covers control input knobs 44 and switches 46 . Cover 42 covers the left and right sides 42 a , 42 b , of the pump top surface and a narrow connecting portion 42 c . A separate film or cover may be used for rotary switch 48 .
Note that in this application, one or more users will naturally tend to touch, and possibly contaminate the outer features or surfaces with which they will be in contact, such as the handle 40 , control panel 34 , knobs 44 , switches 46 , and rotary switch 48 , as well as the housing 32 itself, for example, when moving or positioning the infusion pump. These features are the ones which should thus be covered with an antimicrobial plastic or elastomeric film. Alternatively, these features themselves should be made from a polymer material with an antimicrobial treatment or coating.
Since the infusion pump may have more than one operator, nurse, or patient in contact with housing 30 , control panel/keypad 34 , or screen 36 , cover 38 is thin and is easily removed and replaced. Cover 42 is also thin and easily replaced. A removable, antimicrobial cover will remove one cause of infection among patients, or at least one cause of transfer of germs or other microbes. As described below, the polymeric housing, its surface, or the removable cover may be made from a plastic or an elastomeric material. The housing, its surface or the cover may incorporate a surface coating of the antimicrobial compound, as described below. The device may be prepared, as also described below, to immobilize an antimicrobial agent on the surface. This keeps the antimicrobial compounds on the surface where they are most likely to encounter microbes, rather than within the body of the polymer.
The cover 42 is made from an inexpensive, transparent polymer that naturally clings to the surface of the pump. Such polymers include thin films of polyethylene, polypropylene, and PVC. Also useful in such applications, but opaque, are elastomers, such as silicone, polyurethane, and nitrile. The polymers need not be sterilizable because they are disposed after a set period of time, such as after a shift at a hospital or other care center. Alternatively, they may also be changed after an interval, such as after every user. As discussed above, the housing 32 is made from a structural and medically acceptable plastic that is suitable for the application. These structural materials include nylon, polycarbonate, PET, and many other materials that can accept an anti-microbial treatment or coating.
Other embodiments are described in related application, MEDICAL FLUID ACCESS DEVICE WITH ANTISEPTIC INDICATOR, U.S. patent application Ser. No. 11/780,917, which is assigned to the assignee of the present patent, the entire contents of which are hereby incorporated by reference. Surface 16 a is porous or permeable and the polymer from which the surface is made preferably has an index of refraction from about 1.25 to about 1.6. The permeable surface is typically opaque and may incorporate a small amount of dye. The amount of the dye, such as from about 0.1% to about 1%, is effective in adding a color to the surface, or rendering the surface a translucent with a tint or hint of color.
The surface is porous, so that a disinfecting or antiseptic swabbing solution, such as IPA or a 70% IPA/30% water solution, will permeate the surface. The disinfecting solution may also contain an antimicrobial compound, such as chlorhexidine. If the index of refraction of the swabbing solution, about 1.34, matches or is close to the index of refraction of the polymer from which the porous surface is made, the surface will become transparent, if there is no dye. If a dye is present, the surface will change color as the dye changes state from a first pH to a second, different pH, the pH of the swabbing solution. Solutions or swabbing compounds other than IPA and water may be used, although theses are the most common. For example, ethanol has a refractive index of 1.36. Additions to the swabbing solution, such as chlorhexidine, will also vary the refractive index, thus allowing users to tailor the swabbing solution to insure a visually distinct appearance change, whether from opaque to transparent or from one color to another.
Tetrazolium Salts
In addition to these antimicrobial compounds, tetrazolium compounds and their derivatives, such as their salts, may be used, especially on the surfaces of medical devices, and on their housings and covers. These compounds are initially colorless, but in contact with viable bacteria they enter into the bacteria and are converted by an enzyme (Dehydrogenase) to colored Formazan. The color change is used for microbial detection. Depending on the structure of the substituent on tetrazolium ring, Formazan can be red, blue, purple, brown or fluorescent. These compounds often have, or can be modified to include, a functional group suitable for binding to a polymeric surface, such as a carboxyl group, —COOH, or an amino group, —NH 2 . In one embodiment, tetrazolium salts have the general structure shown below, compound 4, wherein R 2 , R 3 and R 5 independently represent substituted phenyl group, 4,5-dimethylthiazolyl group or cyano group.
The tetrazolium salt can be modified to bear a long chain or tether terminated with an active function group, such as the above-mentioned amino or carboxyl group, so that the structure is used to immobilize the compound to a medical device surface as described above for nylon, polycarbonate, or polyester (PET) surfaces. For example, a tetrazolium salt can be reacted to form TTC, MTT, or CTC derivates. TTC is 2,3,5-triphenyl-tetrazoliumchloride. MTT is 3-(4,5-dimethylthiazol-2-yl)-2,5-diphenyl-tetrazolium bromide. CTC is 5-cyano-2,3-ditolyl tetrazoloium. Examples of these structures are depicted below as, respectively, Structures 5, 6, and 7, where n≧0 and X═Cl—, Br—, I—. As will be readily apparent to those with skill in the art, structure 5 and its derivatives are commonly known as the dye red Formazan. Structure 6 and its derivatives are known as deep blue Formazan, and structure 7 and its derivative as red fluorescent Formazan. The Formazans are inherently antimicrobial, at least when water-insoluble Formazans crystallize and accumulate inside bacteria or in a biomass such as a biofilm. It is believed that Formazans are cidal to microorganisms because they induce cellular-organelle crystallization-induced death (COCID).
These structures are achieved according to the synthetic scheme below.
The Formazan are prepared by the condensation of appropriate diazolium chloride (d) with phenylhydrazone (c) which is obtained by condensation of aldehyde (a) and hydrazine (b). Oxidation of Formazan produces tetrazolium salt. Aryl aldehyde (a), arylhydrazine (b) and diazolium salt (d) are commercially available. The X (chloride, bromide or iodide) salt of tetrazolium salt is water soluble/solvent soluble and can be attached to the polymeric housing or cover through amide linkage using amino alkyl tether.
Solvatochromic Dyes
The dyes described above, Reichardt's dye, 4,6-dichloro-2-[2-(6-acrylamido-hexyl-4-pyridinio)vinyl]phenolate, and 4,6-dichloro-2-[2-(6-amino-hexyl-4-pyridinio)vinyl]phenolate, are only a few of many examples of useful solvatochromic dyes that may be used in these applications. There are many other solvatochromic dyes that could be used. As noted above, the principal requirements are the ability to reversibly change color when swabbed, e.g., with IPA. Without being bound to any particular theory, it is believed that the conjugation between the pyridine ring and the benzene ring, with the intermediary double bond, whether one, two, or three, that accounts for the solvatochromic activity in the new structures. Since these structural features are present in merocyanine dyes, it is believed that a number of these dyes would also be effective as indicators for swabbing, whether incorporated into a coating, as the acrylics described above, or used as part of a surface treatment. Of course, merocyanine dyes typically have a phenoxide ring, rather than a substituted benzene ring. The phenoxide ring functions as the aromatic donor and the pyridine or pyridinium ring functions as the acceptor. Of course, in the new structures, the benzene ring is the donor and the pyridine ring is the acceptor. Thus, it is believed that merocyanine dyes, compound 8 below, with conjugated pyridinium-phenoxide rings (having resonance with a pyridine-benzene structure)
are also suitable, where n is an integer, including 0, and R is an alkyl or aryl group. Examples include 1-methyl-4-(4′-hydroxybutyl)pyridinium betaine and Brooker's merocyanine dye, 4′-hydroxy-1-methylstilbaxolium betaine.
Other solvatochromic dyes may also be used, such as an abundance of previously-known dyes, and for which the small change from their normal environment to a slightly acidic environment, such as the 6-7 pH range of IPA, will produce a color change. The table below lists a number of these dyes and their colors before and after. Note that the “before” environment of the coating or LAD housing material may be altered, such as by making it basic, by simple adjustments during the formation of the coating, the method of treating the surface, or the species used for attaching the dye. A few examples of solvatochromic dyes are presented in Table 2 below.
TABLE 2
Solvatochromic Dyes
First state
Second
Dye
pH
Color
state, pH
Color
Bromocresol purple
6.8
blue
5.2
yellow
Bromothymol blue
7.6
blue
6.0
yellow
Phenol red
6.8
yellow
8.2
red
Cresol red
7.2
red
8.8
Red/purple
Methyl red
4.2
pink
6.2
yellow
Reichardt's Dye
Unk
green
6-7
dark blue
Morin hydrate
6.8
red
8.0
yellow
Disperse orange 25
5.0
yellow
6.8
pink
Nile red
Unk
Blue/purple
6-7
bright pink
These and many other solvatochromic and merocyanine dyes many be used in applications according to this application. Other solvatochromic dyes include, but are not limited to, pyrene, 4-dicyanmethylene-2-methyl-6-(p-dimethyl-aminostyryl)-4H-pyran; 6-propionyl-2-(dimethylamino) naphthalene; 9-(diethyl-amino)-5H-benzo[a]phenoxazin-5-one; phenol blue; stilbazolium dyes; coumarin dyes; ketocyanine dyes, Reichardt's dyes; thymol blue, congo red, methyl orange, bromocresol green, methyl red, bromocresol purple, bromothymol blue, cresol red, phenolphthalein, seminaphthofluorescein (SNAFL) dyes, seminaphtharhodafluor (SNARF) dyes, 8-hydroxypyrene-1,3,6-trisulfonic acid, fluorescein and its derivatives, oregon green, and a variety of dyes mostly used as laser dyes including rhodamine dyes, styryl dyes, cyanine dyes, and a large variety of other dyes. Still other solvatochromic dyes may include indigo, 4-dicyanmethylene-2-methyl-6-(p-dimethylaminostyryl)-4H-pyran (DCM); 6-propionyl-2-(dimethylamino)naphthalene (PRODAN); 9-(diethylamino)-5H-benzo[a]phenox-azin-5-one (Nile Red); 4-(dicyanovinyl)julolidine (DCVJ); phenol blue; stilbazolium dyes; coumarin dyes; ketocyanine dyes; N,N-dimethyl-4-nitroaniline (NDMNA) and N-methyl-2-nitroaniline (NM2NA); Nile blue; 1-anilinonaphthalene-8-sulfonic acid (1,8-ANS), and dapoxylbutylsulfonamide (DBS) and other dapoxyl analogs. Other suitable dyes that may be used in the present disclosure include, but are not limited to, 4-[2-N-substituted-(1,4-hydropyridin-4-ylidine)ethylidene]cyclohexa-2,5-di-en-1-one, red pyrazolone dyes, azomethine dyes, indoaniline dyes, and mixtures thereof.
Other merocyanine dyes include, but are not limited to, Merocyanine dyes (e.g., mono-, di-, and tri-merocyanines) are one example of a type of solvatochromic dye that may be employed in the present disclosure. Merocyanine dyes, such as merocyanine 540, fall within the donor—simple acceptor chromogen classification of Griffiths as discussed in “Colour and Constitution of OrganiC Molecules” Academic Press, London (1976). More specifically, merocyanine dyes have a basic nucleus and acidic nucleus separated by a conjugated chain having an even number of methine carbons. Such dyes possess a carbonyl group that acts as an electron acceptor moiety. The electron acceptor is conjugated to an electron donating group, such as a hydroxyl or amino group. The merocyanine dyes may be cyclic or acyclic (e.g., vinyl-alogous amides of cyclic merocyanine dyes). For example, cyclic merocyanine dyes generally have the following structure of compound 9, in association with compound 8 above:
where n is an integer, including 0, and R is an alkyl or aryl group. As indicated above by the general structures of compounds 8 and 9, merocyanine dyes typically have a charge separated “zwitterionic”) resonance form. Zwitterionic dyes are those that contain both positive and negative charges and are net neutral, but highly charged. Without intending to be limited by theory, it is believed that the zwitterionic form contributes significantly to the ground state of the dye. The color produced by such dyes thus depends on the molecular polarity difference between the ground and excited state of the dye. One particular example of a merocyanine dye that has a ground state more polar than the excited state is set forth above as compounds 8 and 9.
The charge-separated left hand canonical 8 is a major contributor to the ground state, whereas the right hand canonical 9 is a major contributor to the first excited state. Still other examples of suitable merocyanine dyes are set forth below in the following structures 10-20, wherein, “R” is a group, such as methyl, alkyl, aryl, phenyl, etc. See Structures 10-20 below.
In addition to dyes and antimicrobial compounds, the preparations discussed herein may be used to attach to desired surfaces other compounds or substances containing amino alkyl groups. Examples of these types of compounds include polyethylene glycol) (PEG)-containing amino alkyl groups, peptides including antimicrobial peptides, proteins, Factor VIII, polysaccharides such as heparin, chitosan, hyaluronic acid derivatives containing amino alkyl groups, and condroitin sulfate derivates containing amino alkyl groups. One example of a protein is albumin, and an example of a peptide is polymyxin. The one thing these compounds have in common is an amino alkyl group, such as the amino alkyl group discussed above in the dye, 4,6-dichloro-2-[2-(6-aminohexyl-4-pyridinio)vinyl]phenolate.
Per the discussion above for surface preparation, the same preparation used to attach dyes and antimicrobial compounds containing alkyl amino groups will be suitable for these additional compounds. The amino alkyl groups will bind to the N-succinimidyl carboxylate groups. One technique for treating these groups is to clean the surface, followed by treatment with acid at elevated temperature, and then contacting the surface with poly(N-succinimidyl)acrylate (PNSA). It is believed that this induces carboxylate groups on the nylon surface, suitable for binding to aminoalkyl groups. Other methods are also described. For polycarbonate surfaces, treating with chlorosulfonic acid followed by washing is believed to induce chlorosulfonyl groups. These are suitable for binding by aminoalkyl groups. The treatment above of the PET surfaces is believed to result in attachment of carboxyl groups to the surface, making the also suitable for attachment of aminoalkyl groups.
Thus, polymeric surfaces as described above may also be used for attachment of peptides, proteins, Factor VIII or other anti-clotting Factors, polysaccharides, polymyxins, hyaluronic acid, heparin, chitosan, condroitin sulfate, and derivatives of each of these.
It should be understood 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 can be made without departing from the spirit and scope of the present subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims. | A method for immobilizing dyes and antimicrobial agents on a polymeric cover or housing for a medical device is disclosed and described. The surface may be that of a catheter, a connector, a drug vial spike, a bag spike, a prosthetic device, an endoscope, a surface of an infusion pump, a key pad, a touch screen or a handle. The surfaces may also be one or more of those associated with a infusion of a medicament or dialysis treatment, such as peritoneal dialysis or hemodialysis, where it is important that the working surface for the dialysis fluid be sterile. These surfaces include connectors for peritoneal dialysis sets or for hemodialysis sets, bag spikes, dialysis catheters, and so forth. A method for determining whether a surface has been sterilized, and a dye useful in so indicating, is also disclosed. | 2 |
FIELD OF THE INVENTION
This invention concerns a method for reducing the wear of the electrode in machine tools using electro-erosion.
BACKGROUND OF THE INVENTION
Before explaining the object of this invention, it is considered necessary to briefly explain the process of electro-erosion, and then to present the improvements which will be expounded and which constitute the object of the invention.
It is known that the process of electro-erosion is carried out by making a series of electrical discharges jump between two conductors, one of them called an electrode and the other a part or workpiece.
The purpose of the is the faithful reproduction of the shape of the first on the second. It is widely used for making molds, dies, wire-drawers, etc.
To carry out the erosion, both electrodes are connected to a source of current impulses (also referred to as current pulses), generally of rectangular shape, and both being submerged in a dielectric liquid. This liquid performs various functions: it acts as insulator, as refrigerant, and for carrying away particles detached during the work.
The process of electro-erosion is brought about first and foremost by the heat effect of the electrical discharge, although there are also mechanical and electro-magnetic effects.
At the initial moment, an impulse of tension (i.e. voltage or potential) is applied to both electrodes, and if the electrodes are separated by a distance sufficiently small for the impulse of tension to overcome the dielectric resistance of the liquid, this ionizes, creating a small channel through which an electrical current of a determined value circulates. This impulse will produce a localized fusion on the part to be machined, leaving a small crater in it. Each new impulse will repeat the process by which the electrode continues to reproduce itself in the part, leaving a cavity with the profile of the part.
It is necessary for the current to be pulsating so that each time a new channel opens, a new discharge passes, since if this were not the case, it would always be produced at the same point and the desired reproduction would not be achieved.
During the work, a series of residues proceeding from the fusion of the material are detached; they remain in suspension in the dielectric liquid, which should carry them away from the working zone. If they are not eliminated, these residues have a pernicious effect, since the accumulation of them makes the electrical discharges become anomalous. When this happens, some of them tend to pass by the same channel and finish by producing a continuous discharge in the form of an arc with the consequent destructive burning effect.
The process also requires the impulses to be unidirectional, since in this form it has been seen that the wear of the electrode is asymmetrical with respect to the part, the wear being less in the electrode and more in the part. The ideal would be if there were no wear at all in the electrode. Unfortunately, this is not the case in practice, and this is due to various factors.
The main objective of this invention, apart from other improvements, is to reduce the wear of the electrode practically to about half of the wear which now takes place in electro-erosion machines.
It is known that electro-erosion made a great advance in respect of wear and speed of mechanization when, instead of using systems based on relaxation circuits, the system of pre-established impulses of current was introduced.
The use of impulses made a great advance thanks to modern power transistors which make it possible to control very high current intensities and which, in addition, can work at considerable commutation speeds, making it possible to use sufficiently high frequencies.
One of the most suitable forms of making a transistor work to control strong currents is by using the so-called commutation or switching system or in which the transistor presents two clearly defined states: the off state and the state of saturation. This system has the advantage of high performance and little dissipation of heat in the commuting (switching) element, since tension and current do not coincide in this element at the same time.
The greatest losses in such a system are produced more or less exclusively at the moment of transition from one state to the other, so the attempt should be made to produce this transition in the shortest possible time. The shorter it is, the better the transistor will work and the smaller will be the losses in it, although naturally the type of load coupled to it also influences its working. That is, smaller load currents will naturally permit longer transition times without excessive losses, and heavier load currents will require shorter transition times.
For a better explanation of the phenomenon, see FIG. 1 which shows an impulse of current and in which we can see that the shorter are the "t" on and the "t" off times, the less will be the dissipation in the transistor, i.e. what is claimed is that both sides will be as vertical as possible, with the greatest attainable value of di/dt.
Returning to the process, we see that in FIG. 2, an impulse of tension in open circuit is represented at (a), and an impulse of tension in working conditions at (b) and (c). Represented at (d) and (e) is the impulse of current corresponding to each of the above.
In an open circuit, i.e. when the electrode and the part are separated by a distance greater than that necessary for ionization, the impulse has the shape represented at (a). This impulse has had no effect, so that it is a lost impulse. In (b), the impulse of tension already represents a distinct shape since in this case both electrodes will be at the correct distance, and therefore the ionization will have been produced. The time t, on is the time of ionization after which the impulse of current would have circulated between both electrodes. At (c) we see another impulse of tension which presents a longer time of ionization than the previous one.
This delay in the ionization is completely random, although by increasing the tension in the casting mold (i.e. increasing the voltage between the electrode and workpiece) it is possible to reduce this time considerably. If the ionization time is lengthened, we see that the impulse of current is narrower and circulates for a shorter time.
Since, in addition, the energy of the impulse is proportional to its area, the material torn out and thus the crater left will be different in both cases.
In practice, there are two fundamental systems: the isoenergetic impulses and the heteroenergetic impulses. The former have an equal time of duration, while the latter have completely irregular times.
Between two consecutive impulses of current, there must always be a pause, the purpose of which is to allow the dielectric liquid to recover its insulating properties so that it can close the channel of conduction in the mold, and in this way make it possible to reinitiate the process at another different point of the part.
In practice, we try to make the pause as short as possible so that the frequency of recurrence can be as high as possible, in order to increase the productivity of the removal of material. However, either because there are residues in the gap between electrode and part, or because hot points are produced, if the pause is excessively short, there are times when various consecutive impulses travel through the same channel, with the result that there is no de-ionization and the process degenerates into a continuous electrical arc, damaging the part and the electrode and forming a carbon which could have fatal consequences and which must be eliminated by the worker himself.
One of the procedures used to avoid this phenomenon is to give a periodical reciprocal movement to the electrode, so that when the electrode moves away, it is easier to evacuate the residues. However, since the accumulation or residues depends on various factors such as the speed of working, the geometry of the part, the depth of the cavity, etc., it is practically impossible to optimize the cleaning cycles so as to avoid the problem completely, unless this is done at the price of poor performance by the machine.
It is possible to detect the instant at which these abnormal discharges are going to be produced is by observing the peak tension of ionization, since before the degenerative phenomenon is produced, it is possible to observe that these peak tensions diminish or even arrive at total cancellation, so this makes it possible to take pertinent measures to attack the problem before it worsens.
The system of temporary withdrawal of the electrode also has another disadvantage in that it is totally independent of the conditions of work. Frequently the electrode withdraws when it is needed, and fails to withdraw when it is not needed. Giving this alternating movement to the electrode brings about a spectacular reduction in the performance of the machine, since during these withdrawal and advance intervals, the machine does not erode. So if we add up these fractions of time lost at the end of a working day, the total ineffective time can be considerable, with a corresponding considerable loss of productivity.
In all electro-erosion machines, the pause times are controlled totally independent of the control of the impulse times, so that at each new regulation of the impulse time, it is necessary to regulate the pause time to obtain good stability and performance in each new regime selected.
This will become clearer if we take an example. Supposing that we have selected as a first work pass an impulse time of 100 microseconds and a pause time of 10 microseconds. Once the work at this speed is finished, we want to change to an impulse time of 10 microseconds. If we do not modify the pause, we shall see that, while in the first case we had an impulse to pause ratio of 10 to 1, in the second case we would have a ratio of 1 to 1, i.e. of 50%, with which the performance (efficiency) obviously cannot be the same.
In the circuit developed in this invention, the ratio is maintained constant, since the pause time is always expressed as a percentage of the impulse time selected.
Let us now go on to analyse the wear suffered by the electrode. In this respect, the inventor has been able to find that almost 50% of the wear suffered by the electrode takes place at the moment of establishing the channel of ionization (i.e. increasing the voltage between the electrode and workpiece), and the shorter the time of transition between break- and conduction, the greater is the wear produced. This led him to frame the hypothesis that at the moment of initiating the discharge, the channel is infinitely small, and if a very high current circulates in it, the resulting density of current is very high. With the passage of time, the channel progressively widens, thus distributing the same current over a greater area, so that the density of the current logically diminishes. However that may be, one thing is certain: the more vertical the slope of the rising side of the current impulse, the greater the wear, i.e. the wear is in a certain manner proportional to the ratio di/dt.
Moreover, the initial peak of current can be reinforced by the fact that, due to the parasite capacities present in the circuit and capacity proper to electrode and part, if these capacities are loaded before the ionization, they discharge their energy at the moment the ionization is produced, with an initial energy at 1/2 Cy 2 .
Since this necessary reduction of slope in order to avoid wear is incompatible with good commutation of the power transistors, since its dissipation could go outside the safety area, a method has been established which complies with both requirements.
So a method has been invented which does not present these disadvantages and, in addition, makes it possible to give time to the channel to widen progressively.
The method consists in giving the generator of impulses various stages of power, distributed in weighted form in respect of the intensities of current referred to, of which the first could be supplied at the same tension as the others, or at a higher tension than the others, with which the initial ionization could be facilitated.
The different stages of current are disposed in such a way that the discharge of each of them is produced sequentially and preferably regulated by a code determined to be able to produce the whole range of necessary values of current, with a minimum number of them, such as, for example, the BCD code.
The interval of time between each discharge of the stages is, in the same way, variable at will, so as to be able to produce the desired delay between each one of them.
The first step of power supplies an impulse of current the value of which should be equal to or slightly more than the minimum intensity of current needed for maintenance of the discharge, and always less than the working current selected. It should be noted in passing that the maintenance current is the minimum value of intensity, below which the discharge of each impulse is made unstable and its establishment unpredictable.
In the system developed, once the ionization is initiated, a circuit detects that this is the case and sets off a programmable counter which begins to count impulses proceeding from the time base, the frequency of which is much higher than those of the working impulses, and once the preselected count has been reached, the circuit gives a signal of conduction to (switching on) the following stage of power, which supplies an impulse of current stronger than the previous one, with a certain delay in respect of the first. The third stage will be connected at the end of a certain time after the second has been connected, and so on.
In this way, we make it possible for the preselected current not to be established instantaneously at the moment of ionization, but in a spaced-out form, thus giving sufficient time to the channel to widen to a sufficient degree to let the strong impulse pass.
We can see that this spacing out can be made in various jumps or steps so that the selected currents increase progressively until they arrive at the desired peak value, and from that moment onwards, the impulse continues normally in rectangular form (FIG. 10).
So what is invented is the power to vary the slope of the rising side (leading edge) of the current impulse step by step, the breadth of each step being a function of the time and the height, and since a function of the current varies each one of these parameters, it is possible to achieve an infinite range of shapes of the rising side of the impulse of working current, thereby giving it the form most suitable for reducing the wear of the electrode to its minimum value. FIG. 10 shows different forms of the rising side of the impulse.
It has been found with this method that the wear of the electrode diminishes by practically 50%. This is of importance, mainly in production involving fine relief work in which the cost of the electrode can represent an important item. Moreover, with this method, the small amount of wear is much more uniform and regular than with the known method, since it is precisely on sharp edges that the greatest wear is produced.
With this method, the transistors can always work with perfect commutation (switching) permitting unlimited adjustment in the breadth and height of the step in question.
As the initial intensity is relatively weak, and therefore it is not practical to carry out an infinitesimal stepping, this first stage of supply can be equipped with means for varying the slope of the rising side of the current. For example, the slope of the vertical leading edge of the first stage current pulse can be varied as shown by the broken line in FIG. 10. Taking especial account of the fact that in spite of what has been said about the dissipation of power, and given that in this first stage the current the is low, it would not therefore present problems of heat dissipation.
It is obvious that if 50% of the wear of the electrode takes place in the rising side of the current impulse, the wear will be in direct relation to the number of impulses or to the frequency, and this is confirmed in practice, since the wear is greater in the higher frequency regimes, which are precisely those used for finishing work, i.e. precisely those in which the wear is most inopportune.
The method can be applied to any system for producing impulses, whether or not the impulses are isoenergetic; if they are not, however, there could be a considerable loss of performance in the machine, since if the time of ionization is considerably prolonged (see FIG. 2(c)), the strong current impulse could fall outside the period of duration of the ionization voltage impulse, i.e. during the pause, which would mean that these impulses would irremediably lost and therefore would contribute very little to the useful work.
In the same way, the stepping can be produced in the falling side of the current impulse, which would make it possible to obtain an additional reduction of the wear, albeit a less significant one, since in consequence a small inversion of the current takes place, which may be produced when the instantaneous impulse of strong intensity is cut, there being--as there always are--parasite inductances in the circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing current impulses;
FIG. 2 is a diagrammatic showing of voltage and current impulses;
FIG. 3 is a block diagram of the inventive method;
FIG. 4 illustrates the components within the block B of FIG. 3;
FIG. 5 is a diagrammatic showing of the output signal;
FIG. 6 is a diagrammatic illustration of the block C of FIG. 3;
FIG. 7 illustrates several time diagrams according to the invention;
FIG. 8 illustrates additional time diagrams according to the invention;
FIG. 9 is a diagrammatic showing of the impulses; and
FIG. 10 is a further time diagram.
DETAILED DESCRIPTION
For greater clarity, we explain one of the possible practical implementations of the system.
In FIG. 3 can be seen a block diagram in which A represents the general source of supply, B an oscillator circuit, C a decision logic, D the power amplifier, E the servo activating the electrode, F the electrode and G the part to be worked.
Let us now look at the working of each of them, block by block. Starting with block A; this consists of a series of supply tensions (voltages) with their transformers, rectifiers and filters, well known to technicians in this field, so that we need not here go into more detail on them.
Block B is shown in FIG. 4, and in it we see that b 1 represents a clock generating impulses with a frequency much higher than that of the working impulses of the machine. It will preferably be a quartz crystal clock, so as to guarantee good precision and stability. We will suppose that this clock works at a frequency of 100 MHz.
The impulses proceeding from the clock enter block b 2 which is a frequency divider composed of a fixed division unit of value 100 and a unit that can, be programmed from outside by means of the preselectors Pr, or via a computer. This divider constitutes the generator of pause times. The impulses leaving block b 2 pass to block b 3 , consisting of another programmable frequency divider, and this is the one which generates the impulse times of the working current. The output from this block is applied to a bistable circuit (b4) which changes state with each impulse that reaches it. Its output arrives at block b 2 in such a way that in each of its states it selects alternately the fixed counter or the programmable counter.
Let us suppose that an impulse time of 120 microseconds has been selected, and a pause time of 10% of the impulse time. Starting with a frequency of 100 Mhz, whose period is 0.01 microseconds, we enter a signal of these characteristics at the divider b 2 . If the signal proceeding from the bistable is a 1, in that case a fixed counter of value 100, for example will be selected, and the output of this divider will therefore be a signal whose period will equal 0.1×100=1 microsecond. This signal, applied in turn at the divider b 3 , which is programmed, let us suppose, at 120 microseconds, will give an output of 120×1=120 microseconds which, when it arrives at the bistable, will cause it to change state to give an output equal to 0 with which the divider b 2 , which was dividing by a fixed value of 100, will now divide by the programmed value which could, for example, be 10, which would give us 0.01×10=0.1 microseconds at the input of divider b 3 which is still programmed at 120. So at the output of this divider, we will now have a signal of 0.1×120=12 microseconds (10% of the 120 microsecond pulse time), which is what we wished. This signal will again commute or switch the bistable b 4 , which will return to its state 1. The output signal now obtained will be as that of FIG. 5.
In the divider b 2 , it has also been foreseen that, by means of an external signal, it is possible to vary the factor of division for the purpose of widening the pause time when the working conditions are anomalous, and in this way we can avoid the formation of arcs between electrode and part.
This can either be a single signal giving a fixed and preestablished pause width, or the pause width can preferably be variable so that if the problem has not been solved with the first pause width, the following anomalous impulse produced will increase the factor of division by a certain value, and so on at each new anomalous impulse.
This progressive widening of the pause is in itself capable of preventing the formation of arcs, but in this circuit we have also provided an interrelation between the width and the control system of the servo, so that when the pause width is produced, as the average electrode/part tension (gap voltage) diminishes progressively, this reduction is picked up by the comparator of the servo control circuit which "sees" a reduced tension and "gives" the order to open up the gap between electrode and part progressively, and proportionally to the reduction of the electrode-part tension.
If the widening continues, a second comparator, which is adjusted at a higher level, gives the order to withdraw the electrode rapidly for cleaning the gap between electrode and part. If for any reason this rapid withdrawal does not take place, it also emits a signal which inhibits the production of impulses of strong current, so that it is practically impossible for an arc to be produced.
Both divider b 3 and b 2 are also provided with an asynchronous input by which it is possible to reload the counters at any moment, reinitiating the count from that moment onwards, and in this way it is possible to obtain an impulse time the length of which is perfectly controlled.
This signal arrives at the counters from the moment at which the detector circuit, which will be described below, has detected that the ionization has been produced.
We now go on to describe the discriminator block C for working conditions, shown in FIG. 6. In this we see that VC1, VC 2 and VC are dynamic comparators of the level of ionization ion. Each of them is adjusted at the suitable detection or threshold value. Their detection is made impulse by impulse, so as to obtain a total realtime monitoring of the working conditions.
The comparators VC4 and VC5 measure the average working tension, or they can also be accumulators recording the number of anomalous impulses as a function of the time, or also digital comparators which record the correct impulses that should be produced and compare them with those that actually are produced.
All the comparators have an adjustable threshold level which, in the case of VC 5 can have an outside control for making the adjustment manually if desired.
In the block C 6 is included the comparator of tension VC 1 and a logic circuit which converts the level of tension compared into a synchronization signal which is applied to the frequency dividers b 2 and b 3 of the oscillator block, which re-initiates the count of impulse time from the instant in which ionization is produced, according to the time diagrams of FIG. 7, in which diagram S 1 represents the electrode-part tension, and in it we can see the different times of ionization "t" ion 1 and "t" ion 2.
V comp. represents the level of comparation of the comparator VC1.
At the output of comparator VC1, the appears only during the time of ionization of diagram S 1 , and it represents the tension which has been able to cross the threshold of the level of comparation V comp.
From the signal S 2 is extracted the information useful at the beginning of the ionization, which is converted into a signal (S 3 ) suitable for modifying the frequency dividers of the oscillator in such a way that the counters of the divider chains b 2 and b 3 re-initiate their count at the instant of receiving this signal, obtaining a result in accordance with diagram S 4 . The duration of each impulse of S 4 is equal to the sum of the delay in ionization and the time of the working impulse. As can be seen, with this system, we have succeeded in giving the impulses of working current an equal breadth, independently of the delay associated with producing ionization, and they are equal to the programmed value tp. See diagram S 5 .
The delay circuit (block C 7 ) includes the comparator VC 2 , a logic circuit, and some output stages, preferably optocoupled, which are directly attached to the power stages.
The comparator of this circuit detects, like the VC 1 , the level of ionization tension, and its output is applied to a delay generator circuit, to which is also applied the output of the general oscillator. With both inputs, and via some bistables and a frequency divider chain, some outputs are generated, out of phase with one another, according to the time diagram of FIG. 8 in which, for greater clarity, we show only two outputs which is the minimum necessary for the system to work.
These diagrams show two inputs E 1 and E 2 which correspond respectively to the signal of the oscillator and to the voltage across the gap. The signal S 6 is the output of the comparator and corresponds to the ionization delay. The signals S 8 and S 9 correspond to the output of the bistables, and S 11 is the output signal of the frequency divider.
The output S 7 is a faithful reproduction of the signal of the oscillator which, preferably via an optocoupler as we said above, is input into the stage generating the impulse of weak current for ionization.
The output S 10 is delayed relative to S 7 which is the sum of the programmed delay plus the time of ionizatation. This output, via another optocoupler, is input into the following stage of strong current. This means that the signal S 7 , amplified in the stage of weak intensity power, initiates the discharge with an ionization time "t" ion 1 according to the signal E 2 .
At the instant ionization occurs the step of current of value Ia shown in FIG. 8, graph Is, is initiated in the same way, starting the count to produce the desired delay in the frequency divider chain included in this block.
When this time has passed, this divider chain emits a signal S 11 to one of the bistables of the circuit which, on changing state, generates a signal S 9 , and the optocouplers mentioned above give the signal S 10 to the amplification stages of strong current of value I b of the graph of I a (FIG. 8).
The result obtained is that the total duration of the current impulse is tp=t w +t f , i.e. weak current during the time initiated by the channel, and strong current during the time Tf, which is the rest of the working impulse.
With this circuit configuration, by simply cancelling the signal S 10 by means of appropriate logic, we inhibit the impulses of strong current, leaving only those of weak current which, moreover, are produced with a pause of greater than normal width, so that they are continuously exploring the state of the gap.
While the anomaly persists, there will be broad pauses and--arriving at the extreme case--there will be no impulses of strong current, thus avoiding the formation of arcs. When the gap returns to normal conditions, the machining impulses of strong current will be re-established by removing the inhibition of the signal S 10 .
The practical effect this produces is reflected in the signal I s (FIG. 8) in which we observe that the impulse of current is stepped in the rising side. The small stepping corresponds to the initial impulse, and the large stepping to the power impulse.
The pause widening system block C 8 includes the comparator VC 3 and a decision logic.
The comparator analyses the level of ionization tension of each impulse signal S 13 , generating an output signal S 14 in cases where it is higher than the threshold level of the comparator.
To the logic circuit, we input the signal from the comparator, and its output is applied to the divider B 2 of the oscillator block, supplying it with the value of the factor of division, which will be t o if it is taken from the pause preselector, or t e , with a value greater than t o , which will produce a longer pause. The decision between one or the other will depend on the comparator, according to the threshold level VC.
The logic circuit acts as follows: a bistable goes into one of its two states at the beginning of each impulse arriving at it from the oscillator (X), and changes state with the descending side of each impulse of ionization via the comparator (Y). See FIG. 9.
If an anomalous impulse is produced ("h" in the graph S 13 ) the bistable remains during the whole of the cycle in the first state. The impulse Z which should have appeared if the impulse had been normal, fails to appear, and the pause is prolonged in consequence. This signal from the output of the bistable is the signal that decides between t o and t e .
Therefore the circuit continues to suppose that the following impulse is going to be anomalous, and consequently programs a longer pause, but as soon as the ionization side characteristic of normal impulses appears, the circuit switches over and programmes a normal pause, doing so while the current impulse is taking place.
The circuit C 9 is the one responsible for producing the signal for the withdrawal of the electrode by the servo, and consists of a medium tension comparator VC 4 and of a logic circuit by means of which a signal is sent for interrupting the work impulses and thus leaving the electrode and the part without tension; at the same time, another signal is sent to counters for them to record the impulses emitted by an encoder coupled to the servo, such as an encoder which emits impulses as a function of the distance traveled by the electrode. When the counters arrive at a predetermined number, the servo signal is inverted, and the servo causes the electrode to approach the part, at the same time as the counters begin to deduct. All these operations are carried out at high servo velocity, in both withdrawal and approach, but when the counters reach a certain value in their deduction, they emit a signal which orders the servo to change to its slow speed. This allows the operation of cleaning to be completed as quickly as possible and also avoids the electrode, in its new approach to the part, going too far and impacting against the part by the inertia effect of the system.
The circuit C 10 is a servo regulation circuit and consists of a tension comparator and a differential amplifier which supplies an output of ±10 V capable of controlling a servo-valve, if the servo is of the hydraulic type, or a speed regulator with four quadrants if the servo is of the electro-mechanical type, with a DC motor, or a tension-frequency converter if the motor is of the step by step type.
Block D is a power amplifier composed of transistors working in commutation, in which it is possible to use both bipolar transistors and MOSFETS, although the latter are preferable in view of their characteristics of high commutation speed, low control power, absence of second break, etc., these advantages being already known in the state of the art.
The invention, in its essentials, can be put into practice in forms other than those shown in detail in the description, to which the protection of the patent would also extend. Thus, the invention can be implemented by the most suitable means, while still being included in the spirit of the claims.
Although a particular preferred embodiment of the invention has been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention. | Method of reducing the wear of the electrode in machine tools using electro-erosion. There is provided a circuit with different stages of power; the tension of the first can be superior, facilitating the ionization of the channel and reducing the delay of ionization. A circuit detects the ionization and sets going some programmable counters which count impulses proceeding from the time base, the frequency of which is superior to that of the work impulses; when the preselected count has been reached, the circuit emits a signal of conduction to the following power stage, which supplies an impulse of stronger current, with a certain delay with respect to the first, and so on. By succeeding in establishing the working current in a spaced-out form, it can materialize in one or more jumps so that the currents selected continue to increase progressively, varying at will the shape of the rising side of the current impulse. This method reduces the wear of the electrode by at least about 50%. | 1 |
TECHNICAL FIELD
The subject invention generally relates to dock levelers, and more specifically to a dock leveler whose deck is raised by an inflatable member.
BACKGROUND
Loading docks often include a dock leveler to facilitate the loading or unloading of a truck's cargo. The dock leveler provides a bridge that material handling equipment and personnel can use to travel between a loading dock platform and the bed of the truck. Dock levelers usually include a deck or ramp that can pivot about its rear edge to raise or lower its front edge. Often a lip plate extends from the front edge of the deck and is adapted to engage the rear of the truck bed. The lip plate is usually movable between a stored, retracted position and an extended, vehicle-engaging position. The pivotal movement of the deck enables the dock leveler to set the lip plate on or remove it from the truck bed.
To pivot a deck, a dock leveler usually includes some type of actuator that extends, expands or otherwise moves to force the deck upward. Downward movement of the deck may be achieved by relying on the weight of the deck (biased down dock leveler) or by physically pushing the deck back down with an external force or weight (biased up dock leveler), such as the weight of a person standing on the deck.
There are a wide variety of well-known actuators available today. Some common ones include, hydraulic cylinders, pneumatic cylinders, coil springs, high-pressure air springs, linear motors, and inflatable actuators. The subject invention pertains to inflatable actuators, which comprise an inflatable chamber disposed underneath a deck. To raise the deck, a blower discharges pressurized air into the chamber, which causes the chamber to expand and lift the deck. Upon de-energizing the blower, the weight of the deck forces the air within the chamber to backflow through the blower, whereby the chamber controllably collapses to lower the deck.
Although inflatable actuators are effective at raising a deck, the blowers of such actuators can be particularly loud. Moreover, a pit in which a dock leveler is installed can become quite dirty from the traffic across the deck and by debris infiltration from the adjacent driveway. An inflatable chamber, its blower and various other dock leveler components underneath the deck can be difficult to clean due to the limited space of a typical dock leveler pit.
Consequently, a need exists for an inflatable actuator that is quieter and easier to clean and whose blower is protected from debris.
SUMMARY
In some embodiments, an inflatable actuator for a dock leveler has an internal volume of air contained between a pliable upper section a more rigid base.
In some embodiments, the inflatable actuator is substantially cylindrical.
In some embodiments, the more rigid base includes an upwardly extending flange joined to which the pliable upper section is joined.
In some embodiments, the inlet and/or outlet of the blower passes through the more rigid base to maintain the integrity of the pliable upper section.
In some embodiments, the blower is installed inside the inflatable actuator.
In some embodiments, the blower is mounted to the base of inflatable actuator.
In some embodiments, the inflatable actuator includes an access opening.
In some embodiments, an inflatable actuator includes a valve system that enables a blower to selective inflate or forcibly deflate the actuator.
In some embodiments, a blower can forcibly collapse an inflatable actuator while the dock leveler deck remains elevated and substantially stationary.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a dock leveler whose deck, shown in a cross-traffic position, can be raised by an inflatable actuator.
FIG. 2 is a cross-sectional side view similar to FIG. 1 but with the actuator inflated to lift the deck.
FIG. 3 is similar to FIG. 1 but with the actuator deflated and the lip of the dock leveler resting upon the rear of a truck bed.
FIG. 4 is similar to FIG. 2 but showing another embodiment where the blower is inside the actuator.
FIG. 5 is similar to FIG. 4 but showing the blower installed at another location inside the actuator.
FIG. 6 is similar to FIGS. 4 and 5 but showing an inflatable actuator with various access openings that are covered or otherwise closed.
FIG. 7 is cross-sectional side view showing an inflated actuator with an internal blower and valve system, wherein the valve system is schematically illustrated.
FIG. 8 is a side view of the actuator of FIG. 7 but with a portion cut away to show the inside of the actuator when forcible deflated up against the underside of the deck.
FIG. 9 a is a schematic diagram showing one embodiment of an inflated actuator, a valve system in an inflate configuration, and a blower.
FIG. 9 b is a schematic diagram similar to FIG. 9 a but showing the valve system in a deflate configuration, wherein the blower forcibly deflates the actuator.
FIG. 10 a is a schematic diagram showing a second embodiment of an inflated actuator, a valve system in an inflate configuration, and a blower.
FIG. 10 b is a schematic diagram similar to FIG. 10 a but showing the valve system in a deflate configuration, wherein the blower forcibly deflates the actuator.
FIG. 11 a is a schematic diagram showing a second embodiment of an inflated actuator, valve system in an inflate configuration, and a blower.
FIG. 11 b is a schematic diagram similar to FIG. 11 a but showing the valve system in a deflate configuration, wherein the blower forcibly deflates the actuator.
DETAILED DESCRIPTION
FIGS. 1-3 show various operating positions of a dock leveler 10 and its inflatable actuator 12 which are installed within a pit 14 of a loading dock 16 . To facilitate loading or unloading cargo from a vehicle 19 (e.g., truck trailer, etc.), dock leveler 10 includes a pivotal deck 18 and a lip 22 that provide a path for personnel and material handling equipment to travel between a platform 24 of the dock and vehicle 19 . To selectively raise and lower a front edge 26 of the deck, inflatable actuator 12 can pivot deck 18 about a hinge 28 that couples a rear edge 30 of the deck to a supporting frame 32 . This enables dock leveler 10 to set lip 22 on or remove it from the truck bed. Lip 22 extends from deck 18 to bridge the gap between front edge 26 and a rear edge 34 of vehicle 19 .
To raise deck 18 , a blower 36 or some other source of pressurized air forces air through an inlet 38 to expand inflatable actuator 12 . To lower deck 18 , blower 36 is de-energized, which allows the deck's weight to controllably collapse actuator 12 by forcing air to backflow through blower 36 .
The sequence of operation at dock 16 typically begins with dock leveler 10 at its stored, cross-traffic position of in FIG. 1 . In this position, inflatable actuator 12 is deflated, lip 22 is at its pendant position supported by a set of lip keepers 40 , and the top surface of deck 18 is generally flush with platform 24 . Arrow 42 represents vehicle 19 backing the rear edge of its truck bed toward a bumper 44 of dock 16 .
Next, in FIG. 2 , blower 36 is energized to inflate actuator 12 with relatively low-pressure air (preferably less than 10 psig.). A centrifugal blower is just one example of such a source of low-pressure air. As inflatable actuator 12 expands, it forces deck 18 upward. Lip 22 , which a hinge 46 pivotally couples to the deck's front edge 26 , pivots outward to extend out over the truck bed of vehicle 19 . Arrow 48 schematically represents any actuator capable of moving lip 22 (e.g., by acting upon a lug 50 extending from lip 22 ). Examples of such a lip actuator include, but are not limited to, pneumatic cylinders, low-pressure air actuator, coil springs, high-pressure air springs, linear motors, mechanical linkages responsive to the movement of deck 18 , and various combinations thereof.
After lip 22 extends out over rear edge 34 of vehicle 19 , it is selectively locked or otherwise held in this position and blower 36 is de-energized to deflate actuator 12 . This allows deck 18 to descend to lower lip 22 upon the truck bed of vehicle 19 , as shown in FIG. 3 . In this position, cargo can be readily added or removed from vehicle 19 .
To enable inflatable actuator 12 to raise and lower deck 18 in such a manner, actuator 12 comprises a pliable upper section 52 , such as a nylon fabric tube, bladder, bag, or the like. An upper panel 54 of section 52 seals the upper end of actuator 12 . To seal a lower end of the actuator, upper section 52 can be bonded, fused, welded, or otherwise attached to a more rigid base 56 . Together, the side portion of pliable upper section 52 , upper panel 54 , and base 56 define an expandable chamber that contains an internal volume of air 58 . A tube 60 places inlet 38 of actuator 12 in fluid communication with a discharge outlet 62 of blower 36 , so blower 36 can force air into the chamber to expand actuator 12 . When blower 36 is de-energized, the weight of deck 18 can force the air out of the chamber in reverse flow through blower 36 , as deck 18 descends.
Although the structural details of actuator 12 may vary, in some embodiments, pliable upper section 52 is made of a nylon fabric and base 56 is made of ABS (Acrylonitrile Butadiene Styrene). Actuator 12 is generally cylindrical when inflated. In some cases, base 56 includes an upwardly extending flange 64 that adds rigidity to base 56 and provides a generally strong, stationary wall through which tube 60 can extend. The rigidity of base 56 and joining the base in direct sealing relationship to upper section 52 at a circumferential joint 66 may provide several benefits. First, a rigid base may be less likely to bulge under pressure, thus actuator 12 maintains a generally constant area of contact between the bottom of actuator 12 and a floor 68 of pit 14 . With a constant area of contact, debris in the pit is less likely to work itself underneath actuator 12 . Second, a rigid base may be more durable and less likely to be punctured by debris on pit floor 68 . Third, a smooth, rigid base may be easier to clean. Fourth, having upper section 52 sealingly joined to base 56 at joint 66 eliminates the need for an additional internal sealing member just to seal off the bottom of actuator 12 .
Referring to FIGS. 4 and 5 , in some cases blower 36 may be installed somewhere inside the inflatable actuator to provide quieter operation and help keep the blower clean. In FIG. 4 , for example, blower 36 is mounted to base 56 , and an inlet tube 70 extending from the suction opening of blower 36 and passing through flange 64 or through upper section 52 places the internal volume of air 58 in fluid communication with the exterior air. A suitable air filter can be connected in series with tube 70 and installed outside of the inflatable actuator so that the filter can be readily serviced.
In FIG. 5 , an upper section 72 of an inflatable actuator 74 supports blower 36 . Tube 76 (e.g., a flexible hose) extending from the suction opening of blower 36 and passing through an upper panel 78 of upper section 72 places the internal volume of air in fluid communication with the exterior air. Although tube 76 is shown extending thorough upper panel 78 , alternatively tube 76 could also be routed through upper section 72 , a base 75 or any other part of inflatable actuator 74 .
In this example, base 75 is shown to include a drain plug 81 for draining condensation 87 or any other fluid that may happen to collect at the bottom of base 75 . Base 75 may also include a raised central portion 83 that creates a trough 85 for collecting the fluid and directing it toward drain plug 81 . Bases 56 , 64 and 86 can be modified to also include such a drain plug and trough.
Referring to FIG. 6 , to provide service access to an internally mounted blower, an inflatable actuator 80 may include an access opening, which may be selectively closed by some appropriate device, such as a zipper 82 or a removable cover 84 . Zipper 82 is preferably installed horizontally as shown because the bursting stress in an upper section 85 is greater in the circumferential direction than vertically, thus a horizontal zipper is less likely to pull apart. Moreover, a horizontal zipper avoids being creased at multiple locations when upper section 85 folds as actuator 80 collapses.
Referring to FIGS. 7 and 8 , it may be desirable to elevate deck 18 and lift a base 86 of an inflatable actuator 88 off the dock pit floor 68 for the purpose of cleaning the pit area or for other service reasons. To raise base 86 as shown in FIG. 8 , actuator 88 first lifts deck 18 to the position of FIG. 7 , and a prop 90 is installed to keep it there. Once prop 90 supports the weight of deck 18 , blower 36 in conjunction with a valve system evacuates the air from within actuator 88 , whereby the reduced air pressure inside actuator 88 draws base 86 up to its position of FIG. 8 because the top of actuator 88 is secured to the underside of deck 18 . Once base 86 is elevated, a retainer system 92 such as a chain, hook, latch, strap, cable, or the like can hold the base 86 in its raised position even after blower 36 is de-energized.
Referring further to FIGS. 9 a , 9 b , 10 a , 10 b , 11 a , and 11 b , to selectively pressurize actuator 88 to raise deck 18 or to depressurize actuator 88 to lift base 86 for servicing, a valve system 94 a , 94 b , or 94 c determines whether blower 36 inflates or deflates actuator 88 . Valve system 94 a , for example, includes a 2-position, 4-way valve 96 that could be actuated electrically, manually, or otherwise. Valve 96 in the position shown in FIGS. 7 and 9 a allows blower 36 to draw in exterior air through a first line 98 and discharge the air through a second line 100 into actuator 88 , thereby pressurizing actuator 88 to raise deck 18 . A filter 102 can be added to help keep the interior of actuator 88 , valve 96 , and blower 36 clean. To lift base 86 , valve 96 can be positioned as shown in FIGS. 8 and 9 b , whereby valve 96 allows blower 36 to evacuate air from within actuator 88 via line 100 and discharge the air through line 98 .
It should be noted that one or more subcomponents of valve system 94 a , blower 36 and filter 102 can be installed inside actuator 88 as shown in FIGS. 7 and 8 , or valve system 94 a can be installed outside of actuator 88 as shown in FIGS. 9 a and 9 b (also similar to FIGS. 1-3 ). The same applies to valve systems 94 b and 94 c , which are alternatives to valve system 94 a.
Valve system 94 b of FIGS. 10 a and 10 b includes two 2-position, 3-way valves 104 and 106 that can be actuated electrically, manually, or otherwise. Valves 104 and 106 in their positions shown in FIG. 10 a allow blower 36 to draw in exterior air through a first line 108 and discharge the air through a second line 110 into actuator 88 , thereby pressurizing actuator 88 to raise deck 18 . To lift base 86 , valves 104 and 106 can be positioned as shown in FIG. 10 b , whereby valves 104 and 106 allow blower 36 to evacuate air from within actuator 88 via line 110 and discharge the air through a discharge line 112 .
In another embodiment, a valve system 94 c of FIGS. 11 and 11 b includes four 2-position, 2-way valves 114 that can be actuated electrically, manually, or otherwise. Valves 114 in their positions shown in FIG. 11 a allow blower 36 to draw in exterior air through a first line 116 and discharge the air through a second line 118 into actuator 88 , thereby pressurizing actuator 88 to raise deck 18 . To lift base 86 , valves 114 can be positioned as shown in FIG. 11 b , whereby the valves allow blower 36 to evacuate air from within actuator 88 via line 118 and discharge the air through a discharge line 120 .
Although the invention is described with respect to a preferred embodiment, modifications thereto will be apparent to those of ordinary skill in the art. | A dock leveler for a truck loading dock includes a pivotal deck that is raised by an inflatable actuator. The actuator includes a pliable upper section that when inflated has a generally vertical cylindrical shape that can provide a heavy deck with substantial columnar support. The actuator also includes a relatively rigid base that is sealingly joined to the pliable upper section such that upper section and the rigid base define an inner chamber of air. A blower for inflating the actuator can be installed inside or outside the actuator. In some embodiments, a valve system reverses the airflow so that the blower can forcibly deflate and compress the actuator up against the bottom of the deck so that the area underneath the actuator can be cleaned. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to a harness routing structure for a link for routing a wire harness for power feeding along a rotary type link from a harness protector in an automobile or the like.
[0003] 2. Background Art
[0004] FIG. 5 shows one form of a conventional harness routing structure for a link (refer to patent document 1).
[0005] In this structure, a pair of links 41 and 42 are rotatably connected to each other, a proximal end portion of one link 41 is rotatably supported by a vehicle body 43 of an automobile by means of a shaft portion 44 , a distal end portion of the other link 42 is supported freely by a slide door 45 , and a wire harness 46 for power feeding is routed from the vehicle body 43 to the slide door 45 along the both links 41 and 42 . The arrangement provided is such that, in conjunction with the opening and closing of the slide door 45 , the one link 41 is made swingable in the longitudinal direction of the vehicle by using the shaft portion 44 as a fulcrum, while the other link 42 is made swingable with a greater angle than the one link 41 by using an intermediate shaft portion 47 as a fulcrum, to thereby follow the movement of the slide door 45 .
[0006] The wire harness 46 is fixed to the links 41 and 42 by taping 48 . A connector 49 at a leading end of the wire harness 46 is connected to the wire harness on the slide door side. A wire harness portion 50 led from a distal end of the other link 42 is extended and contracted in conjunction with the opening and closing of the slide door 45 .
[0007] FIG. 6 shows one form of a conventional harness routing structure (refer to patent document 2).
[0008] In this structure, to effect feeding electric power to a rotary type side door 51 of an automobile, a harness protector 53 is provided in the door 51 , and a wire harness 56 is bendably routed in the protector 53 from an elastic grommet 54 on a vehicle body 52 side by means of a slidable hard tube (guide member) 55 and is led out from the protector 53 into the door interior, to be thereby connected to an electrical device, an auxiliary machine, or the like
[0009] When the door 51 shown in FIG. 6 is opened, the hard tube 55 is drawn out from the protector 53 , the wire harness 56 is extended along a front-side inner surface 57 of the protector 53 . When the door 51 is closed, the hard tube 55 enters the protector interior, and the wire harness 56 is compressed along a rear-side inner surface 58 of the protector 53 , as indicated by chain lines.
[0010] FIGS. 7A and 7B show another form of a related harness routing structure for a link.
[0011] In this structure, a link 2 is pivotally supported by a vertical supporting plate 1 , a harness protector 61 is provided on the supporting plate 1 , and a wire harness 6 is routed from the link 2 along the protector 61 .
[0012] The wire harness 6 is fixed to the link by a band 15 or the like, is fixed to a lower end-side leading-out port 62 of the protector 61 by a band 16 or the like, and swings along an upper opening 63 of the protector 61 in conjunction with the rotation of the link 2 . The link 2 rotates at a large angle of 180° or thereabouts. FIG. 7A shows the state before the rotation, and FIG. 7B shows the state after the rotation.
[0013] [Patent Document 1] JP-A-2001-260770 (FIG. 1)
[0014] [Patent Document 2] JP-A-2006-117054
[0015] However, with the above-described structure of FIG. 5 , there has been concern that, in conjunction with the rotation of the links 41 and 42 , the wire harness 46 becomes loose at the connecting portion 47 between the both links 41 and 42 and can possibly cause interference with other members. In addition, with the above-described structure of FIG. 6 , there has been concern that the hard tube (guide member) 55 , which is a separate member, is required for guiding the wire harness 56 into the protector 53 , so that the structure becomes complex and results in higher cost.
[0016] In addition, with the above-described structure of FIGS. 7A and 7B , an excess length (slack) of the harness at least occurs within the scope of the dimensional tolerance of the wire harness 6 . Additionally, a large excess length of the harness is likely to occur in the vicinity of the shaft portion of the link 2 in conjunction with the rotation of the link 2 at a large angle of 180° or thereabouts. Hence, there has been concern that the excess length portion of the harness interferes with the link 2 and the like and can possibly cause damage or generate abnormal noise.
SUMMARY OF THE INVENTION
[0017] In view of the above-described aspects, an object of the invention is to provide a harness routing structure for a link which is capable of reliably absorbing the excess length of the wire harness with a simple structure in correspondence with the link which rotates at a large angle as in the case of FIGS. 7A and 7B , for example.
[0018] To attain the above object, in accordance with a first aspect of the invention there is provided a harness routing structure, including: a supporting portion; a link pivotally supported by the supporting portion; and a harness protector provided on the supporting portion. The harness protector includes: a harness guide portion for guiding to lead a wire harness thereto; a harness guide path, successive to the harness guide portion, along which the wire harness is routed; and a harness accommodating portion, successive to the harness guide path, for accommodating the wire harness bendably. The wire harness is led from the link to the harness protector to be routed in the harness protector. An excess length of the wire harness is absorbed into the harness accommodating portion in conjunction with rotation of the link.
[0019] Preferably, the harness guide portion has a first curved guide wall along which the wire harness is routed in a first direction before the rotation of the link, and a second curved guide wall along which the wire harness is routed in a second direction differed from the first direction after the rotation of the link.
[0020] By virtue of the above-described configuration, the wire harness is led from the link, is passed via an inlet-side harness guide portion of the harness protector and the harness guide path continuing therefrom, is accommodated in such a manner as to be capable of absorbing an excess length (bendably in the harness accommodating portion, and is led out from an exit port on the harness accommodating portion side to the outside. The harness guide portion guides the wire harness smoothly into the harness guide path without being caught, and the harness guide path supports the wire harness slidably. In conjunction with the rotation of the link, the wire harness is drawn into the harness accommodating portion while sliding on the harness guide path, and the excess length is absorbed as the wire harness is deflected or curved and undergoes expansion (enlargement) of the radius of curvature inside the harness accommodating portion. Alternatively, the wire harness is drawn out from the harness guide portion toward the link side while sliding on the harness guide path from the harness accommodating portion.
[0021] As for the harness routing structure for a link according to a second aspect of the invention, the wire harness is constantly curved to form a substantially loop-shaped bent portion in the harness accommodating portion so that a radius of the loop-shaped bent portion is expanded to absorb the excess length of the wire harness in conjunction with the rotation of the link.
[0022] By virtue of the above-described configuration, the substantially loop-shaped bent portion is routed in the harness accommodating portion of the harness protector in a loop form with leeway (loosely movably). As the substantially loop-shaped bent portion constantly tends to expand outward by the restoring force (resilient force due to rigidity) of its own, when slack (excess length) has occurred in the wire harness outside the harness protector, that excess length is immediately drawn into the harness protector and is thereby absorbed.
[0023] By virtue of the above-described configuration, an excess length produced due to the variation of the length of the wire harness is absorbed into the harness accommodating portion of the harness protector irrespective of the presence or absence of the rotation of the link and on the basis of a principle similar to that of the excess length of the harness produced in conjunction with the rotation of the link. Thus, the length of the wire harness portion which is led out from the harness protector to the link side becomes fixed irrespective of the variation of the length o the wire harness.
[0024] As for the harness routing structure for a link according to a third aspect of the invention, a spring portion is provided in the harness accommodation portion to urge the loop-shaped bent portion in a direction of expanding the radius of the loop-shaped bent portion.
[0025] By virtue of the above-described configuration, the substantially loop-shaped bent portion is constantly urged by the resiliency of the spring portion outward (in the direction of expanding the radius of curvature). Thus, when an excess length has been produced in the wire harness outside the harness protector (on the link side), the spring portion causes the substantially loop-shaped bent portion to undergo expansion of its radius of curvature, thereby absorbing the excess length of the harness speedily and reliably into the harness protector. The spring portion may be integrally resin-molded with the harness protector, or may be a metal spring separate from the harness protector.
[0026] According to the above-described configurations of the invention, since the harness protector has the harness guide portion, the harness guide path, and the harness accommodating portion, the separate guide member as in the related example of FIG. 6 becomes unnecessary, so that the structure becomes simplified and is made low in cost and lightweight. In addition, since the excess length of the wire harness is absorbed into the protector during the rotation of the link, the concern over the excess length of the harness interfering with other members and causing damage or generating abnormal noise can be overcome, and the reliability of electric power feeding by the wire harness is enhanced.
[0027] According to the above-described configurations of the invention, since the substantially loop-shaped bent portion of the wire harness undergoes enlargement of its radius of curvature inside the harness protector and absorbs the excess length of the harness in the outside, the interference of the excess length of the harness in the first aspect of the invention is reliably prevented.
[0028] According to the above-described configurations of the invention, the dimensional tolerance of the overall length of the wire harness is absorbed into the harness protector as an excess length of the harness, and the length of the wire harness portion outside the harness protector becomes fixed irrespective of the dimensional tolerance, thereby overcoming the problems of the interference, appearance, and the like due to the excess length.
[0029] According to the above-described configurations of the invention, the substantially loop-shaped bent portion is made to undergo enlargement of its radius of curvature by the resiliency of the spring portion, thereby reliably absorbing into the harness protector the excess length of the harness outside the harness protector. In addition, as the spring portion is constantly in pressing contact with the inner surface of the substantially loop-shaped bent portion of the wire harness, there are no possibilities of unwanted free movement of the bent portion as well as abnormal noise, wear, and the like accompanying the same inside the harness protector.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The above objects and advantages of the present invention will become more apparent by describing in detail preferred exemplary embodiments thereof with reference to the accompanying drawings, wherein like reference numerals designate like or corresponding parts throughout the several views, and wherein:
[0031] FIGS. 1A and 1B illustrate a first embodiment of a harness routing structure for a link in accordance with the invention, in which FIG. 1A is a front elevational view of a state before the rotation of a link, and FIG. 1B is a front elevational view of a state after the rotation of the link;
[0032] FIGS. 2A and 2B illustrate a protector which is similarly used in the harness routing structure for a link, in which FIG. 2A is a front elevational view of a case in which the line length of a wire harness is short, and FIG. 2B is a front elevational view of a case in which the line length of the wire harness is long;
[0033] FIGS. 3A and 3B illustrate a second embodiment of the harness routing structure for a link in accordance with the invention, in which FIG. 3A is a front elevational view of a state before the rotation of the link, and FIG. 3B is a front elevational view of a state after the rotation of the link;
[0034] FIGS. 4A and 4B illustrate a third embodiment of the harness routing structure for a link in accordance with the invention, in which FIG. 4A is a front elevational view of a state before the rotation of a link, and FIG. 1B is a front elevational view of a state after the rotation of the link;
[0035] FIG. 5 is a perspective view illustrating a related harness routing structure for a link;
[0036] FIG. 6 is a front elevational view illustrating one form of a related harness routing structure; and
[0037] FIGS. 7A and 7B illustrate another form of a related harness routing structure for a link, in which FIG. 7A is a front elevational view of a state before the rotation of a link, and FIG. 1B is a front elevational view of a state after the rotation of the link.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] FIGS. 1A and 1B illustrate a first embodiment of a harness routing structure for a link in accordance with the invention. A description will be given by denoting those component parts that are similar to those of FIGS. 7A and 7B by the same reference numerals.
[0039] In this structure, a link 2 is rotatably connected to a vertical supporting plate (supporting portion) 1 on a fixing side by means of a shaft portion 3 , a harness protector 5 is vertically disposed in such a manner as to extend alongside both the supporting plate 1 and a base portion 4 continuing from a lower side of the supporting plate 1 , and a wire harness 6 is led from the link 2 side toward the base portion 4 side via the protector 5 . In this structure, the protector 5 has a harness accommodating space 8 provided on a lower half side and surrounded by a substantially annular peripheral wall 7 ; an upwardly extending narrow guide path 9 provided on an upper half side and communicating with the accommodating space 8 ; and a harness leading-out port 10 continuing from an upper end side of the guide path 9 and having its width expanded in a substantially flared form.
[0040] In addition, as the wire harness 6 is bent substantially in a loop form (a form close to an annular shape and is accommodated in a harness accommodating portion 11 having a substantially annular outer shape and including the harness accommodating space 8 , a resilient force acting in the direction of enlarging the radius of curvature is generated in a substantially loop-shaped harness portion (bent portion) 12 , to thereby allow an excess-length portion of the wire harness 6 to be drawn into the protector 5 by the resilient force of the wire harness itself.
[0041] The protector 5 is composed of a synthetic resin-made protector body or protector base (reference numeral 5 is also used for it) and a cover (not shown), and the cover is fixed to the protector body ( 5 ) by a retaining means (not shown). The supporting plate 1 and the link 2 are formed of a metal or a synthetic resin. The supporting plate 1 may be called a fixing link or a bracket, and the link 2 may be called a movable link or a rotary link.
[0042] The base portion 4 is flush with the supporting plate 1 and continues therefrom as an integral or separate unit. A proximal end portion 2 a of the link 2 is brought into sliding contact with a surface of the supporting plate 1 opposite to its protector joining surface (fixing surface) 1 a rotatably about the shaft portion 3 . The proximal end portion 2 a and a longitudinally intermediate portion of the link 2 continue with each other via a stepped portion 13 . The intermediate portion of the link is located flush with the projector joining surface. The wire harness 6 is routed in a substantially flush plane in a range covering the protector 5 and the link 2 .
[0043] The wire harness 6 is fixed to the intermediate portion of the link 2 and to a vicinity of a harness leading-out port 14 on the harness accommodating portion 11 side of the protector 5 by banding members (harness fixing portions) 15 and 16 such as bands and tapes. If necessary, a protector (not shown) may be provided on the link 2 side as well, and the wire harness 6 may be inserted and fixed in that protector. The shaft portion 3 is provided in the supporting plate 1 in such a manner as to project horizontally to be passed through and support the link 2 without interfering, for instance, the protector 5 .
[0044] As also shown in FIGS. 2A and 2B , the harness accommodating portion 11 of the protector 5 is composed of a substantially semicircular left half portion 11 a and a substantially triangular right half portion 11 b. A curved wall portion 7 a on the left half side integrally continues to a right-upwardly slanting tilted wall portion 7 b on the right half side, and the tilted wall portion 7 b integrally continues to a horizontal wall portion 7 c on the upper side, to hence form the peripheral wall 7 . The wall portion 7 c on the upper side and the curved wall portion 7 a on the left half side integrally continue to a cylindrical or rectangular tube-shaped wall portion (reference numeral 9 is also used for it) which forms the harness guide path 9 . The peripheral wall 7 is formed in the periphery of a vertical wall portion (base board portion) 24 on the reverse surface side contiguous to the base portion 4 ( FIG. 1A ).
[0045] A guide wall 17 having a circular arc-shaped or curved guide surface with a small radius of curvature integrally continues from an upper portion of a left-side wall portion 9 a of the harness guide path 9 , while a guide wall (reference numeral 18 is also used for it) having a curved guide surface 18 with a large radius of curvature is integrally formed on an upper portion of a right-side wall portion 9 b of the guide path 9 . The right-side guide wall 18 protrudes more upward than the left-side guide wall 17 , and the both guide walls 17 and 18 are connected to each other by a substantially fan-shaped rear surface-side wall portion 19 having a circular arc-shaped upper end 19 a. The wall portion 19 is located flush with the wall portion 24 on the lower half side.
[0046] The narrow port 14 for leading out the harness is provided along the upper right wall portion 7 c of the harness accommodating portion 11 , and a frame portion (harness fixing portion) 20 for inserting a band is integrally provided in the vicinity of the port 14 . The harness accommodating portion 11 on the lower half side protrudes (bulges) more to the left and right than a harness guide portion 21 constituted by the upper half guide walls 17 and 18 . It should be noted that, in this specification, the “left and right” directions are for the sake of explanation, and do not necessarily coincide with the direction in which the protector 5 is mounted in a vehicle or the like. In addition, the shape of the protector 5 is changeable, as required, in correspondence with the shape of the protector 5 as well as the shapes of the supporting plate 1 , the base portion 4 , and the like.
[0047] FIG. 1A shows a state before the rotation of the link, and FIG. 1B shows a state after the rotation of the link when the link 2 is rotated counterclockwise from the state shown in FIG. 1A .
[0048] In FIG. 1A , the link 2 is positioned in such a manner as to be tilted rightwardly upward, and the wire harness 6 is routed rectilinearly from the harness fixing portion 15 of the link 2 toward the curved guide wall 18 on the right side, and is then routed rectilinearly downward from the guide wall 18 along the harness guide path 9 . The wire harness 6 is then curved substantially in a loop form from a lower end of the guide path 9 along the inner surface side of the peripheral wall 7 of the harness accommodating portion 11 , and is led from the right-side port 14 to the outside.
[0049] As the wire harness 6 bulges outward substantially in the loop form inside the harness accommodating portion 11 by the restoring force due to its own rigidity, an excess length of the harness is absorbed (drawn) into the accommodating portion 11 , and the wire harness 6 is routed without slack between the guide wall 18 of the protector 5 and the harness fixing portion 15 of the link 2 . Since the excess length of the harness is not produced, it is possible to prevent the bending of the wire harness 6 and the interference with the link 2 and the like due to the excess length of the harness.
[0050] In FIG. 1B , the link 2 is positioned in such a manner as to be tilted leftwardly downward, and the wire harness 6 is routed in an upwardly curved form from the harness fixing portion 15 of the link 2 toward the curved guide wall 17 on the left side, and is then routed rectilinearly downward from the guide wall 17 along the harness guide path 9 . The wire harness 6 is then curved substantially in a loop form from the lower end of the guide path 9 along the peripheral wall 7 of the harness accommodating portion 11 , and is led from the right-side port 14 to the outside.
[0051] In conjunction with the rotation of the link 2 , the wire harness 6 is slid upward on the guide path 9 and is drawn out from the guide wall 17 , so that the radius of curvature of the loop-shaped harness portion (bent portion) 12 is slightly smaller than that of the state shown in FIG. 1A . As the wire harness 6 bulges outward substantially in the loop form inside the accommodating portion 11 by the restoring force due to its own rigidity, the excess length of the harness is absorbed (drawn) into the accommodating portion 11 , and the wire harness 6 is routed in a smooth curved shape without slack between the guide wall 17 of the protector 5 and the harness fixing portion 15 of the link 2 . Since the excess length of the harness is not produced, it is possible to prevent the bending of the wire harness 6 and the interference with the link 2 and the like due to the excess length of the harness.
[0052] Even at an intermediate position between FIG. 1A and FIG. 1B , i.e., in a state in which the link 2 is positioned at a leftwardly upward halfway in the rotation of the link 2 , in the same way as described above, the wire harness 6 bulges outward (undergoes enlargement of its radius of curvature) substantially in the loop form inside the accommodating portion 11 by the restoring force due to its own rigidity, so that the excess length of the harness is absorbed (drawn) into the accommodating portion 11 , and the wire harness 6 is routed without slack between the upper end of the harness guide path 9 of the protector 5 and the harness fixing portion 15 of the link 2 . Since the excess length of the harness is not produced, it is possible to prevent the bending of the wire harness 6 and the interference with the link 2 and the like due to the excess length of the harness. As the link 2 is rotated from the state shown in FIG. 1B to the state shown in FIG. 1A , the wire harness 6 is lid downward on the guide path 9 , and is drawn into the accommodating portion 11 .
[0053] FIG. 2A shows a state in which the line length of the wire harness 6 is short, and FIG. 2B shows a state in which the line length of the wire harness 6 is long (the relative length of the line length inevitably occurs at least within the scope of the dimensional tolerance of the wire harness). The position of the link 2 corresponds to that in FIG. 1B .
[0054] In the case where the line length is long in FIG. 2B , an excess length can possibly be produced from the guide portion 21 of the protector 5 toward the outside, but since the wire harness 6 undergoes enlargement of its radius of curvature in a loop form within the accommodating portion 11 , as shown by arrow A, the excess length of the harness is absorbed while the wire harness 6 slides downward along the guide path 9 , as shown by arrow B. Therefore, the length of the harness portion L from the guide portion 21 to the outside becomes identical. Since the excess length of the harness is not produced, it is possible to prevent the bending of the wire harness 6 and the interference with the link 2 and the like due to the excess length of the harness.
[0055] FIGS. 3A and 3B show a second embodiment of the harness routing structure for a link. This structure is characterized by providing a harness urging spring portion 23 inside the harness accommodating portion 11 of a harness protector 22 . Since the other configuration portions are similar to those of the embodiment shown in FIGS. 1A and 1B , those component parts that are similar to those of FIGS. 1A and 1B will be denoted by the same reference numerals, and a description thereof will be omitted.
[0056] The spring portion 23 is arranged such that a substantially annular (not completely annular) wall portion 25 is integrally formed projectingly on a wall portion (vertical base board portion) 24 on the rear surface side of the accommodating portion 11 of the protector 22 , and at least a distal end-side half portion (preferably, a portion excluding a proximal end side 25 a ) of the substantially annular wall portion 25 is cut out from the rear surface-side wall portion 24 by vertical slits (not shown), so as to be formed into the shape of leaf spring. The proximal end portion 25 a of the substantially annular wall portion 25 is preferably reinforced by a rib 26 with respect to the rear surface-side wall portion 24 . In this example, a hole 27 is provided in the wall portion 24 on the inner side of the substantially annular spring portion 23 .
[0057] The spring portion 23 resiliently urges an intermediate portion of the substantially loop-shaped bent portion 12 of the wire harness 6 so as to push and enlarge that intermediate portion outward, as shown by arrow C. As a result, before the link rotation in FIG. 3A , after the link rotation in FIG. 3B , and in the course of link rotation intermediate therebetween, the wire harness 6 is constantly spring-urged in a direction in which it is drawn into the accommodating portion 22 , thereby reliably absorbing the excess length of the harness outside the protector. In addition, as the spring portion 23 is constantly in pressing contact with the inner surface of the substantially loop-shaped bent portion 12 , there are no possibilities of unwanted free movement of the bent portion 12 as well as abnormal noise, wear, and the like accompanying the same.
[0058] It should be noted that, instead of the spring portion 23 of the protector body, it is possible to use as the spring portion a resilient member such as a metallic leaf spring separate from the protector 22 . In that case, however, the cost increases as compared with the case where the spring portion 23 is integrally resin-molded on the protector 22 , and a structure for fixing the spring portion 23 to the protector 22 is also required, which results in the complexity of the structure and an increase in the number of steps of fixing operation.
[0059] FIGS. 4A and 4B show a protector structure in a case where the amount of absorption of the excess length of the harness can be small in accordance with a third embodiment of the harness routing structure for a link. Since the structure of the guide portion 21 , the link 2 , and the supporting plate 1 on the upper half side of a harness protector 28 are similar to those of the first embodiment, similar component parts will be denoted by the same reference numerals, and a description thereof will be omitted.
[0060] In this protector 28 , the harness guide portion 21 is integrally formed in the upper half, a harness guide path 9 ′, which continues from the harness guide portion 21 and is shorter than the guide path in the example of FIG. 1A , is integrally formed intermediately, and a substantially trapezoidal harness accommodating portion 29 of a size equivalent to the guide portion 21 is integrally formed in a lower half. The accommodating portion 29 is made compact to a size which is half the accommodating portion 11 of the example of FIG. 1 or smaller.
[0061] A lower half portion of a vertical left-side wall portion 9 a ′ of the guide path 9 ′ forms a portion of the wall portion of the accommodating portion 29 , a lower half portion of the wall portion 9 a ′ continues to a right-downwardly tilted wall portion 31 , and the tilted wall portion 31 continues to a horizontal wall portion 32 on the bottom side. Further, the harness leading-out port 14 and the harness fixing portion 16 are provided on the right end side of the bottom-side wall portion 32 , the port 14 continues to a left-upwardly tilted wall portion 33 , and the tilted wall portion 33 continues at an angle to a vertical right-side wall portion 9 b ′ of the guide path 9 ′. The accommodating portion 29 is thus formed which constitutes a polygonal harness accommodating space 30 by being surrounded by the respective wall portions 9 a ′ and 31 to 33 and by a vertical wall portion (reference numeral 30 is used for it) on the rear surface side. The wall portions 9 a ′ and 9 b ′ may not necessarily be vertical, and the wall portions 9 a ′, 9 b ′, and 31 to 33 may be formed not rectilinearly but in a curved form. It goes without saying that the protector 28 includes the cover (not shown) which covers the accommodating space 30 .
[0062] FIG. 4A shows a state before the rotation of the link, and FIG. 4B shows a state after the rotation of the link when the link 2 is rotated counterclockwise from the state shown in FIG. 4A .
[0063] In FIG. 4A , the link 2 is positioned in such a manner as to be tilted rightwardly upward, and the wire harness 6 is led from the harness fixing portion 15 of the link 2 without slack via the guide wall 18 and the guide path 9 ′, is then routed in a curved manner along the left-side tilted wall portion 31 of the accommodating portion 29 , and is led from the right-end port 14 to the outside.
[0064] In FIG. 4B , the link 2 is positioned in such a manner as to be tilted leftwardly downward, and the wire harness 6 is led from the harness fixing portion 15 of the link 2 in a rightwardly upward direction via the left-side guide wall 17 and the guide path 9 ′ while being curved substantially in an inverse U-shape, is then routed straightly along the right-side tilted wall portion 33 of the accommodating portion 29 , and is led from the right-end port 14 to the outside. At an intermediate position between FIG. 4A and FIG. 4B , i.e., halfway in the rotation of the link 2 , the wire harness 6 is positioned substantially in the center of the accommodating portion 29 inside the accommodating portion 29 without coming into contact with the left and right tilted wall portions 31 and 33 .
[0065] In the state shown in FIG. 4B , the wire harness 6 is drawn out from the protector 29 toward the link 2 side and is curved substantially in the inverse U-shape, whereas, in the state shown in FIG. 4A , the wire harness 6 is drawn into the protector 29 . Since the excess length of the harness is small, the excess length can be absorbed by merely allowing the wire harness 6 to be deflected in the curved form inside the accommodating portion 29 .
[0066] As one example of application of each of the above-described harness routing structures, the supporting plate 1 shown in FIGS. 1A and 1B is disposed in an upwardly oriented manner in a rear portion of a vehicle body in correspondence with a vertically rotatable type back door of an automobile, for example. A wire harness portion 6 b led out from the lower port 14 of the protector 5 is routed and connected to the vehicle body (power supply side), and a wire harness portion 6 a on the link side is routed on the back door side. When the back door is fully closed, as shown in FIG. 1B , the link 2 is positioned in a manner as to be oriented diagonally downward toward the rear side of the vehicle. When the back door is fully open, as shown in FIG. 1A , the link 2 is positioned in a manner as to be oriented diagonally upward toward the front side of the vehicle. The supporting plate 1 and the base portion 4 may be portions of the vehicle body.
[0067] As another example of application, the above-described harness routing structure can also be applied, for example, as a structure for opening and closing a roof of an automobile or for effecting the accommodation of a roof into a luggage space in the rear portion of the vehicle. Still alternatively, it is also possible to cope with the opening and closing of a slide door or a side door by disposing the supporting plate 1 not vertically but horizontally.
[0068] The wire harness 6 is generally composed of a plurality of electric wires and harness protecting tubes (corrugated tubes, net-like tubes, etc.) covering them. In particular, if a corrugated tube alternately having circumferential recessed grooves and projections is used, it is possible to enhance the function of enlarging the radius of curvature of the wire harness 6 inside the accommodating portion 11 of the protector 5 , i.e., the excess length absorbing function. As the wire harness 6 , it is also possible to use a plurality of electric wires by partially winding them by tapes, bands, or the like.
[0069] The wire harness 6 is accommodated in advance within the protector 5 , and in that state the protector 5 is fixed to the supporting plate 1 and the base portion 4 by a fixing means such as retaining clips, bolting, or the like. The protector 5 is preferably constructed in a split fashion (openably) by the protector base (reference numeral 5 is also used for it) and the cover in the light of enhancing the efficiency of inserting (accommodating) operation of the wire harness 6 .
[0070] The above-described configurations shown in FIGS. 1A to 4B are also effective as a protector structure for a link, a harness excess-length absorbing structure, an electric power feeding structure, and the like, apart from the harness routing structure for a link. The link 2 and the supporting plate 1 , together with the protector 5 , can also be formed into a unit as an electric power feeder. | A harness routing structure includes: a supporting portion; a link pivotally supported by the supporting portion; and a harness protector provided on the supporting portion. The harness protector includes a harness guide portion for guiding to lead a wire harness thereto, a harness guide path, successive to the harness guide portion, along which the wire harness is routed, and a harness accommodating portion, successive to the harness guide path, for accommodating the wire harness bendably. The wire harness is led from the link to the harness protector to be routed in the harness protector. An excess length of the wire harness is absorbed into the harness accommodating portion in conjunction with rotation of the link. | 1 |
[0001] The application is a continuation application of U.S. Ser. No. 12/246,153, filed Oct. 6, 2008 which is a continuation application of U.S. Ser. No. 11/077,813, filed Mar. 10, 2005, which is a continuation-in-part of U.S. Ser. No. 10/927,975, filed Aug. 26, 2004, which is a continuation-in-part of U.S. Ser. No. 10/650,365, filed Aug. 28, 2003, which is a continuation-in-part of Int'l App'l No. PCT/CN02/00128, filed Feb. 28, 2002, which claims priority of Chinese App'l No. 01104367.9, filed Feb. 28, 2001. The contents of the above applications are hereby incorporated in their entireties by reference into this application.
[0002] Throughout this application, various publications are referenced. Disclosures of these publications in their entireties are hereby incorporated by reference into this application in order to more fully describe the state of the art to which this invention pertains.
FIELD OF THE INVENTION
[0003] This invention is related to a field of bioengineering. Specifically this invention relates to a recombinant super-compound interferon (rSIFN-co) or its equivalent with changed spatial configuration, high efficacy and low side effects. Therefore, high dose of rSIFN-co may be used. This invention also relates to a process to produce said super-compound interferon (rSIFN-co) or a pharmaceutical composition comprising said super-compound interferon (rSIFN-co) or its equivalent, and uses of said interferon or composition for anti-viral and anti-tumor therapy.
BACKGROUND OF THE INVENTION
[0004] IFN-con is a new interferon molecule constructed with the most popular conservative amino acid found in natural human IFN-α subtypes using genetic engineering methods. U.S. Pat. Nos. 4,695,623 and 4,897,471 have described it. IFN-con had been proven to have broad-spectrum IFN activity and virus- and tumor-inhibition and natural killer cell activity. U.S. Pat. No. 5,372,808 by Amgen, Inc. addresses treatment Infergen® (interferon alfacon-1). Chinese Patent No. 97193506.8 by Amgen, Inc. addresses re-treatment of Infergen® (interferon alfacon-1) on hepatitis C. Chinese Patent No. 98114663.5 by Shenzhen Jiusheng Bio-engineering Ltd. addresses recombinant human consensus interferon-α treatment for hepatitis B and hepatitis C.
[0005] The United States Food and Drug Administration (FDA) authorized Amgen to produce Infergen® (interferon alfacon-1) with E. Coli . for clinical hepatitis C treatment at the end of 1997.
[0006] Hepatitis B patients can be identified when detecting HBsAg and the HBeAg. IFN-α is commonly used in clinics to treat hepatitis B. IFN-α binds superficial cell membrane receptors, thus inhibiting DNA and RNA (ribonucleic acid) duplication and inducing some enzymes to prevent duplication of the virus in hepatitis-infected cells. All IFNs can inhibit DNA duplication of viruses, but they cannot inhibit the e and s antigen expression.
[0007] An outbreak of atypical pneumonia, referred to as severe acute respiratory syndrome (SARS) and first identified in Guangdong Province, China, has spread to several countries. Similar cases were detected in patients in Hong Kong, Vietnam, and Canada from February and March 2003. The World Health Organization (WHO) issued a global alert for the illness. In mid-March 2003, SARS was documented in health care workers and household members who had cared for patients with severe respiratory illness in the Far East. Many of these cases could be traced through multiple chains of transmission to one health care worker from Guangdong Province who visited Hong Kong, where he was hospitalized with pneumonia and died. By late April 2003, thousands of SARS cases and hundreds of SARS-related deaths from over 25 countries around the world were reported to WHO. Most of these cases occurred through exposure to SARS patients in household or health care settings. This invention provides a method to prevent and/or treat SARS. This disclosure describes recombinant super-compound interferon (rSIFN-co), method to produce the same and uses thereof. Particularly, the super-compound interferon disclosed herein is capable of inhibiting, preventing and/or treating the hepatitis viruses, SARS virus, or virus-induced upper respiratory diseases, the Influenza virus, for example Avian Influenza virus and Ebola virus.
[0008] In addition, rSIFN-co is effective in preventing and/or treating viral diseases and tumors with less side effects as compared to other available interferons.
SUMMARY OF THE INVENTION
[0009] This invention provides a recombinant super-compound interferon (rSIFN-co) and its equivalent with changed spatial configuration, high efficacy and low side effects. Therefore, high dose of rSIFN-co may be used.
[0010] This invention also provides artificial gene encoding for the super-compound interferon or its equivalent.
[0011] This invention provides a vector comprising the gene which codes for the super-compound interferon or its equivalent.
[0012] This invention provides an expression system comprising the vector comprising the gene which codes for the super-compound interferon or its equivalent. This invention also provides a host cell comprising the vector comprising the gene which codes for the recombinant super-compound interferon (rSIFN-co) or its equivalent. Said host cell may be eukaryotic or prokaryotic, such as E. Coli.
[0013] This invention provides a method for producing a recombinant super-compound interferon (rSIFN-co) with changed spatial configuration and enhanced antiviral activity comprising steps of:
(a) Introducing nucleic acid molecule which codes for said interferon with preferred codons for expression to an appropriate host; and (b) Placing the introduced host in conditions allowing expression of said interferon.
[0016] This invention provides the method for producing recombinant super-compound interferon (rSIFN-co), further comprising recovery of the expressed interferon.
[0017] This invention provides a method for inhibiting, preventing or treating viral diseases, or for inhibiting or treating tumors in a subject comprising administering to the subject an effective amount of the super-compound interferon or its equivalent.
[0018] This invention provides the above-described method wherein super-compound interferon is administered orally, via vein injection, muscle injection, peritoneal injection, subcutaneous injection, nasal or mucosal administration, or by inhalation via a respirator.
[0019] This invention provides the method to prevent or treat viral diseases wherein the viral diseases is hepatitis A, hepatitis B, hepatitis C, other types of hepatitis, infections of viruses caused by Epstein-Barr virus, Human Immunodeficiency Virus (HIV), Ebola virus, Severe Acute Respiratory Syndrome Virus (SARS), Influenza virus, Cytomegalovirus, herpes simplex viruses, or other types of herpes viruses, papovaviruses, poxviruses, picornaviruses, adenoviruses, rhinoviruses, human T-cell leukemia viruses I, or human T-cell leukemia viruses II, or human T-cell leukemia virus III.
[0020] This invention provides the method to prevent or treat viral diseases wherein the viral diseases are Human Immunodeficiency Virus (HIV) and Ebola virus.
[0021] This invention provides a method for anti-hepatitis activities. It can inhibit HBV-DNA replication, HBsAg and HBeAg production.
[0022] This invention provides a method to prevent or treat upper respiratory infection diseases.
[0023] This invention provides a method to prevent or treat tumors or cancers wherein the tumor is skin cancer, basal cell carcinoma and malignant melanoma, renal cell carcinoma, liver cancer, thyroid cancer, rhinopharyngeal cancer, solid carcinoma, prostate cancer, stomach/abdominal cancer, esophageal cancer, rectal cancer, pancreatic cancer, breast cancer, ovarian cancer, and superficial bladder cancer, hemangioma, epidermoid carcinoma, cervical cancer, non-small-cell lung cancer, small-cell lung cancer, glioma, leucocythemia, acute leucocythemia and chronic leucocythemia, chronica myelocytic leukemia, hairy cell leukemia, lymphadenoma, multiple myeloma, polycythemia vera, or Kaposi's sarcoma.
[0024] This invention provides a method for preventing or treating virus-induced diseases in a subject comprising administering to the subject an effective amount of recombinant super-compound interferon or a functional equivalent thereof.
[0025] The super-compound interferon (rSIFN-co) may be administered orally, via vein injection, muscle injection, peritoneal injection, subcutaneous injection, nasal or mucosal administration, or by inhalation via a respirator.
[0026] This invention provides a method for inhibiting the causative agent of virus-induced diseases, comprising contacting the causative agent with an effective amount of super-compound interferon or its equivalent.
[0027] This invention also provides a method for inhibiting virus-induced diseases, comprising contacting an effective amount of the super-compound interferon with said virus or cells. This contact could be direct or indirect.
[0028] This invention provides a composition comprising an effective amount of the super-compound interferon capable of inhibiting, preventing or treating virus-induced diseases, and a suitable carrier.
[0029] This invention provides a pharmaceutical composition comprising an effective amount of the recombinant super-compound interferon capable of inhibiting, preventing or treating virus-induced diseases in a subject, and a pharmaceutically acceptable carrier.
[0030] This invention provides a method for preventing or treating tumors in a subject comprising administering to the subject an effective amount of recombinant super-compound interferon or a functional equivalent thereof.
[0031] This invention provides a method for inhibiting tumors, comprising contacting the causative agent with an effective amount of super-compound interferon or its equivalent.
[0032] This invention also provides a method for inhibiting tumors, comprising contacting an effective amount of the super-compound interferon with said virus or cells. This contact could be direct or indirect.
[0033] This invention provides a composition comprising an effective amount of the super-compound interferon capable of inhibiting, preventing or treating tumors, and a suitable carrier.
[0034] This invention provides a pharmaceutical composition comprising an effective amount of the recombinant super-compound interferon capable of inhibiting, preventing or treating tumors in a subject, and a pharmaceutically acceptable carrier.
DETAILED DESCRIPTION OF THE FIGURES
[0035] FIG. 1 . rSIFN-co cDNA sequence designed according to E. Coli . codon usage and deduced rSIFN-co amino acid sequence
[0036] FIGS. 2A-B . Sequence of another super-compound interferon
[0037] FIG. 3 . Diagram of pLac T7 cloning vector plasmid
[0038] FIG. 4 . Diagram of pHY-4 expression vector plasmid
[0039] FIG. 5 . Construction process of expression plasmid pHY-5
[0040] FIG. 6-A . Circular Dichroism spectrum of Infergen®
(Tested by Analysis and Measurement Center of Sichuan University)
[0041] Spectrum range: 250 nm-190 nm
Sensitivity: 2 m°/cm
Light path: 0.20 cm
Equipment: Circular Dichroism J-500C
[0042] Samples: contains 30 μg/ml IFN-con1, 5.9 mg/ml of NaCl and 3.8 mg/ml of Na 2 PO 4 , pH7.0.
[0043] Infergen® (interferon alfacon-1), made by Amgen Inc., also known as consensus interferon, is marketed for the treatment of adults with chronic hepatitis C virus (HCV) infections. It is currently the only FDA-approved, bio-optimized interferon developed through rational drug design and the only interferon with data on the label specifically for non-responding or refractory patients. InterMune's sales force re-launched Infergen® in January 2002 with an active campaign to educate U.S. hepatologists about the safe and appropriate use of Infergen®, which represents new hope for the more than 50 percent of HCV patients who fail other currently available therapies.
[0044] FIG. 6-B . Circular Dichroism spectrum of Infergen® From Reference [Journal of Interferon and Cytokine Research. 16:489-499 (1996)]
[0045] Circular dichroism spectra of concensus interferon subforms. Concensus interferon was fractionated using an anion exchange column. Samples were dialyzed into 10 mM sodium phosphate, pH 7.4. Measurements were made on Jasco J-170 spectopolarimeter, in a cell thermostat at 15° C. (—), acylated form; (--) cis terminal form; ( . . . ), met terminal form. A. Far UV Spectrum. B. Near UV Spectrum.
[0046] FIG. 6-C . Circular Dichroism spectrum of rSIFN-co
[0000] Spectrum range: 320 nm-250 nm
Sensitivity: 2 m°/cm
Light path: 2 cm
Equipment: Circular Dichroism J-500C
[0047] Samples: contains 0.5 mg/ml rSIFN-co, 5.9 mg/ml of NaCl and 3.8 mg/ml of Na 2 PO 4 , pH7.0.
[0048] FIG. 6-D . Circular Dichroism spectrum of rSIFN-co
[0000] Spectrum range: 250 nm-190 nm
Sensitivity: 2 m°/cm
Light path: 0.20 cm
Equipment: Circular Dichroism J-500C
[0049] Samples: contains 30 μg/ml rSIFN-co, 5.9 mg/ml of NaCl and 3.8 mg/ml of Na 2 PO 4 , pH7.0.
[0050] Clearly, as evidenced by the above spectra, the secondary or even tertiary structure of rSIFN-co is different from Infergen®.
[0051] FIG. 7 . rSIFN-co Crystal I
[0052] FIG. 8 . rSIFN-co Crystal II
[0053] FIG. 9 . The X-ray Diffraction of rSIFN-co Crystal
[0054] FIG. 10 . Comparison of Inhibition Effects of Different Interferons on HBV Gene Expression
[0055] FIG. 11A-C . Recombinant Super-Compound Interferon Spray
Height: 90 mm
[0056] Width: 25 mm (bottom), 6 mm (top)
Weight: 9 g
[0057] Volume delivery: 0.1 ml
[0058] FIG. 11D . Recombinant Super-Compound Interferon Spray
[0059] When using the spray for the first time, take off the cap and discharge in the air several times until some liquid squirts out. Do not need to test spray for subsequent uses. To use, follow the illustrations shown in the figure, i.e.: (1) Pre-spray and (2) Press down on the nozzle to release the medication.
[0060] FIG. 12 . Comparison of Anti-SARS Activity of Interferons: Left top panel is negative control i.e. no virus added. Right top panel is positive control i.e. virus is added, but no rSIFN-co added. Left bottom panel is rSIFN-co with SARS Virus. Right bottom panel is αIFN.
[0061] FIGS. 13A-1 . Curves of Changes of Body Temperature in Group A (5 patients)
[0062] This figure is the record of body temperature changes of 5 patients in Group A.
[0063] FIGS. 13A-2 . Curves of Changes of Body Temperature in Group A (5 patients)
[0064] This figure is the record of body temperature changes of the other 5 patients in Group A.
[0065] FIGS. 13B-1 . Curves of Changes of Body Temperature in Group B (5 patients)
[0066] This figure is the record of body temperature changes of 5 patients in Group B.
[0067] FIGS. 13B-2 . Curves of Changes of Body Temperature in Group B (6 patients)
[0068] This figure is the record of body temperature changes of the other 6 patients in Group B.
[0069] FIG. 14 . Graph of Inhibition of Wild-Type HIV by rSIFN-co using EXCEL and Luciferase as Y axis and concentration of rSIFN-co as X axis. A clear inverse dose-dependent response has been shown.
[0070] FIG. 15 . Graph of Inhibition of Drug Resistant HIV by rSIFN-co using EXCEL and Luciferase as Y axis and concentration of rSIFN-co as X axis. A clear inverse dose-dependent response has been shown.
[0071] FIG. 16 . rSIFN-co Inhibition of Influenza Virus: on the left, the control well is shown with Influenza virus added and without interferon, the cells had obvious CPE, such as rounding of cells, cell necroses, decrease in reflective light and sloughing off.
[0072] On the right, the experimental wells is shown containing Influenza virus and rSIFN-co at concentration 10 nanogram per milliliter (ng/ml) had morphology comparable to normal cells.
[0073] FIGS. 17A-H . Clinical Report of a patient with mammary and ovarian cancers. These figures show an obvious anti-cancer effect of rSIFN-co on this patient.
DETAILED DESCRIPTION OF THE INVENTION
[0074] Recombinant Super-Compound Interferon (rSIFN-co)
[0075] This invention provides a recombinant super-compound interferon (rSIFN-co) or an equivalent thereof with changed spatial configuration. This invention reveals that proteins with the same primary sequence might have different biological activities. As illustrated in this application, proteins with identical amino acid sequences may have different activities. The efficacy of these proteins may sometimes be improved and, sometimes, proteins with changed spatial configuration would reveal new function.
[0076] As defined herein, equivalents are molecules which are similar in function to the compound interferon. An equivalent could be a deletion, substitution, or replacement mutant of the original sequence. Alternatively, it is also the intention of this invention to cover mimics of the recombinant super-compound interferon (rSIFN-co). Mimics could be a peptide, polypeptide or a small chemical entity.
[0077] The recombinant super-compound interferon (rSIFN-co) described herein includes but is not limited to interferon α, β, γ or ω. In an embodiment, it is IFN-1α, IFN-2β or other mutants.
[0078] In another embodiment, the recombinant super-compound interferon (rSIFN-co) disclosed has higher efficacy than α, β, γ, ω or a combination thereof and as compared to the interferons disclosed in U.S. Pat. Nos. 4,695,623 and 4,897,471. This recombinant super-compound interferon (rSIFN-co) is believed to have unique secondary or tertiary structure, wherein the 3-dimensional change is the result of changes in its production process. (See e.g. FIG. 6 .)
[0079] The recombinant super-compound interferon (rSIFN-co) described herein has spatial structure change(s) resulting from the changes of its production process.
Lower Side Effects
[0080] The recombinant super-compound interferon (rSIFN-co) possesses lower side effects when compared with other interferons. These lower side effects allow for higher dosages to be used on patients in need of interferon treatments. These lower side effects open the possibility of using rSIFN-co for prevention and/or treatment of other diseases. Accordingly, this invention provides the recombinant super-compound interferon (rSIFN-co) with less side effects when administered to a subject.
[0081] This invention provides recombinant super-compound interferon (rSIFN-co) with less side effects as compared to all currently available interferons.
[0082] This invention further provides a method for treating or preventing viral diseases or tumors in a subject comprising administering to the subject an effective amount of the rSIFN-co with less side effects as compared to all currently available interferons. Therefore, high dose of rSIFN-co may be used. In an embodiment, the effective amount of recombinant super-compound interferon is in nanogram level.
[0000] Process to Produce rSIFN-co
Artificial Gene
[0083] This invention also provides artificial gene encoding for the super-compound interferon or its equivalent. It is within the ordinary skill to design an artificial gene. Many methods for generating nucleotide sequence and other molecular biology techniques have been described previously. See for example, Joseph Sambrook and David W. Russell, Molecular Cloning: A laboratory Manual, December 2000, published by Cold Spring Harbor Laboratory Press.
[0084] The recombinant super-compound interferon (rSIFN-co) may also be produced with its gene as artificially synthesized cDNA with adjustment of its sequence from the wild-type according to codon preference of E. Coli . Extensive discussion of said codon usage (preference) may be found in U.S. Pat. No. 4,695,623. See e.g. column 6, line 41—column 7, line 35.
Vector
[0085] This invention provides a vector comprising the gene which codes for the super-compound interferon or its equivalent.
[0086] This invention provides an expression system comprising the vector comprising the gene which codes for the super-compound interferon or its equivalent. The cells include, but are not limited to, prokaryotic or eukaryotic cells.
[0087] This invention also provides a host cell comprising the vector comprising the gene which codes for the recombinant super-compound interferon (rSIFN-co) or its equivalent.
[0088] This invention provides a method for producing a recombinant super-compound interferon (rSIFN-co) with changed spatial configuration and enhanced antiviral activity comprising steps of:
(a) Introducing nucleic acid molecule which codes for said interferon with preferred codons for expression to an appropriate host; and (c) Placing the introduced host in conditions allowing expression of said interferon.
[0091] This invention provides the method for producing recombinant super-compound interferon (rSIFN-co), further comprising recovery of the expressed interferon.
Expression System
[0092] The above-described recombinant super-compound interferon (rSIFN-co) may be produced by a high-efficiency expression system which uses a special promoter, enhancer or other regulatory element. In an embodiment the promoter is inducible. Said inducible promoter includes but is not limited to P BAD , heat shock promoters or heavy metal inducible promoters. Heat shock promoters are activated by physical means, while other promoters are activated by chemical means, for example IPTG or Tetracyclin. IPTG is added to the cells to activate the downstream gene or removed to inactivate the gene. Tetracyclin is used to induce promoters or to regulate the strength of promoters.
[0093] In an embodiment the promoter is P BAD . Since early nineties, the properties of the mechanism of expression and repression of P BAD by AraC have been studied extensively, and their interactions have been dissected at the molecular level. See Schleif, R. S. 1992 DNA looping. Annu. Rev. Biochem. 61:199-223. The AraC protein is both a positive and negative regulator, when present, it turns on the transcription from the P BAD promoter, when absent, the transcription occurs at a very low rate. See Guzman, L. M. et al. (1995) J. Bact. 177: 4121-4130. The efficacy and mechanism of P BAD promoter is well known by other ordinary skilled artisans and is commercially-available.
[0094] The commercially-available Invitrogen expression kit includes pBAD vectors' designed to provide precise control of expression levels. The araBAD promoter initiates gene expression. It's both positively and negatively regulated by the product of the araC gene, a transcriptional regulator that forms a complex with L-arabinose. In the absence of arabinose, the AraC dimer contacts the O2 and I1 half sites of the araBAD operon, forming a 210 bp DNA loop. For maximum transcriptional activation, two events are required: first, Arabinose binds to AraC. The protein releases the O2 site and binds the I2 site, which is adjacent to the I1 site. This releases the DNA loop and allows transcription to begin. Second, the cAMP activator protein (CAP)-cAMP complex binds to the DNA and stimulates binding of AraC to I1 and I2. Basal expression levels can be repressed by introducing glucose to the growth medium. Glucose acts by lowering cAMP levels, which in turn decreases the binding of CAP. As cAMP levels are lowered, transcriptional activation is decreased. Invitrogen's pBAD vectors are specifically designed for maximum expression and ease of use.
[0095] Nine pBAD vectors are currently available: pBAD102/D-TOPO®, pBAD202/D-TOPO®, pBAD-TOPO®, pBAD/Thio-TOPO®, pBAD/His, pBAD/Myc-His, pBAD-DEST49, pBAD/gIII and pBAD/Thio-E. with the following features in all pBAD vectors:
1. araBAD promoter for dose-dependent regulation 2. araC gene for tight control of the araBAD promoter 3. Optimized ribosome binding site for increased translation efficiency 4. rrnB transcription termination region for efficient transcript
[0100] The inducible promoters include but are not limited to heat shock promoters or heavy metal inducible promoters.
[0101] This invention provides a process for production of recombinant super-compound interferon (rSIFN-co) comprising introducing an artificial gene with selected codon preference into an appropriate host, culturing said introduced host in an appropriate condition for the expression of said compound interferon and harvesting the expressed compound interferon.
[0102] The process may comprise extraction of super recombinant super-compound interferon (rSIFN-co) from fermentation broth, collection of inclusion bodies, denaturation and renaturation of the harvested protein.
[0103] The process may maintain the high efficacy even when the recombinant super-compound interferon (rSIFN-co) is used with an agent and in a particular concentration. The process also comprises separation and purification of the recombinant super-compound interferon (rSIFN-co). The process further comprises lyophilization of the purified recombinant super-compound interferon (rSIFN-co). The process comprises production of liquid injection of recombinant super-compound interferon (rSIFN-co).
[0104] In one embodiment, recombinant super-compound interferon (rSIFN-co) was produced with recombinant techniques. On the condition of fixed amino acid sequence, the IFN DNA was redesigned according to the E. Coli . codon usage and then the rSIFN-co gene was artificially synthesized. rSIFN-co cDNA was cloned into the high-expression vector of E. Coli . by DNA recombinant techniques, and a high expression of rSIFN-co was gained by using of induce/activate-mechanism of L-arabinose to activate the transcription of P BAD promoter.
[0105] Compared with usual thermo-induction, pH induction and IPTG induction systems of genetic engineering, arabinose induction/activation system has some advantages: (1) Common systems relieve promoter function by creating a “derepression” pattern. Promoters then induce downstream gene expression. Temperature and pH change and the addition of IPTG cannot activate promoters directly. In the system disclosed herein, L-arabinose not only deactivates and represses but also activates the transcription of P BAD promoter which induces a high expression of rSIFN-co. Therefore, the arabinose induction/activation system is a more effective expression system. (2) The relationship between Exogenous and L-arabinose dosage is linear. This means the concentration of arabinose can be changed to adjust the expression level of the exogenous gene. Therefore, it is easier to control the exogenous gene expression level in E. Coli . by arabinose than by changing temperature and pH value. This characteristic is significant for the formation of inclusion bodies. (3) L-arabinose is resourceful, cheap and safe, which, on the contrary, are the disadvantages of other inducers such as IPTG.
[0106] This embodiment creates an effective and resistant rSIFN-co-expressing E. Coli . engineering strain with an L-arabinose induction/activation system. The strain is cultivated and fermented under suitable conditions to harvest the bacterial bodies. Inclusion bodies are then purified after destroying bacteria and washing repeatedly. The end result, mass of high-purity, spatial-configuration-changed rSIFN-co protein for this invention and for clinical treatment, was gained from denaturation and renaturation of inclusion bodies and a series of purification steps. Said purification would not effect the biological activity of the purified protein.
[0107] The above-described recombinant super-compound interferon (rSIFN-co) possesses anti-viral or anti-tumor activity, and; therefore, is useful in inhibiting, preventing and treating viral diseases, inhibiting or treating tumors, or cancers.
Viral Diseases
[0108] This invention provides a method for treating or preventing viral diseases or tumors in a subject comprising administering to the subject an effective amount of the recombinant super-compound interferon (rSIFN-co) or its equivalent.
[0109] As used herein, viral diseases include, but are not limited to, hepatitis A, hepatitis B, hepatitis C, other types of hepatitis, infections caused by Epstein-Barr virus, Human Immunodeficiency Virus (HIV), Ebola virus, Severe Acute Respiratory Syndrome Virus (SARS), Influenza virus, Cytomegalovirus, herpes simplex viruses, other herpes viruses, papovaviruses, poxviruses, picornaviruses, adenoviruses, rhinoviruses, human T-cell leukemia virus I, human T-cell leukemia virus II, or human T-cell leukemia virus III.
[0110] In an embodiment, the effective amount is at nanogram level. In another embodiment, the virus is Human Immunodeficiency Virus and the effective amount is as low as 4 nanograms per milliliter. In another embodiment, the virus is Influenza and the effective amount is as low as 10 nanogram per milliliter.
Inhibition of DNA Replication and Secretion of HBsAg and HBeAg of Hepatitis B Virus.
[0111] The recombinant super-compound interferon (rSIFN-co) inhibits the DNA duplication and secretion of HBsAg and HBeAg of Hepatitis B Virus.
Severe Acute Respiratory Syndrome Virus (SARS)
[0112] This invention provides a method for preventing or treating Severe Acute Respiratory Syndrome, or virus-induced upper respiratory diseases, of a subject comprising administering to the subject an effective amount of recombinant super-compound interferon (rSIFN-co) or a functional equivalent thereof. In an embodiment of the above method, the interferon is α, β, γ, ω or a combination thereof.
[0113] The recombinant super-compound interferon (rSIFN-co) may be administered orally, via vein injection, muscle injection, peritoneal injection, subcutaneous injection, nasal or mucosal administration, or by inhalation via a spray or a respirator. In an embodiment rSIFN-co is administered subcutaneously or intramuscularly at a dose of higher than or equal to 10 Million International Unit per square meter of surface area. In another embodiment rSIFN-co is administered subcutaneously or intramuscularly at a dose of higher than or equal to 20 Million International Unit per square meter of surface area. In an embodiment, the interferon is delivered by a spray device. In a specific embodiment, the device is described in FIG. 11 . In one of the embodiments, the interferon is lyophilized.
[0114] This invention provides a method for inhibiting the causative agent of Severe Acute Respiratory Syndrome, or virus-induced upper respiratory diseases, comprising contacting the agent with an effective amount of recombinant super-compound interferon (rSIFN-co) or its equivalent.
[0115] It is determined that the causative agent of SARS is a virus. See eg. Rota et al (2003), Characterization of a Novel Coronavirus Associated with Severe Acute Respiratory Syndrome. Science 1085952 and Marra, et al. (2003), The Genome Sequence of the SARS-Associated Coronavirus. Science 1085853.
[0116] This invention also provides a method for inhibiting Severe Acute Respiratory Syndrome virus or Severe Acute Respiratory Syndrome virus-infected cells, or virus-induced upper respiratory diseases, or cells infected with viruses capable of inducing upper respiratory diseases, comprising contacting an effective amount of the recombinant super-compound interferon (rSIFN-co) with said virus or cell. This contact could be direct or indirect.
[0117] This invention provides a composition comprising an effective amount of the recombinant super-compound interferon (rSIFN-co) capable of inhibiting Severe Acute Respiratory Syndrome virus or Severe Acute Respiratory Syndrome virus-infected cells, or virus-induced upper respiratory diseases, or cells infected with viruses capable of inducing upper respiratory diseases, and a suitable carrier.
[0118] This invention provides a composition comprising an effective amount of the super-compound interferon capable of preventing or treating Severe Acute Respiratory Syndrome, or virus-induced upper respiratory diseases, of a subject and a suitable carrier.
[0119] This invention provides a pharmaceutical composition comprising an effective amount of the recombinant super-compound interferon (rSIFN-co) capable of inhibiting Severe Acute Respiratory Syndrome virus or Severe Acute Respiratory Syndrome virus-infected cells, or virus-induced upper respiratory diseases, and a pharmaceutically acceptable carrier.
[0120] This invention provides a pharmaceutical composition comprising an effective amount of the recombinant super-compound interferon (rSIFN-co) capable of preventing or treating Severe Acute Respiratory Syndrome, or virus-induced upper respiratory diseases, in a subject and a pharmaceutically acceptable carrier.
[0121] This invention provides a device to deliver the above-described pharmaceutical composition.
[0122] In a preferred embodiment, the subject is a human. As it can easily be appreciated, the super-compound interferon can be used in other animals or mammals.
[0123] This invention provides a method for preventing Severe Acute Respiratory Syndrome or virus-induced upper respiratory diseases, in humans comprising application of the super-compound interferon three times a day via a spray which contains twenty micrograms of interferon, equal to ten million units of activity in three milliliter.
Viral Upper Respiratory Infection (VURI)
[0124] Viral upper respiratory infection, alternative names common cold, colds. This is a contagious viral infection of the upper respiratory tract characterized by inflammation of the mucous membranes, sneezing, and a sore throat. It is usually caused by over 200 different viruses, known as rhinoviruses. Colds are not caused by the same viruses responsible for Influenza. Colds are spread through droplets from the coughing or sneezing of others with a cold or by hand contact with objects contaminated by someone with a cold. The incidence of colds is highest among children, and the incidence decreases with age because immunity to the virus causing the cold occurs after the illness. Gradually, immunity to a wide variety of viruses that cause colds is developed in adults. Children may have 10 colds a year, and adults may have 3 colds a year.
[0125] The U.S. Centers for Disease Control and Prevention have estimated that the average annual incidence of upper respiratory tract infections (URIs) in the United States is 429 million episodes, resulting in more than $2.5 billion in direct and indirect healthcare costs. The common cold is most often caused by one of several hundred rhinoviruses (52%), but coronaviruses (8%) or the respiratory syncytial virus (7%) may also lead to infection. Other viruses, such as influenza (6%), parainfluenza, and adenoviruses, may produce respiratory symptoms, but these are often associated with pneumonia, fever, or chills.
[0126] Colds occur in a seasonal pattern that usually begins in mid-September and concludes in late April to early May. The common cold is quite contagious and can be transmitted by either person-to-person contact or airborne droplets. Upper respiratory symptoms usually begin 1 to 2 days after exposure and generally last 1 to 2 weeks, even though viral shedding and contagion can continue for 2 to 3 more weeks. Symptoms may persist with the occurrence of complications such as sinusitis or lower respiratory involvement such as bronchitis or pneumonia.
[0127] The common cold has a variety of overt symptoms, including malaise, nasal stuffiness, rhinorrhea, nonproductive cough, mild sore throat, and, in some cases, a low-grade fever. Because of the similarity of symptoms, a cold may be mistaken for perennial allergic rhinitis, but allergies can usually be ruled out because of the differences in chronicity.
[0128] If a patient presents with a viral URI, the spectrum of remedies is extensive. Since most of these infections are self-limiting, clinicians usually recommend rest and fluids, but other treatments include environmental and nutritional therapies, over-the-counter and prescription decongestant and antihistamine products, new antihistamine and anticholinergic nasal formulations, and antibiotics. Table 1 lists commonly used cough and cold medications and their side effects.
[0000]
TABLE 1
A Profile of Common Cough and Cold Medications and Their Side
Effects
Side Effects and Special
Medication
Purpose
Considerations
Aerosolized beta2
Reverse
Raises heart rate and may
agonists (eg,
postinflammatory
cause tremor
albuterol)
bronchospasm
Alcohol-based
Treat multiple
Potential drowsiness and
liquid combination
symptoms
coordination problems
products
Alpha1 agonists
Decongestion
May cause tachycardia,
(oral) (eg,
nervousness, transient
pseudoephedrine,
stimulation, dizziness,
phenyl-
drowsiness, elevation of
propanolamine)
blood pressure
Anticholinergic
Drying
May cause nasal dryness and
compounds:
occasional epistaxis
Ipratropium
bromide
(topical)
Other
Drying
May cause orthostasis,
anticholinergics
dysfunction of heat
(eg,
regulation, dry mouth,
methscopolamine,
constipation
atropine,
hyoscyamine)
Antihistamines
Drying
Drowsiness, dry mouth,
(oral) (eg,
orthostatic hypertension
chlorpheniramine,
diphenhydramine)
Benzonatate
Cough suppression,
Chewing can numb the
capsules
local anesthesia
mouth; can cause sedation,
dizziness
Codeine,
Cough suppression
Drowsiness, constipation,
hydrocodone
nausea
Dextromethorphan
Cough suppression
Drowsiness possible, but
side effects uncommon
Guaifenesin
Promote
No side effects; must be
expectoration
taken with lots of water to
(mucolysis)
improve efficacy
Topical
Decongestion
Local burning; prolonged use
decongestants (eg,
may cause dependence
oxymetazoline,
phenylephrine)
Zinc and vitamin C
Possible reduction
Possible taste disturbance,
lozenges
in symptom severity
increase of oxalate stones
and duration
if susceptible
Prevention and Treatment of Upper Respiratory Tract Infections (URI)
[0129] Nearly 70˜80% URI are caused by viruses such as respiratory Syncytical virus, adenovirus, rhinovirous, cox-sackie virus, corona virus and its variant, influenza A virus and its variant, influenza B virus and its variant, parainfluenza virus and its variant, or enterovirus and its variant. A main cause of URI in adults is from rhinovirous. For children, respiratory syncytical virus and parainfluenza virus are two leading causes of URI.
[0130] Recombinant super-compound interferon (rSIFN-co) plays an important role in the fight against virus that causes URI. Super-compound interferon gains its anti-virus affects mainly via two mechanisms:
1. Attach to surface of sensitive cells and induce them to produce anti-virus protein, then block the duplication and reproduction of viruses in vivo. 2. recombinant super-compound interferon (rSIFN-co) can adjust immune response, including T-cell immune response, activity of NK cell, the phagocytosis function of monokaryon, and even formation of some antibodies in vivo.
[0133] In treatment for URI, recombinant super-compound interferon (rSIFN-co) can be directly applied to the affected area via a spray or a respiration. This method of treatment allows the interferon to reach the target cells first hand. Consequently, marketing the supply as a spray, rather than via oral or injection, would be safer and more effective for administrating the interferon.
Prevention and Treatment of SARS
[0134] With the consent of the Sichuan (a province in China) working group on SARS prevention and control, the distribution of recombinant super-compound interferon (rSIFN-co) began in May of 2003. Super-compound interferon spray was allocated to doctors and nurses in hospitals, populated areas with a high risk for SARS, and to the National research group on prevention and control of SARS. Among the 3,000 users as of Dec. 19, 2003, there were no reports of any side effects connected to the use of the spray. Furthermore, none of the doctors and nurses, the people of Sichuan Province, or other organizations that have used the Super-compound interferon spray has been infected by SARS.
[0135] Therefore, this invention provides a method for inhibiting, preventing or treating virus replication or virus-infected cells by contacting said virus or infected cells with an effective amount of the recombinant super-compound interferon (rSIFN-co) or its equivalent.
Prevention and Treatment of Tumors
[0136] This recombinant super-compound interferon (rSIFN-co) is useful in inhibiting, preventing or treating the following cancers or tumors:
[0000]
Cancer
Skin Cancer
Basal Cell Carcinoma
Malignant Melanoma
Renal cell carcinoma
Liver Cancer
Thyroid Cancer
Rhinopharyngeal Cancer
Solid Carcinoma
Prostate Cancer
Stomach/Abdominal Cancer
Esophageal Cancer
Rectal Cancer
Pancreatic Cancer
Breast Cancer
Ovarian Cancer &
Superficial Bladder Cancer
Hemangioma
Epidermoid Carcinoma
Cervical Cancer
Non-small Cell Lung Cancer
Small Cell Lung Cancer
Glioma
Malignant
Leucocythemia
Acute Leucocythemia
Hemal
Chronic Leucocythemia
Disease
Chronic Myelocytic Leukemia
Hairy Cell Leukemia
Lymphadenoma
Multiple Myeloma
Polycythemia Vera
Others
Kaposi's Sarcoma
[0137] Accordingly, this invention provides a method for inhibiting tumor or cancer cell growth by contacting the recombinant super-compound interferon (rSIFN-co) or its equivalent with said tumor or cancer cells.
Formulation and Route of Administration
[0138] This invention also provides the produced super-compound interferon by the above processes.
[0139] This invention provides a composition comprising recombinant super-compound interferon (rSIFN-co) or its equivalent and a suitable carrier.
[0140] This invention provides a pharmaceutical composition comprising the recombinant super-compound interferon (rSIFN-co) or its equivalent and a pharmaceutically acceptable carrier.
[0141] This invention provides the above-described method wherein recombinant super-compound interferon (rSIFN-co) was administered via orally via vein injection, muscle injection, peritoneal injection, subcutaneous injection, nasal or mucosal administration, or by inhalation via a spray or a respirator.
[0142] This invention provides the above-described method wherein recombinant super-compound interferon (rSIFN-co) was administered following the protocol of injections of 9 μg, 15 μg or 24 μg every two days, 3 times a week, for 24 weeks.
[0143] It was surprising to find that recombinant super-compound interferon (rSIFN-co), the spatial structure of which has been changed, is not only a preparation to inhibit the DNA duplication of hepatitis B, but to inhibit the secretion of HBsAg and HBeAg on 2.2.15 cells.
[0144] One objective of this invention is to offer a preparation of recombinant super-compound interferon (rSIFN-co) to directly inhibit the DNA duplication of hepatitis B viruses and the secretion of HBeAg and HBsAg of hepatitis B and decrease them to normal levels.
Formulation
[0145] The following are some rSIFN-co preparations: tablets, capsules, liquids for oral consumption, pastes, injections, sprays, suppositories, and solutions. Injections are recommended. It is common to subcutaneously inject or vein-inject the medicine. The medicine carrier could be any acceptable medicine carrier, including carbohydrates, cellulosum, adhesive, collapse, emollient, filling, add-dissolving agent, amortization, preservative, thickening agent, matching, etc.
[0146] This invention also provides a pharmaceutical composition comprising the above composition and a pharmaceutically acceptable carrier.
[0147] For the purposes of this invention, “pharmaceutically acceptable carriers” means any of the standard pharmaceutical carriers. Examples of suitable carriers are well known in the art and may include, but are not limited to, any of the standard pharmaceutical carriers, such as a phosphate buffered saline solution and various wetting agents. Other carriers may include additives used in tablets, granules, capsules, etc. Typically such carriers contain excipients such as starch, milk, sugar, certain types of clay, gelatin, stearic acid or salts thereof, magnesium or calcium stearate, talc, vegetable fats or oils, gum, glycols or other known excipients. Such carriers may also include flavor and color additives or other ingredients. Compositions comprising such carriers are formulated by well-known conventional methods.
[0000] Increase of the Half-Life of rSIFN-co
Pegylation
[0148] Pegylation is the process by which polyethylene glycol chains are attached to protein and peptide drugs to increase pharmacokinetics by shielding these proteins and peptide drugs from proteolytic enzymes. See Harris and Chess, Effect of pegylation on pharmaceuticals . Nat Rev Drug Discov. 2003 March; 2(3):214-21.
[0149] Pegylations is a well-established method for increasing the circulating half-life of protein and liposomal pharmaceuticals based on large hydrodynamic volume of polyethylene glycols. These polyethylene glycols shield the proteins and peptide drugs from renal clearance, enzymatic degradation and immune system recognition, thus their half-life and making them more acceptable to patients. See Molineux, Pegylation: engineering improved pharmaceuticals for enhanced therapy . Cancer Treat Rev. 2002 April; 28 Suppl A: 13-6. The author concludes that pegylation has beneficial effect on the quality of life of cancer patients.
[0150] Pegylation of the interferon increases the amount of time the interferon remains in the body by increasing the size of the interferon molecule by decreasing the rate of absorption, prolonging the half-life and the rate of interferon clearance. Thus, the duration of biological activity is increased with pegylated interferon over nonpegylated interferon, thus providing an advantage over nonpegylated interferons with less frequent administration and comparable tolerability. The author states that monotherapy with pegylated interferon produces a better response in some patients than monotherapy with the nonpegylated formulation. See Baker, Pegylated Interferons. Rev Gastroenterol Disord. 2001; 1(2):87-99.
Sustained Release or Controlled Release
[0151] Sustained release delivery matrices and liposomes maybe used with rSIFN-co to create sustained release and controlled release formulation. See Robinson and Talmadge, Sustained Release of Growth Factors . In Vivo 2002 November-December; 16(6): 535-40. The authors state that both pegylation and sustained release delivery matrices and liposomes improve the pharmacokinetic and pharmacodynamic properties of recombinant molecules, and thus by improving clinical efficacy these approaches increase patient compliance.
[0152] This invention provides recombinant super-compound interferon (rSIFN-co) comprising an agent or encapsulated by an agent, capable of affecting the half-life or delivery of said interferon. In an embodiment this agent is polyethylene glycol (PEG).
[0153] This invention further provides a method for treating or preventing viral diseases or tumors in a subject comprising administering to the subject an effective amount of the recombinant super-compound interferon (rSIFN-co) or its equivalent comprising an agent or encapsulated by an agent, capable of affecting the half-life or delivery of said interferon. In an embodiment this agent is polyethylene glycol (PEG).
[0154] This invention will be better understood from the examples which follow. However, one skilled in the art will readily appreciate that the specific methods and results discussed are merely illustrative of the invention as described more fully in the claims which follow thereafter.
EXPERIMENTAL DETAILS
[0155] IFN-con is a new interferon molecule constructed according to conservative amino acids in human IFN-α subtype using genetic engineering methods. It has been proven that IFN-con has broad-spectrum IFN activity, such as high antivirus and tumor inhibition activity, especially for effectively treating hepatitis C.
[0156] E. Coli . codon was used to redesign rSIFN-co cDNA and then artificially synthesize cDNA of rSIFN-co from published Infergen® (interferon alfacon-1) DNA sequences and deduced amino acid sequences ( FIG. 1 ).
[0157] In order to get pure rSIFN-co protein, rSIFN-co cDNA was cloned into E. Coli . high-expression vector, and L-arabinose, which can activate strong P BAD promoter in vectors, was used to induce high expression of rSlFN-co gene.
Example 1
Synthesis of E. Coli . cDNA Sequence
[0158] Redesign of rSIFN-co cDNA Sequence
[0159] rSIFN-co cDNA was redesigned according to the codon usage of E. Coli . to achieve high expression in E. Coli . Deduced amino acid sequence from the redesigned cDNA sequence of rSIFN-co is completely coincidental with primitive amino acid sequence of published Infergen® (interferon alfacon-1) ( FIG. 1 ).
[0000] rSIFN-co cDNA Sequence Synthesis
rSIFN-co cDNA 5′-Terminus and 3′-Terminus Semi-Molecular Synthesis
[0160] Two semi-moleculars can be directly synthesized: rSIFN-co cDNA 5′-terminus 280 bp (fragment I) and 3′-terminus 268 bp (fragment II) by PCR. There are 41 bp overlapping among fragment II and fragment I.
(1) Chemical Synthesis Oligodeoxynucleotide Fragment:
[0161]
[0000]
Oligomer A:
(SEQ ID NO: 10)
5′ATGTGCGACCTGCCGCAGACCCACTCCCTGGGTAACCGTCGTGCTCTGATCCTGCTGGCTCA
GATGCGTCGTATCTCCCCGTTCTCCTGCCTGAAAGACCGTCACGAC3′
Oligomer B:
(SEQ ID NO: 11)
5′CTGAAAGACCGTCACGACTTCGGTTTCCCGCAGGAAGAATTCGACGGTAACCAGTTCCAGAAAGCT
CAGGCTATCTCCGTTCTGCACGAAATGATCCAGCAGACCTTC3′
Oligomer C:
(SEQ ID NO: 12)
5′GCTGCTGGTACAGTTCGGTGTAGAATTTTTCCAGCAGGGATTCGTCCCAAGCAGCGGAGGAG
TCTTTGGTGGAGAACAGGTTGAAGGTCTGCTGGATCATTTC3′
Oligomer D:
(SEQ ID NO: 13)
5′ATCCCTGCTGGAAAAATTCTACACCGAACTGTACCAGCAGCTGAACGACCTGGAAGCTTGCG
TTATCCAGGAAGTTGGTGTTGAAGAAACCCCGCTGATGAAC3′
Oligomer E:
(SEQ ID NO: 14)
5′GAAGAAACCCCGCTGATGAACGTTGACTCCATCCTGGCTGTTAAAAAATACTTCCAGCGTAT
CACCCTGTACCTGACCGAAAAAAAATACTCCCCGTGCGCTTGGG3′
Oligomer F:
(SEQ ID NO: 15)
5′TTATTCTTTACGACGCAGACGTTCCTGCAGGTTGGTGGACAGGGAGAAGGAACGCATGATTT
CAGCACGAACAACTTCCCAAGCGCACGGGGAGTATTTTTTTTCGGTCAGG3′
[0162] PCR I for Fragment I: oligodeoxynucleotide B as template, oligodeoxynucleotide A and C as primers, synthesized 280 bp Fragment I.
[0000]
PCR I mixture (units: μl)
sterilized distilled water
39
10xPfu buffer (Stratagen American Ltd.)
5
dNTP mixture (dNTP concentration 2.5 mmol/L)
2
Oligomer A primer (25 μmol/L)
1
Oligomer C primer (25 μmol/L)
1
Oligomer B template (1 μmol/L)
1
Pfu DNA polymerase (Stratagen American Ltd.) (25 U/μl)
1
Total volume
50
μl
PCR Cycle:
95° C.2m→(95° C.45s→65° C.1m→72° C.1m)×25 cycle→72° C.10m→4° C.
PCR II for Fragment II: oligodeoxynucleotide E as template, oligodeoxynucleotide D and F as primers, synthesized 268 bp Fragment II.
[0000]
PCR II mixture (units: μl)
sterilized distilled water
39
10xPfu buffer (Stratagen American Ltd.)
5
dNTP mixture (dNTP concentration 2.5 mmol/L)
2
Oligomer D primer (25 μmol/L)
1
Oligomer F primer (25 μmol/L)
1
Oligomer E template (1 μmol/L)
1
Pfu DNA polymerase (Stratagen American Ltd.) (25 U/μl)
1
Total volume
50
μl
PCR cycle: the same as PCR I
Assembling of rSIFN-co cDNA
[0167] Fragment I and II were assembled together to get the complete cDNA molecular sequence of rSIFN-co using the overlapping and extending PCR method. Restriction enzyme Nde I and Pst I were introduced to clone rSIFN-co cDNA sequence into plasmid.
[0168] (1) Chemical Synthesis Primers
[0000]
Oligomer G:
(SEQ ID NO: 16)
5′ATCGGCCATATGTGCGACCTGCCGCAGACCC3′
Oligomer H:
(SEQ ID NO: 17)
5′ACTGCCAGGCTGCAGTTATTCTTTACGACGCAGACGTTCC3′
[0169] (2) Overlapping and Extending PCR
[0000]
PCR mixture (units: μl)
sterilized distilled water
38
10xPfu buffer (Stratagen American Ltd.)
5
dNTP mixture (dNTP concentration 2.5 mmol/L)
2
primer G (25 μmol/L)
1
primer H (25 μmol/L)
1
*fragment I preduction (1 μmol/L)
1
*fragment II preduction (1 μmol/L)
1
Pfu DNA polymerase (Stratagen American Ltd.) (2.5 U/μl)
1
Total volume
50μ
*Separate and purify PCR production with StrataPrep PCR purification kit produced by Stratagen American Ltd. And dissolve into sterilized distilled water.
PCR cycle: the same as PCR I
rSIFN-co Gene Clone and Sequence Analysis
[0171] pLac T7 plasmid as cloning vector. pLac T7 plasmid is reconstructed with pBluescript II KS(+) plasmid produced by Stratagen ( FIG. 3 ).
[0172] Purified PCR production of rSIFN-co cDNA with StrataPrep PCR purification kit. Digest cDNA and pLac T7 plasmid with NdeI and PstI. Run 1% agarose gel electrophoresis and separate these double-digested DNA fragments. Recover 507 bp long rSIFN-co DNA fragment and 2.9 kb plasmid DNA fragment. Ligate these fragments by T4 DNA ligase to form a recombinant plasmid. Transform DH 5α competent cells (Gibco) with the recombinant plasmid, culture at 37° C. overnight. Identify the positive recombinant colony, named pHY-1.
[0173] Run DNA sequencing with SequiTherm™ Cycle Sequencing Kit produced by American Epicentre Technologies Ltd using L1-COR Model 4000L. Primers are T7 and T3 common sequence primer, the DNA sequencing result matches theoretic design.
[0174] Purify the rSIFN-co, sequence the N-terminus amino acids, the N-terminus amino acid sequence matches experimental design which is as follows: N-Cys-Asp-Leu-Pro-Gln-Thr-His-Ser-Leu-Gly-Asn-Arg-Arg-Ala-Leu-
Construction, Transformation, Identification, and Hereditary Stability of Expression Vector
Construction and Transformation of Expression Vector
[0175] Digested E. Coli . expression vector pHY-4 (see FIG. 3 ) with Nde I to linearize and subsequently digest with Xba I. Run 1% agarose gel electrophoresis, and purify the 4.8 kb pHY-4 Nde I-Xba I digest fragment with QIAEX II kit produced by QIAGEN Germany Ltd.
[0176] At the same time, the pHY-4 plasmid is double digested with Nde I-Xba I. Run 1% agarose gel electrophoresis and purify the 715 bp fragment. Ligate the rSIFN-co and pHY-4 fragments with T4 DNA ligase to construct the recombinant plasmid (See FIG. 4 ). Transform DH 5α competent cells with the recombinant plasmid. Spread the transformed cells on LB plate with Amp, 37° C. culture overnight.
Positive Cloning Strain Screening
[0177] Randomly choose E. Coli . colonies from above LB-plate, screening the positive strains containing recombinant vector by endonuclease digesting and PCR analysis. Name one of the positive recombinant plasmid pHY-5, and name the strain containing pHY-5 plasmid PVIII. Amplify and store the positive strain with glycerol in −80° C.
[0000] High Expression of rSIFN-co gene in E. Coli . In pHY-5 plasmid, rSIFN-co gene is under the control of strong promoter P BAD . This promoter is positively and negatively regulated by the product of the gene araC. AraC is a transcriptional regulator that forms a complex with arabinose. In the absence of arabinose, the AraC dimer binds O 2 and I 1 , forming a 210 bp loop. This conformation leads to a complete inhibition of transcription. In the presence of arabinose, the dimer is released from O 2 and binds I 1 and I 2 leading to transcription. Arabinose binding deactivates, represses, and even activates the transcription of P BAD promoter, which stimulates P BAD , inducing high expression of rSIFN-co. rSIFN-co expression level in PVIII is more than 50% of the total E. Coli . protein.
Summary
[0178] rSIFN-CO is a new interferon molecule artificially built according to the conservative amino acid of human a interferons. It has been proven as an effective anti-hepatitis drug. In order to get enough pure rSIFN-co protein, a stable recombinant E. Coli . strain which highly expresses rSIFN-co protein was constructed.
[0179] First, according to published Infergen® (interferon alfacon-1) amino acid sequence, E. Coli . codon was used to synthesize the whole cDNA of rSIFN-co. This DNA fragment was sequenced, proving that the 501 bp codon sequence and TAA termination codon sequence are valid and identical to theocratic design. Subsequent analysis revealed that the N-terminus amino acid sequence and amino acid composed of rSIFN-co produced by the recombinant strain were both identical to the prediction.
[0180] The rSIFN-co cDNA was cloned into E. Coli . high-expression vector pHY-4 plasmid to construct the recombinant plasmid pHY-5 . E. Coli . LMG194 strain was further transformed with pHY-4 plasmid to get stable rSIFN-co high-expression transformant. This transformant was cultured for 30 generations. The heredity of pHY-5 recombinant plasmid in E. Coli . LMG194 was normal and stable, and the expression of rSIFN-co was high and steady.
[0181] E. Coli . LMG194, which contains recombinant pHY-5 plasmid, is actually an ideal high-expression engineering strain.
REFERENCES
[0000]
1. Blatt L M, Davis J M, Klein S B. et al. The biologic activity and molecular characterization of a novel synthetic interferon-alpha species, consensus interferon. Journal of Interferon and Cytokine Research, 1996; 16(7):489-499.
2. Alton, K. et al: Production characterization and biological effects of recombinant DNA derived human IFN-α and IFN-γ analogs. In: De Maeger E, Schellekens H. eds. The Biology of Interferon System. 2nd ed. Amsterdam: Elsevier Science Publishers, 1983: 119-128
3. Pfeffer L M. Biologic activity of natural and synthetic type 1 interferons. Seminars in Oncology, 1997; 24 (3 suppl 9):S9-63—S9-69.
4. Ozes O N, Reiter Z, Klein S, et al. A comparison of interferon-con1 with natural recombinant interferons-α antiviral, antiproliferative, and natural killer-inducing activities. J. Interferon Res., 1992; 12:55-59.
5. Heathcote E J L, Keeffe E B, Lee S S, et al. Re-treatment of chronic hepatitis C with consensus interferon. Hepatology, 1998; 27(4):1136-1143.
6. Klein M L, Bartley T D, Lai P H, et al. Structural characterization of recombinant consensus interferon-alpha. Journal of Chromatography, 1988; 454:205-215.
7. The Wisconsin Package, by Genetics Computer Group, Inc. Copyright 1992, Medison, Wis., USA
8. Nishimura, A et al: A rapid and highly efficient method for preparation of competent E. coli cells. Nuclei. Acids Res. 1990, 18:6169
9. All molecular cloning techniques used are from: Sambrook, J., E. F. Fritsch and T. Maniatis. Molecular Cloning: A laboratory manual, 2nd ed. CSH Laboratory Press, Cold Spring Harbour, N.Y. 1989.
10. Guzman, L. M et al: Tight regulation, modulation, and high-level express-ion by vectors containing the arabinose P BAD promoter. J. Bacteriol. 1995, 177: 4121-4130.
rSIFN-co cDNA Sequence Designed According to E. coli . Codon Usage and deduced rSIFN-co amino acid sequence
[0000]
5′ 11 21 31 41 51
+1
M C D L P Q T H S L G N R R A L I L L A
1
ATGTGCGACC TGCCGCAGAC CCACTCCCTG GGTAACCGTC GTGCTCTGAT CCTGCTGGCT
TACACGCTGG ACGGCGTCTG GGTGAGGGAC CCATTGGCAG CACGAGACTA GGACGACCGA
5′ 71 81 91 101 111
+1
Q M R R I S P F S C L K D R H D F G F P
61
CAGATGCGTC GTATCTCCCC GTTCTCCTGC CTGAAAGACC GTCACGACTT CGGTTTCCCG
GTCTACGCAG CATAGAGGGG CAAGAGGACG GACTTTCTGG CAGTGCTGAA GCCAAAGGGC
5′ 131 141 151 161 171
+1
Q E E F D G N Q F Q K A Q A I S V L H E
121
CAGGAAGAAT TCGACGGTAA CCAGTTCCAG AAAGCTCAGG CTATCTCCGT TCTGCACGAA
GTCCTTCTTA AGCTGCCATT GGTCAAGGTC TTTCGAGTCC GATAGAGGCA AGACGTGCTT
5′ 191 201 211 221 231
+1
M I Q Q T F N L F S T K D S S A A W D E
181
ATGATCCAGC AGACCTTCAA CCTGTTCTCC ACCAAAGACT CCTCCGCTGC TTGGGACGAA
TACTAGGTCG TCTGGAAGTT GGACAAGAGG TGGTTTCTGA GGAGGCGACG AACCCTGCTT
5′ 251 261 271 281 291
+1
S L L E K F Y T E L Y Q Q L N D L E A C
241
TCCCTGCTGG AAAAATTCTA CACCGAACTG TACCAGCAGC TGAACGACCT GGAAGCTTGC
AGGGACGACC TTTTTAAGAT GTGGCTTGAC ATGGTCGTCG ACTTGCTGGA CCTTCGAACG
5′ 311 321 331 341 351
+1
V I Q E V G V E E T P L M N V D S I L A
301
GTTATCCAGG AAGTTGGTGT TGAAGAAACC CCGCTGATGA ACGTTGACTC CATCCTGGCT
CAATAGGTCC TTCAACCACA ACTTCTTTGG GGCGACTACT TGCAACTGAG GTAGGACCGA
5′ 371 381 391 401 411
+1
V K K Y F Q R I T L Y L T E K K Y S P C
361
GTTAAAAAAT ACTTCCAGCG TATCACCCTG TACCTGACCG AAAAAAAATA CTCCCCGTGC
CAATTTTTTA TGAAGGTCGC ATAGTGGGAC ATGGACTGGC TTTTTTTTAT GAGGGGCACG
5′ 431 441 451 461 471
+1
A W E V V R A E I M R S F S L S I N L Q
421
GCTTGGGAAG TTGTTCGTGC TGAAATCATG CGTTCCTTCT CCCTGTCCAC CAACCTGCAG
CGAACCCTTC AACAAGCACG ACTTTAGTAC GCAAGGAAGA GGGACAGGTG GTTGGACGTC
5′ 491 501
+1
E R L R R K E # (SEQ ID NO: 1)
481
GAACGTCTGC GTCGTAAAGA ATAA (SEQ ID NO: 2)
CTTGCAGACG CAGCATTTCT TATT (SEQ ID NO: 3)
Example 2
Separation and Purification of rSIFN-co
1. Fermentation
[0192] Inoculate the recombinant strain in LB media, shaking (200 rpm) under 37° C. overnight (approximate 18 h), then add 30% glycerol to the fermentation broth to get final concentration of 15%, allotted to 1 ml tube and kept in −20° C. as seed for production.
[0193] Add 1% of the seed to LB media, shaking (200 rpm) under 37° C. overnight to enlarge the scale of the seed, then add to RM media with a ratio of 10%, culturing under 37° C. Add arabinose (20% solution) to 0.02% as an inductor when the OD 600 reaches about 2.0. 4 hours after that, stop the culture process, collect the bacteria by centrifuge, resuspend the pellet with buffer A, and keep in −20° C. overnight. Thaw and break the bacteria by homogenizer, then centrifuge. Wash the pellet with buffer B, buffer C, and distilled water to get a relatively pure inclusion bodies.
2. Denaturation and Renaturation
[0194] Dissolve the inclusion body in Guanidine-HCl (or urea) of 6 mol/L. The solution will be a little cloudy. Centrifuge it at a speed of 10000 rpm. Determine the protein concentration of the supernatant. This supernatant is called “denaturation solution.” Add the denaturation solution to renaturation buffer, and keep the final protein concentration under 0.3 mg/ml. It is better to add the totally denatured solution in three steps instead of one step. Keep the solution overnight under 4° C. Afterwards, dialyze 10 mol/L, 5 mol/L PB buffer and distilled water, then adjust its pH by 2 mol/L HAc-NaAc. Let it stand, then filtrate.
3. Purification
[0000]
POROS HS/M anion exchange chromatography:
[0000]
[0196] Condense the eluted solution by POROS HS/M. Sometimes a purification by sephacryl S-100 step can be added to meet stricter purity requirements.
Note:
[0000]
Buffer A: 100 mmol/L Tris-HCl, pH 7.5-10 mmol/L EDTA-100 mmol/L NaCl
Buffer B: 50 mmol/L Tris-HCl, pH 7.5-1 mol/L Urea-10 mmol/L EDTA-0.5% Triton X-100
Buffer C: 50 mmol/L Tris-HCl, pH 7.5-2 mol/L Urea-10 mmol/L EDTA-0.5% Triton X-100
Buffer D: 1 mol/L NaCl- - -50 mmol/L Na 2 HPO 4 (pH 5.5)
Buffer E: 1 mol/L NaCl- - -50 mmol/L Na 2 HPO 4 (pH 5.0)
Buffer F: 1 mol/L NaCl- - -50 mmol/L Na 2 HPO 4 (pH 4.0)
Buffer G: 1 mol/L NaCl- - -50 mmol/L Na 2 HPO 4 (pH 3.6)
Renaturation buffer: 0.5 mol/L Arginine—150 mmol/L Tris-HCl, pH 7.5-0.2 mmol/L EDTA
LB Media: 1 L
[0205]
[0000]
Tryptone
10 g
Yeast extracts
5 g
NaCl
10 g
RM Media: 1 L
[0206]
[0000]
Casein
20 g
MgCl
1 mmol/L (0.203 g)
Na 2 HPO 4
4 g;
KH 2 PO 4
3 g,
NaCl
0.5 g
NH 4 Cl
1 g
[0207] After purification, the buffer was changed to PBS (pH 7.0) along with the step of condensing by POROS HS/M. This is called the “Protein Stock Solution.” It can be directly used in the preparation of injections or sprays, or stored at 2-8° C.
Formula for Injection:
[0208]
[0000]
Solution
Lyophilized powder
Solution of rSIFN-co
34.5 μg/ml
34.5 μg/ml
PB (pH7.0)
25 mmol/L
10 mmol/L
Glycine
—
0.4 mol/L
NaCl
0.1 mol/L
—
For Spray:
[0209]
[0000]
EDTA
0.01%
Tween 80
0.05%
Trisodium citrate
10 mmol/L
Glycerol
1.26%
Sodium Chloride
0.03%
Phenylmethanol
0.5%
HSA
0.1%
rSIFN-co
10 μg/ml
Quality Control Process
[0210] During purification, tests for protein content, protein purity, specific activity and pyrogen are conducted after each step. When the stock solution is obtained, all the tests listed in the table are done one after the other.
[0211] The quality of the product is controlled according to “Chinese Requirements for Biologics.”
1. Original Protein Solution
[0212]
[0000]
Item of Test
Method
Protein Stock Solution:
Test for Protein Content
Lowry
Test for Protein Purity
Non-reductive SDS-PAGE
(sodium dodecyl sulfate
polyacrylamide gel
electrophoresis)
HPLC Analysis
Test for Molecular Weights
Reductive SDS-PAGE
Test for Specific Activity
According to Method in
“Specific Activity Test of
Interferon
Test for Leftover Exogenetic
Using DNA Labeling and
DNA
Detection Kit
Test for Activity of
According to Method in
Leftover Antibiotics
“Chemical and Other Test
Methods for Biologics”
Test for Bacterial Endotoxin
According to Method in
“Requirements for Bacterial
Endotoxin Test of Biologics”
Test for Isoelectronic Point
Isoelectric Focusing
Electrophoresis
Test for Identify
UV spectrum (range of
Characteristics of the
wavelength: 190-380 nm)
Protein
Peptide Mapping (hydrolyzed
by pancreatic enzyme,
analyzed by C-18 column)
N-terminal Sequence Test
C-terminal Sequence Test
Circular Dichroism
Amino Acid Analysis
Semi-finished Product
Test for Bacterial Endotoxin
According to Method in
“Requirements for Bacterial
Endotoxin Test of Biologics”
Product
Appearance Check
Chemical
According to Method in
“Chemical and Other Test
Methods for Biologics”
Test for Specific Activity
According to Method in
“Specific Activity Test of
Interferon
Sterility Test
According to Method in “c”
Abnormal Toxicity Test
Test on Mouse
Pyrogen Test
According to Method in
“Requirements for Pyrogen
Test of Biologics”
Test for Stability of
Product
Note:
“Chemical and Other Test Methods for Biologics”, “Requirements for Pyrogen Test of Biologics” and “Requirements for Bacterial Endotoxin Test of Biologics” all can be found in the “Chinese Requirements for Biologics.” “Chinese Requirements for Biologics,” PAN Zhengan, ZHANG Xinhui, DUAN Zhibing, et al. Chinese Biologics Standardization committee. Published by Chemical Industry Publishing Company, 2000.
Example 3
Stability of Lyophilized Powder of Recombinant Super-Compound Interferon Injection
[0213] The stability experiments were carried out with samples of lyophilized powder of recombinant super-compound interferon (rSIFN-co) injection in two specifications and three batches. The experiments started in April 2000.
1. Sample Source
[0214] Samples were supplied by Sichuan Huiyang Life-engineering Ltd., Sichuan Province. Lot: 990101-03, 990101-05, 990102-03, 990102-05, 990103-03, 990103-05
2. Sample Specifications
[0215] Every sample in this experiment should conform with the requirements in the table below.
[0000]
TABLE 1
Standard of Samples in Experiment
Items
Standards
1. Appearance
white loose powder
2. Dissolving time
dissolve rapidly in injection water (within
2 min) at room temperature
3. Clarity
colorless liquid or with little milk-like
glisten; should not be cloudy, impurity or
with indiscernible deposit
4. pH value
6.5~7.5
5. Potency (IU/dose)
80%~150% of indicated quantity (9 μg:
4.5 × 10 6 IU, 15 μg: 7.5 × 10 6 IU)
6. Moisture
no more than 3.0% ( W/W)
3. Experimental Content
[0216] Test samples at 2˜8° C.: The test samples were put into a 2˜8° C. refrigerator, then the above items of these samples were respectively tested in the 1 st , 3 rd , 6 th , 9 th , 12 th , 18 th , 24 th , 30 th , 36 th month. The results were recorded.
[0217] Test samples at 25° C.: The test samples were put into a thermostat at 25° C., then the above items of these samples were respectively tested in the 1 st , 3 rd , 6 th , 9 th , 12 th , 18 th , 24 th , 30 th month. The results were recorded.
[0218] Test samples at 37° C.: The test samples were put into a thermostat at 37° C., then the above items of these samples were respectively tested in the 1 st , 3 rd , 6 th , 9 th , 12 th , 18 th , 24 th month. The results were recorded.
4. Results and Conclusion
[0000]
1) At 37° C., according to data collected at designated points during testing and compared with data before testing, the potency began descending from the 6 th month and the changes in the three batches were similar. The appearance of other items had no changes.
2) At 25° C., according to data collected at designated points during testing and compared with data before the testing, the potency only had a little change, and the changes in the three batches were similar. The appearance of other items had no changes.
3) At 2-8° C., according to data collected at designated points during testing and compared with data before testing, the potency of the three batches all were stable. The appearance of other items also had no changes.
In conclusion, it is suggested that the lyophilized powder of recombinant super-compound interferon for injection should be better stored and transported at low temperatures. Without such conditions, the product can also be stored for short periods (i.e., 3 months) at room temperature.
Example 3.5
Production Flow Chart of rSIFN-co
1. Production
[0223] 1.1 Fermentation
Use mixture of LB+M9 as culturing medium. The amount of innoculum will be 1.5%. Agitate to OD 600 =0.4 (about 3.5 hours) under 32° C., then raise temperature to 42° C. Continue the agitation for another 6 hours, the expression of rSIFN-co will reach the maximum level. The examination under scanning of the gel resulting from SDS-PAGE shows that the level of expression is up to 57%, which is the highest standard in China.
[0225] 1.2 Purification
[0000]
[0226] The purity of the product (rSIFN-co) from this production procedure is shown to 95% under the test of SDS-PAGE where molecular weight is 14.5 Kda. The reverse phase HPLC shows a single peak and the purity is up to 97%. Its specific activity is up to 1×10 9 IU/mg protein.
[0227] 1.3 Packaging and Inspection
After HPLC purification, 2% human serum albumin, 1% sucrose and 1% glucose are added to the rSIFN-co. It is then separated and lyophilized into injection sample. When tested under the Wish-VVS inspection system, the result was 4.5×10 8 IU. When tested with aseptic inspection and pyrogen inspection under the standard requirement of China, the results were negative. This result complies with the requirements for IV injection.
2. Quality Control
[0229] 2.1 Biological Characteristics
(1) When using LB+M9 to cultivate bacteria, the characteristics should match with the typical characteristics of E-coli bacteria. No other bacteria were detected. (2) When smeared for Gram staining and inspected under a microscope, it is bacteria-negative. (3) Reaction to antibiotics is the same as those original bacteria. (4) Electron microscope inspection shows typical characteristics of E-coli bacteria. No mycoplasma, virus spore or other micro pollutes was detected. (5) Biochemical reaction test shows characteristics of E-coli bacteria.
[0235] 2.2 Quality Control of Interferon Expression
(1) Interferon expression (cultivated in an agitating platform) matches the amount of expression in original input bacteria. (2) When tested with anti-interferon serum, a reaction is shown. (3) Plasmid inspection: Restriction digest matched with the original plasmid.
[0239] 2.3 Bacteria Strain Product
Bacteria strain product denotes the specimen from the original bacteria strain that was produced from the procedures shown in 1.2. The bacteria strain product should be inspected as follows to make sure there is no derivation: Use LB to plate 2-3 pieces and cultivate. Separate and take 5-10 bacteria groups for the test of interferon expression. Repeat the test at least two (2) times. Only use the one which shows the highest % to be the bacteria strain product.
[0242] 2.4 Inoculum
The inoculum denotes the chosen bacteria strain product after fermentation. The amount, cultivation time and most appropriate OD value of inoculum can be decided according to bacteria strain. An anti-polluted bacteria procedure should apply for whatever inoculum would be produced.
[0244] 2.5 Growing of Bacteria Strain
Growing of bacteria strain would be done in a Bacteria Free room environment where no more than one bacterium is growing in the same room. Same culturing medium will be used for both bacteria strain and inoculum. The one used in rSIFN-co is LB.
[0246] 2.6 Fermentation
(1) Fermentation only takes place in a clean fermentation room with a single bacteria fermentation environment. (2) Cleaning of fermentation container and tube is done twice, before and after the insertion of culturing medium. Then, the container should be frozen to reach the appropriate temperature for inoculum. (3) Avoid using antibiotic which might affect cell growth in the culturing medium. (4) Fermentation parameters like temperature, pH value, dissolved oxygen and time required could be varied according to different types of bacterial strains.
[0251] 2.7 Bacteria Collection
(1) Centrifuge the bacteria solution to collect bacteria or use another method. All apparatus should be cleaned before and after the operation. The waste solution should be drained after the cleaning procedure. (2) The bacteria should be kept under 4-8° C. if they are going to be split within 24 hours. Otherwise, they should be kept under −30° C. Those are kept under such conditions can be used within 6 months.
[0254] 2.8 Bacteria Cell Lysis
(1) Use appropriate buffer solution to balance the bacteria strain. Cell lysis can be done by physical, chemical or biological methods. Use centrifuge to precipitate the bacteria and apply cleaning solutions. (2) If the chemical method is used to split cells, no solutions harmful to human beings should be used.
[0257] 2.9 Purification
(1) Purification will get rid of most of the non-interferon contents. In the process of purification, no toxic materials should be found if extra elements are added. (2) If using antibody affinity chromatography for purification, there should be an indication of the source and degree of purity. Also, inspection of small quality IgG should be performed. (3) During the process of purification, clearance of pyrogen is critical. All apparatus should be checked to eliminate this interference. (4) The highly concentrated interferon is known as “intermediate product”. After inspection and tests, add albumin to raise the concentration to 2% which is now known as “albumin intermediate product”. After examination and tests, it should be kept at −30° C. and never thawed before use. This product should be used within 6 months. (5) The albumin that is used in this process should also fulfill tests and requirements such as: negativity under RBSAG inspection and an indication of the ratio among monomer, dimer and polymer.
[0263] 2.10 Production into Tube Product
(1) Filtration: Use 0.22μ membrane to filter the bacteria. The product should be handled with aseptic techniques. Samples should be taken to test the value of the interferon. (2) Dilution: Dilute the albumin intermediate product with 2% diluent. No preservative should be added. The product can be lyophilized after the aseptic inspection and pyrogen inspection.
[0266] 2.11 Lyophilization
The lyophilization should not affect the activity of interferon, and the water content of said lyophilite will be maintained.
[0268] 2.12 Inspection
There are two types of rSIFN-co made. One is for injection and the other for topical use. The specifications for the two are different. There are intermediate products and final products for each type. In the injection type, intermediate products include purified interferon, albumin intermediate product, and bacteria free albumin intermediate product. Final product from the injection type will denote only lyophilized product. The intermediate product in the topical type denotes only purified interferon. The final product from the topical type denotes only separated packed liquid formed lyophilized products.
[0270] 2.13 Packaging
There is different packaging for the injection type and the topical type.
[0272] 2.14 Storage
The product should be kept at 4° C. The purification solution should not be stored in a frozen state.
[0274] 2.15 Expiration
The expiration period is two (2) years after the lyophilization procedure for lyophilized products. The expiration period is 6 months after individual packing for liquidated products.
Example 4
Preparation of rSIFN-co
[0276]
[0000]
Preparation of lyophilized injection
Lyophilized powder
Stock Solution of
34.5
μg/ml
rSIFN-co
PB (pH7.0)
10
mmol/L
Glycine
0.4
mol/L
[0277] Preparation technique: Weigh materials according to recipe. Dissolve with sterile and pyrogen-free water. Filter through 0.22 μm membrane to de-bacterialize, preserve at 6-10° C. Fill in vials after affirming they are sterile and pyrogen-free, 0.3 ml/vial or 0.5 ml/vial, and lyophilize in freeze dryer.
[0000]
Preparation of liquid injection
Solution
Stock Solution of
34.5
μg/ml
rSIFN-co
PB (pH7.0)
25
mmol/L
NaCl
0.1
mol/L
[0278] Preparation: Weigh materials according to recipe. Add to desired level with sterile and pyrogen-free water. Filter through 0.22 μm membrane to de-bacterialize, preserve at 6-10° C. Fill in airtight vial after affirming it is sterile and non-pyrogen at 0.3 ml/vial or 0.5 ml/vial. Store at 2-10° C., and protect from light.
Example 4.5
Acute Toxicity of rSIFN-co
[0279] Treat mice with large dose (150 μg/kg, equal to 1000 times of the normal dose per kilo used in treatment of adult patients) of rSIFN-co at one time by intramuscular injection. Then observe and record their deaths and toxic reactions. Results show that: 24 hours after injection, no abnormal reaction had been recorded. The organs of the animals which had been selected to be killed also had no signs of abnormal changes. Those remaining mice were all kept alive and were normal after two weeks. The weights of mice in the experimental group and control group all increased, and the ratio of increase showed no obvious difference between the two groups (P>0.05) according to their weights on the fourteenth day. No abnormal changes were seen from the main organs of those mice after two weeks.
1. Experimental Material
1.1 Animals
[0280] 40 healthy adult mice, weighing 18-22 g, half male and half female, qualified by Sichuan experiment animal control center.
1.2 Medicines
[0281] rSIFN-co (Provided by Sichuan Huiyang Life-engineering Ltd.) sterilized solution, 0.15 mg/ml, Lot: 981201
[0282] rSIFN-co was administered i.m. in saline.
2. Method
[0283] Separate the 40 mice into two groups randomly, one for experimental medicine, another for control. Inject medicines or saline at the same ratio (0.1 ml/10 g) through muscle to each mouse according to which group they belong. (150 μg/kg of rSIFN-co for experimental group; and saline for control group). After injection, observe and record acute toxicity shown in mice. Kill half of the mice (male and female each half) to check whether there were any abnormal pathologic changes in their main organs, such as heart, spleen, liver, lung, kidney, adrenal gland, stomach, duodenum, etc. after 24 hours. Those that remain are kept and observed until the fourteenth day. Weigh all mice, kill them, and then observe the appearance of the organs listed above to see if there are any abnormalities. Take pathological tissue and examine it, using the examination to assess the difference in weight increases in the two groups.
3. Results
[0284] Results show that there was no acute toxicity seen after all mice were treated with i.m. rSIFN-co with 150 μg/kg at a time, equal to 1000 times the normal dose per kilo used in treatment of adult patients. In the 14 days after injection, all mice lived well. They ate, drank, exercised, and excreted normally and showed normal hair conditions. None of them died. The observation of the main organs of the randomly selected mice shows no abnormal changes 24 hours after injection. 14 days after injection, all remaining mice were killed. Autopsies also showed no changes. The weights of mice in the two groups all increased, but no obvious difference was shown when accessed with statistic method (p>0.05). See Table 6.1:
[0000]
TABLE 6.1
Influence to weights of mice after injection of rSIFN-co
Weights
Weights
Increased
before
after
value of
injection
injection
weights
Group
Dose
Animal
(g)
(g)
(g)
Control
0
20
19.8 ± 1.7
30.8 ± 2.8
11.0 ± 2.9
rSIFN-co
150
20
19.4 ± 1.7
32.1 ± 3.3
12.7 ± 4.3
4. Conclusion
[0285] Under conditions of this experiment, there were no toxic reactions in all mice after injection of rSIFN-co with 150 μg/kg. The conclusion can be reached that the maximum tolerable dose of i.m. in mice is 150 μg/kg, which is equal to 1000 times the normal dose per kilo used in treatment of adult patients.
[0000] 2002 rSIFN-co Drug Inspection Report:
[0286] Nov. 14, 2002 rSIFN-co Drug Inspection Report by China Drugs & Biological Products Inspection Laboratory.
[0287] On Nov. 14, 2000, 80 vials of rSIFN-co each containing 9 μg (micrograms) provided by Sichuan Biotechnology Research Center were tested. rSIFN-co Drug was white in color with produced no precipitation when water was added. The pH value was 6.9 while the standard was between 6.5 to 7.5. The water content of rSIFN-co was 2.3% while the standard was smaller than 3.0%. Test for bacteria showed no bacterial grown. rSIFN-co passed pyrogen test. The toxicity test on mice showed no harm. Mice were alive and gained weight. The specific activity test was 6.0×10 6 IU/vial while the standard was between 3.6×10 6 IU/vial to 6.8×10 6 IU/vial. The identification test was positive.
Example 5
[0288] Crystal Growth of rSIFN-co and Test of Crystallography Parameter
[0289] Crystal of rSIFN-co. Two types of crystal were found after systematically trial and experiment. (See FIGS. 7-9 )
1. Crystal Growth
[0000]
Dissolve rSIFN-co protein with pure water (H 2 O) to 3 mg/ml in density. Search of crystallization by using Hampton Research Crystal Screen I and II which was made by Hampton Company. By using Drop Suspension Diffusion Method, liquid 500 μl, drop 1 μl protein+1 μl liquid, in 293K temperature. First 2 different types of small crystals were found as listed in Table 12.1.
[0000]
TABLE 12.1
Screen of rSIFN-co Crystallin
Condition
I
II
Diluent
0.1M Tris-HCl
0.1M HEPES
PH = 8.75
PH = 7.13
Precipitant
17.5% (w/v) PEG550 MME
10% (w/v) PEG6K
Additives
0.1M NaCl
3% (w/v) MPD
Temperature
293K
293K
Crystal Size (mm)
0.2 × 0.2 × 0.1
0.6 × 0.02 × 0.02
Crystallogram
FIG. 7
FIG. 8
2. Data Collection and Processing
[0000]
Crystal I was used to collect X-Ray diffraction data and preliminary analysis of crystallography. Parameters were also tested. The diffraction data was collected under room temperature. Crystal I (Condition I) was inserted into a thin siliconized wall tube. Using BrukerAXS Smart CCD detector, the light source is CuKα (λ=1.5418 Å) generated by Nonius FR591 X-ray generator. Light power 2000 KW (40 kv×50 mA), wave length 1.00 Å, under explosion 60 second, Δφ=2°, the distance between crystal and detector was 50 mm. Data was processed for using Proteum Procedure Package by Bruker Company. See FIG. 9 for crystal diffraction pattern (partially). See Table 12.2 for the result of the process.
[0000]
TABLE 12.2
Results of Crystallography Parameters
Parameters
a (Å)
82.67
b (Å)
108.04
c (Å)
135.01
α (Å)
90.00
β (Å)
90.00
γ (Å)
98.35
Space Group
P2 or P2 1
Sharpness of separation
5 Å
Asymmetric molecule #
10
Dissolution
57.6%
[0292] Besides, there was no crystal growth of rSIFN-co based on previous publications. The closest result to the rSIFN-co was huIFN-α2b but the screen was very complicated. After seeding 3 times, crystal grew to 0.5×0.5×0.3 mm, sharpness of separation was 2.9 Å, space group was P2 1 . The crystals were also big, asymmetric molecule number was 6, and dissolution was about 60%.
Clinical Report 1:
[0293] Evidence of effectiveness of rSIFN-co in healing cancer. See FIGS. 17A-H .
[0294] The ultra sound inspection showed an enlarged right ovary and abdominal fluid. The patient was suspected of having ovarian cancer.
[0295] Western China No. 2 Hospital reported a patient with ovarian cancer and breast gland cancer diagnosed on Jul. 14, 2004. Her serum contained CA-125>600 U/ml and CA-153>250 U/ml. Also 2000 ml abdominal water was found. On Jul. 16, 2004, malignant cancer cells and low differential gland cancer cells (likely a low graded differential Adenocarcinoma) were found from the abdominal water and cancer cells and death materials were found from the mammary gland check up. On Aug. 4, 2004, it was concluded diagnosis as ovary cancer.
[0296] The patient was treated with rSFIN-co starting Jul. 14, 2004. She was injected with 15 μg of rSFIN-co on Jul. 14, 2004, Jul. 16, 2004, Jul. 18, 2004, Jul. 20, 2004 and Jul. 22, 2004 respectively. She began chemotherapy on Jul. 22, 2004. On Aug. 3, 2004 abdominal surgery was performed. It was expected that her abdominal water would be more than 2000 ml. However, only 200 ml were recorded. On Aug. 4, 2004 the examination results showed she had mammary gland cancer, ovarian cancer of right and left ovary and lymphoma. She was treated with rSIFN-co and chemotherapy at the same time. She did not have operation on mammary glands.
[0297] On Dec. 27, 2004 the examination report showed her CA-125 dropped to 5 U/ml and CA-153 dropped to 13 U/ml. On Feb. 25, 2005, her PET examination report from Daping Hospital, Third Military Medical University of PRC showed there was no obvious abnormal difference on metabolic reactions on her body and brain. The symptoms of her mammary gland cancer disappeared. No traces of cancer were found.
PET Imaging:
[0298] On Feb. 25, 2005 PET imaging report on Feb. 25, 2005 of this 43 years old patient diagnosis with left side ovary cancer and was treated with rSIFN-co since Jul. 14, 2004; PET imaging was done at PET Center of the Daping Hospital, Third Military Medical University of PRC.
[0299] Fasting patient was intravenously injected with 18 F-FDG14.8mCi. Brain images were taken 50 minutes after injection. The images were clear, no obvious abnormal increase or decrease of radiation were observed on cerebral epidermis, both sides of cerebellum, both sides of hypothalamus and basal.
Whole body imaging was done 60 minutes after injection. The images were clear. No obvious abnormal increase or decrease of radiation on neck, lungs, mediastinum, liver, both sides of adrenals, abdominal lymph gland, pelvic cavity, bones.
[0301] The image of heart was clear.
[0302] Result: The FDG-PET images of the whole body and brain did not show abnormal FDG metabolic increase or decrease after five-and-half (5.5) months of rSIFN-co treatment of ovarian ovary cancer.
[0000] Conclusion: Comparison of CA-153 and CA-125 levels before and after rSFIN-co treatment evidenced that rSFIN-co is effective against breast and ovarian cancer.
Clinical Report 2:
[0303] A kidney cancer patient was treated in the following manner. In a half-month period, the patient was given 3 injections of 9 μg of rSIFN-co and 3 injections of 15 μg of rSIFN-co. In the one and a half months following these injections, he received 24 μg injections of rSIFN-co every day. A kidney biopsy showed no metastasis after this course of treatment. The patient showed a full recovery. Every half year after recovery, the patient received 15 μg injections of rSIFN-co 15 times over a one-month period.
Example 6
rSIFN-co Inhibits HBV-DNA Duplication and Secretion of HBsAg and HBeAg
[0304] Materials
[0305] Solvent and Dispensing Method: Add 1 ml saline into each vial, dissolve, and mix with MEM culture medium at different concentrations. Mix on the spot.
[0306] Control drugs: IFN-α2b (Intron A) as lyophilized powder, purchased from Schering Plough. 3×10 6 IU each, mix to 3×10 6 IU/ml with culture medium; Infergen® (liquid solution), purchased from Amgen, 9 μg, 0.3 ml each, equal to 9×10 6 IU, and mix with 9×10 6 IU/ml culture medium preserve at 4° C.; 2.2.15 cell: 2.2.15 cell line of hepatoma (Hep G2) cloned and transfected by HBV DNA, constructed by Mount Sinai Medical Center.
[0307] Reagent: MEM powder, Gibco American Ltd. cattle fetal blood serum, HycloneLab American Ltd. G-418 (Geneticin); MEM dispensing, Gibco American Ltd.; L-Glutamyl, imported and packaged by JING KE Chemical Ltd.; HBsAg and HBeAg solid-phase radioimmunoassay box, Northward Reagent Institute of Chinese Isotope Ltd.; Biograncetina, Northern China Medicine; And Lipofectin, Gibco American Ltd.
[0308] Experimental goods and equipment: culture bottle, Denmark Tunclon™; 24-well and 96-well culture board, Corning American Ltd.; Carbon Dioxide hatching box, Shel-Lab American Ltd.; MEM culture medium 100 ml: 10% cattle fetal blood serum, 3% Glutamyl 1%, G418 380 μg/ml, biograncetina 50 U/ml.
Method:
[0309] 2.2.15 cell culture: Added 0.25% pancreatic enzyme into culture box with full of 2.2.15 cell, digest at 37° C. for 3 minutes, and add culture medium to stop digest and disturb it to disperse the cells, reproduce with ratio of 1:3. They will reach full growth in 10 days.
[0310] Toxicity test: Set groups of different concentrations and a control group in which cells are not acted on with medicine. Digest cells, and dispense to a 100,000 cell/ml solution. Inoculate to 96-well culture board, 200 μl each well, culture at 37° C. for 24 h with 5% CO 2 . Test when simple cell layer grows.
[0311] Dispense rSIFN-co to 1.8×10 7 IU/ml solution, then prepare a series of solutions diluted at two-fold gradients. Add into 96-well culture board, 3 wells per concentration. Change the solution every 4 days. Test cytopathic effect by microscope after 8 days. Fully destroy as 4, 75% as 3, 50% as 2, 25% as 1, zero as 0. Calculate average cell lesion and inhibition rate of different concentrations. Calculate TC 50 and TC 0 according to the Reed Muench method.
[0000]
TC
50
=
Antilog
(
B
+
50
-
B
A
-
B
×
C
)
[0312] A=log>50% medicine concentration, B=log<50% medicine concentration, C=log dilution power
[0313] Inhibition test for HBeAg and HBsAg: Separate into positive and negative HBeAg and HBsAg contrast groups, cell contrast group and medicine concentration groups. Inoculate 700,000 cells/ml of 2.2.15 cell into 6-well culture board, 3 ml each well, culture at 37° C. for 24 h with 5% CO 2 , then prepare 5 gradiently diluted solutions with 3-fold as the grade (Prepare 5 solutions, each with a different protein concentration. The concentration of Solution 2 is 3 times lower than that of Solution 1, the concentration of Solution 3 is 3 times lower than that of Solution 2, etc.) 4.5×10 6 IU/ml, 1.5×10 6 IU/ml, 0.5×10 6 IU/ml, 0.17×10 6 1 U/ml, and 0.056×10 6 1 U/ml, 1 well per concentration, culture at 37° C. for 24 h with 5% CO 2 . Change solutions every 4 days using the same solution. Collect all culture medium on the 8 th day. Preserve at −20° C. Repeat test 3 times to estimate HBsAg and HBeAg with solid-phase radioimmunoassay box (Northward Reagent Institute of Chinese Isotope Ltd.). Estimate cpm value of each well with a γ-accounting machine.
[0314] Effects calculation: Calculate cpm mean value of contrast groups and different-concentration groups and their standard deviation, P/N value such as inhibition rate, IC50 and SI.
[0000]
1
)
Antigen
inhibition
rate
(
%
)
=
A
-
B
A
×
100
A=cpm of control group; B=cpm of test group;
2) Counting the half-efficiency concentration of the medicine
[0000]
Antigen
inhibition
IC
50
=
Antilog
(
B
+
50
-
B
A
-
B
×
C
)
[0000] A=log>50% medicine concentration, B=log<50% medicine concentration, C=log dilution power
3) SI of interspace-conformation changed rSIFN-co effect on HBsAg and HBeAg in 2.2.15 cell culture
[0000]
SI
=
TC
50
TC
50
4) Estimate the differences in cpm of each dilution degree from the control group using student t test
[0319] Southern blot: (1) HBV-DNA extract in 2.2.15 cell: Culture cell 8 days. Exsuction culture medium (Separate cells from culture medium by means of draining the culture medium). Add lysis buffer to break cells, then extract 2 times with a mixture of phenol, chloroform and isoamyl alcohol (1:1:1), 10,000 g centrifuge. Collect the supernatant adding anhydrous alcohol to deposit nucleic acid. Vacuum draw, re-dissolve into 20 μlTE buffer. (2) Electrophoresis: Add 6×DNA loading buffer, electrophoresis on 1.5% agarose gel, IV/cm, at fixed pressure for 14-18 h. (3) Denaturation and hybridization: respectively dip gel into HCl, denaturaion buffer and neutralization buffer. (4) Transmembrane: Make an orderly transfer of DNA to Hybond-N membrane. Bake, hybridize and expose with dot blot hybridization. Scan and analyze relative density with gel-pro software. Calculate inhibition rate and IC 50 .
Results
[0320] Results from Tables 4.1, 4.2 and 4.3 show: After maximum innocuous concentration exponent culturing for 8 days with 2.2.15 cell, the maxima is 9.0±0×10 6 IU/ml average inhibition rate of maximum innocuous concentration rSIFN-co to HBeAg is 46.0±5.25% (P<O. 001), IC 50 is 4.54±1.32×10 6 IU/ml, SI is 3.96; rate to HBsAg is 44.8±6.6%, IC 50 is 6.49±0.42×10 6 IU/ml, SI is 2.77. This shows that rSIFN-co can significantly inhibit the activity of HBeAg and HBsAg, but that the IFN of the contrast group and Infergen® cannot. It has also been proven in clinic that rSIFN-co can decrease HBeAg and HBsAg or return them to normal levels.
[0000]
TABLE 4.1
Results of inhibition rate of rSIFN-co to HBsAg and HBeAg
Inhibition rate
Average
1-
Accumulated
Concentration
First
Second
Third
First
Second
Third
inhibition
Accu-
inhibition
(×10 4 IU/ml)
well
well
well
well
well
well
rate
Accumulation
mulation
rate
First batch: (rSIFN-co)
Inhibition effect to HBeAg
900
9026
8976
10476
0.436227
0.43935
0.345659
0.407079
0.945909
0.592921
0.614693546
300
9616
12082
10098
0.3993754
0.245347
0.369269
0.337997
0.5388299
1.254924
0.300392321
100
9822
16002
12800
0.386508
0.0005
0.2005
0.195836
0.200833
2.059088
0.08867188
33.33333
15770
19306
16824
0.014991
0
0
0.004997
0.0049969
3.054091
0.001633453
11.11111
19172
22270
18934
0
0
0
0
0
4.054091
0
Control
Cell
16010
Blank
0
Dilution
3
IC50
602.74446016
Inhibition effect to HBsAg
900
7706
7240
7114
0.342155
0.381936
0.392693
0.372261
0.922258
0.627739
0.595006426
300
8856
7778
9476
0.2439816
0.336008
0.191053
0.257014
0.5499972
1.370724
0.286349225
100
10818
10720
10330
0.07649
0.084856
0.118149
0.093165
0.292983
2.27756
0.113977019
33.33333
10744
11114
10570
0.082807
0.051221
0.097661
0.07723
0.1998179
3.20033
0.058767408
11.11111
10672
9352
10810
0.088953
0.201639
0.077173
0.122588
0.122588
4.077742
0.02918541
Control
Cell
11714
Blank
0
Dilution
3
IC50
641.7736749
Second batch: (rSIFN-co)
Inhibition effect to HBeAg
900
7818
8516
9350
0.554378
0.514592
0.467054
0.512008
1.371181
0.487992
0.737521972
300
10344
10628
9160
0.4103967
0.394209
0.477884
0.427497
0.8591731
1.060496
0.447563245
100
12296
14228
13262
0.299134
0.18901
0.244072
0.244072
0.4316522
1.816423
0.19201839
33.33333
15364
17414
16188
0.124259
0.00741
0.77291
0.069653
0.1876045
2.74677
0.063933386
11.11111
17386
13632
15406
0.009006
0.222982
0.121865
0.117951
0.117951
3.628819
0.03148073
Control
Cell
16962
Blank
0
Dilution
3
IC50
365.9357846
Inhibition effect to HBsAg
900
5784
6198
5792
0.498265
0.462353
0.497571
0.486063
0.893477
0.513937
0.634835847
300
7150
8534
8318
0.379771
0.259715
0.278452
0.30598
0.4074138
1.207957
0.252210647
100
9830
11212
10210
0.147294
0.027412
0.11433
0.096345
0.101434
2.111612
0.04583464
33.33333
13942
12368
13478
0
0
0
0
0.0050891
3.111612
0.001632835
11.11111
12418
11634
11352
0
0
0.015267
0.005089
0.005089
4.106523
0.001237728
Control
Cell
Blank
0
Dilution
3
IC50
611.0919568
Third batch: (rSIFN-co
Inhibition effect to HBeAg
900
9702
9614
8110
0.428016
0.433204
0.521872
0.461031
1.316983
0.538969
0.709599543
300
8914
10032
8870
0.4744723
0.40856
0.477066
0.453366
0.8559525
1.085603
0.440859127
100
16312
12688
13934
0.038321
0.251975
0.178517
0.156271
0.402586
1.929332
0.172641621
33.33333
15080
12814
13288
0.110954
0.244547
0.216602
0.190701
0.2463153
2.738631
0.082519158
11.11111
21928
15366
15728
0
0.094093
0.072751
0.0055615
0.055615
3.683017
0.014875633
Control
Cell
17544
Blank
0
Dilution
3
IC50
382.0496935
Inhibition effect to HBsAg
900
5616
6228
5346
0.496864
0.442035
0.521054
0.486651
0.763125
0.513349
0.597838293
300
8542
8590
7096
0.234725
0.230425
0.364272
0.276474
0.2764738
1.236875
0.182690031
100
11420
11360
11394
0
0
0
0
0
2.236875
0
33.33333
12656
11582
13110
0
0
0
0
0
0
11.11111
13142
12336
13342
0
0
0
0
0
4.236875
0
Control
Cell
11528
Blank
0
Dilution
3
IC50
694.7027149
HBeAg: Average
IC50: 450.2434
SD: 132.315479
HBsAg: Average
IC50: 649.1894
SD: 42.29580
[0000]
TABLE 4.2
Results of inhibition rate of Intron A(IFN-α2b) to HBsAg and HBeAg
Inhibition rate
Average
Accumulated
Concentration
First
Second
Third
First
Second
Third
inhibition
Accumula-
1-
inhibition
(×10 4 IU/ml)
well
well
well
well
well
well
rate
tion
Accumulation
rate
Inhibition effect to HBeAg
300
14918
11724
9950
0
0.029711
0.176529
0.068747
0.068747
0.931253
0.068746724
100
14868
16890
15182
0
0
0
0
0
1.931253
0
33.33333
16760
21716
16400
0
0
0
0
0
2.931253
0
11.11111
20854
15042
16168
0
0
0
0
0
3.931253
0
3.703704
12083
12083
12083
0
0
0
0
0
4.931253
0
Control
Cell
17544
Blank
0
Dilution
3
IC50
FALSE
Inhibition effect to HBsAg
300
9226
8196
9658
0.152489
0.247106
0.521054
0.1708
0.189295
0.8292
0.185857736
100
10946
10340
10828
0
0.050156
0.364272
0.018495
0.0184947
1.810705
0.010110817
33.33333
12250
12980
13934
0
0
0
0
0
2.810705
0
11.11111
12634
12342
12000
0
0
0
0
0
3.810705
0
3.703704
10886
10886
10886
0
0
0
0
0
4.810705
0
Control
Cell
10886
Blank
0
Dilution
3
IC50
FALSE
[0000]
TABLE 4.3
Results of inhibition rate of Infergen ® to HBsAg and HBeAg
Inhibition rate
Concentration
First
Second
Third
First
Second
Third
Average
Accumulated
(×10 4 IU/ml)
well
well
well
well
well
well
inhibition rate
Accumulation
1-Accumulation
inhibition rate
First batch: (Infergen ®)
Inhibition effect to HBeAg
900
14172
12156
17306
0.091655
0.220869
0
0.104175
0.306157
0.895825
0.254710274
300
13390
12288
16252
0.1417767
0.212409
0
0.118062
0.2019827
1.777764
0.102024519
100
14364
18834
14194
0.079349
0
0.090245
0.056531
0.083921
2.721232
0.029916678
33.33333
15722
16034
16340
0
0
0
0
0.0273897
3.721232
0.007306592
11.11111
17504
17652
14320
0
0
0.082169
0.02739
0.02739
4.693843
0.005801377
Control
Cell
15602
Blank
0
Dilution
3
IC50
FALSE
Inhibition effect to HBsAg
900
12080
11692
12234
0
0.01275
0
0.00425
0.025163
0.99575
0.024647111
300
12840
11484
12350
0
0.030313
0
0.010104
0.0209125
1.985646
0.010422073
100
12894
14696
15086
0
0
0
0
0.010808
2.985646
0.003606955
33.33333
15032
12928
13020
0
0
0
0
0.0108081
3.985646
0.002704416
11.11111
11794
11984
11508
0.004137
0
0.028287
0.010808
0.010808
4.974837
0.002167838
Control
Cell
11843
Blank
0
Dilution
3
IC50
FALSE
Second batch: (Infergen ®)
Inhibition effect to HBeAg
900
6278
6376
6408
0.200051
0.187564
0.183486
0.190367
0.274635
0.809633
0.253290505
300
7692
9092
6394
0.0198777
0
0.18527
0.068383
0.0842678
1.74125
0.046161005
100
8960
7474
8190
0
0.047655
0
0.015885
0.015885
2.725365
0.005794856
33.33333
8530
8144
9682
0
0
0
0
0
3.725365
0
11.11111
7848
7848
7848
0
0
0
0
0
4.725365
0
Control
Cell
7848
Blank
0
Dilution
3
IC50
FALSE
Inhibition effect to HBsAg
900
12364
12268
12274
0.036171
0.043655
0.043187
0.041004
0.140162
0.958996
0.12751773
300
11590
12708
13716
0.0965076
0.009355
0
0.035287
0.0991581
1.923709
0.0490186
100
12448
13468
13982
0.029623
0
0
0.009874
0.063871
2.913834
0.02144964
33.33333
12616
11346
12444
0.016526
0.115529
0.029935
0.053996
0.0539965
3.859838
0.013796309
11.11111
12828
12828
12828
0
0
0
0
0
4.859838
0
Control
Cell
12828
Blank
0
Dilution
3
IC50
FALSE
Third batch: (Infergen ®)
Inhibition effect to HBeAg
900
7240
6642
6158
0.064599
0.14186
0.204393
0.136951
0.217399
0.863049
0.201211735
300
11072
8786
6902
0
0
0.108269
0.03609
0.0804479
1.82696
0.042176564
100
7016
9726
7552
0.09354
0
0.024289
0.039276
0.044358
2.787683
0.015663017
33.33333
7622
8866
8676
0.015245
0
0
0.005082
0.0050818
3.782601
0.001341671
11.11111
7740
7740
7740
0
0
0
0
0
4.782601
0
Control
Cell
7740
Blank
0
Dilution
3
IC50
FALSE
Inhibition effect to HBsAg
900
11048
11856
11902
0.04775
0
0
0.015917
0.015917
0.984083
0.015916796
300
13454
12896
11798
0
0
0
0
0
1.984083
0
100
12846
13160
12546
0
0
0
0
0
2.984083
0
33.33333
12680
12458
12360
0
0
0
0
0
3.984083
0
11.11111
11602
11602
11602
0
0
0
0
0
4.984083
0
Control
Cell
11602
Blank
0
Dilution
3
IC50
FALSE
HBeAg: Average
IC50: 0
SD: 0
HBsAg: Average
IC50: 0
SD: 0
Example 7
The Clinic Effects of Recombinant Super-Compound Interferon (rSIFN-co)
[0321] The recombinant super-compound interferon (rSIFN-co) is an invention for viral disease therapy, especially for hepatitis. Meanwhile, it can inhibit the activity of EB viruses, VSV, Herpes simplex viruses, cornaviruses, measles viruses, et al. Using Wish cells/VSV system as the assay for anti-virus activity, the results showed that: the other rIFN, was 0.9×10 8 IU/mg, Intron A was 2.0×10 8 IU/mg and rSIFN-co was 9×10 8 IU/mg. The anti-viral activity of rSIFN-co is much higher than those of the former two.
[0322] Under the permission of the State Food and Drug Administration (SFDA), People's Republic of China, the clinical trials have taken place in West China Hospital, Sichuan University, the Second Hospital of Chongqing Medical University, the First Hospital of School of Medical, Zhejiang University since the February 2003. The clinical treatment which focuses on hepatitis B is conducted under the guidance of the mutilcenter, double-blind random test. IFN-α1b was used as control, and the primary results showed the following:
[0000] The Effect of rSIFN-co Compared with IFN-α1b in the Treatment of Chronic Active Hepatitis B
1. Standard of Patients Selection:
[0323] Standards 1-4 are effective for both treatment with rSIFN-co (9 μg) and IFN-α1b (5 MU, 50 μg), and Standard 1-5 are for rSIFN-co (15 μg) treatment.
1). Age: 18-65
[0324] 2). HBsAg-test positive over last six months, HBeAg-test positive, PCR assay, HBV-DNA copies ≧10 5 /ml
3). ALT ≧two times the normal value
4). Never received IFN treatment; or received the Lamividine treatment but failed or relapsed
5) Once received other IFNs (3 MU or 5 MU) treatment six months ago following the standard of SFDA, but failed or relapsed
2. Evaluation of the Effects:
[0325] In reference to the recommendations from the Tenth China National Committee of Virus Hepatitis and Hepatopathy, the effects were divided into three degrees according to the ALT level, HBV-DNA and HBeAg tests.
Response: ALT normal level, HBV-DNA negative, HBeAg negative Partial response: ALT normal level, HBV-DNA or HBeAg negative Non response: ALT, HBV-DNA and HBeAg unchanged The response and partial response groups were considered effective cases.
3. Results of Clinic Trial:
[0330] Group A: treatment with rSIFN-co (9 μg)
[0331] Group B: treatment with IFN-α1b (5 MU, 50 μg)
[0000]
HBsAg
HBeAg
HBV-DNA
Transfer
Transfer
Transfer
Heptal
to
to
to
function
Effective
negative
negative
negative
Recovery
Period
group
Medicine
cases
Rate
rate
rate
rate
rate
8-12
A
rSIFN-
32
46.88
9.38
28.13
37.50
84.38
week
co(9 μg)
(15)
(3)
(9)
(12)
(27)
B
IFN-α1b
32
21.88
0.00
9.38
15.63
56.25
(5MU, 50 μg)
(7)
(0)
(3)
(5)
(18)
16-24
A
rSIFN-
64
54.69
7.81
25.00
34.38
90.63
week
co(9 μg)
(35)
(5)
(16)
(22)
(58)
B
IFN-α1b
64
25.00
0.00
9.38
18.75
78.13
(5MU 50 μg)
(16)
(0)
(6)
(12)
(50)
[0332] In Group C, the cases were prior treatment of chronic active hepatitis B with other IFNs (3 MU or 5 MU) that failed or relapsed and then were treated with rSIFN-co (15 μg), subcutaneous injection, every one day, for 24 weeks. The total cases were 13. After 12 weeks treatment, 7 of 13 (53.85%) were effective. 3 of 13 (23.08%) HBeAg transferred to negative; 7 of 13 (53.85%) HBV-DNA transferred to negative; 11 of 13 (84.62%) heptal functions recovered to normal.
[0000] 4. The Side Effects of rSIFN-co Compared with IFN-α1b in the Treatment
[0333] The side effects of IFN include fever, nausea, myalgia, anorexia, hair loss, leucopenia and thrombocytopenia, etc. The maximum dose of IFN-α1b is 5 MIU per time; the routine dose is 3 MIU. When taken the routine dose, 90% patients have I-II degree (WHO standard) side effects. They had fever lower than 38° C., nausea, myalgia, anorexia, etc. When taken at maximum dose, the rate of side effects did not rise obviously, but were more serious. The maximum dose of rSIFN-co is 24 μg, subcutaneous injection, every one day for 3 months. The routine dose is 9 μg. When routine doses were used, less than 50% of patients had I-II degree (WHO standard) side effects, including fever below 38° C., nausea, myalgia, anorexia, leucopenia and slight thrombocytopenia. With maximum dosage, about 50% patients suffered from leucopenia and thrombocytopenia after using rSIFN-co one month, but those side effects disappeared after stopping treatment for one week. It is safe for continued use.
[0000] The Observations of rSIFN-co Treat Hepatitis C
1. Standard of Patients Selection
[0334] 1) age: 18-65
2) HCV antibody positive
3) ALT≧1.5 times of the normal value, last more than 6 months
2. Evaluation of the Effects:
[0335] Referring to the standard of Infergen® for treatment of hepatitis C and according to the ALT level and HCV-RNA test, divided the effects into three degree:
[0336] Response: ALT normal level, HCV-RNA negative
[0337] Partial response: ALT normal level, HCV-RNA unchanged
[0338] Non response: ALT and HCV-RNA unchanged
3. Effects in Clinic
[0339] The clinical trial was done at the same time with hepatitis B treatment. 46 cases received the treatment, 9 μg each time, subcutaneous injection, every day for 24 weeks. After treatment, 26 of 46 (56.52%) have obvious effects, 12 of 46 (26.09%) HCV-RNA transferred to negative, 26 of 46 (56.52%) heptal functions recovered to normal.
Example 8
Comparison of Inhibitory Effects of Different Interferons on HBV Gene Expression
[0340] Hepatitis B virus (HBV) DNA contains consensus elements for transactivating proteins whose binding activity is regulated by interferons. Treatment of HBV-infected hepatocytes with interferons leads to inhibition of HBV gene expression. The aim of the present study was to characterize the effects of different interferons on HBV regulated transcription. Using transient transfection of human hepatoma cells with reporter plasmids containing the firefly luciferase gene under the control of HBV-Enhancer EnH I, Enh II and core promoter, Applicant studied the biological activities of three different interferons on transcription.
Materials and Methods
[0341] 1. Interferons: IFN-con1 (Infergen®), IFN-Hui-Yang (rSIFN-co) and IFNα-2b (Intron A).
2. Reporter plasmid: The DNA fragments containing HBV-Enhancer EnH I, Enh II and core promoter were prepared using PCR and blunt-end cloned into the Smal I site of the promoter- and enhancer-less firefly luciferase reporter plasmid pGL3-Basic (Promega, WI, USA). The resulting reporter plasmid was named as pGL3-HBV-Luc.
3. Cell Culture and DNA transfection: HepG2 cells were cultured in DMEM medium supplemented with 10% FBS and 100 U/ml penicillin and 100 ug/ml streptomycin. The cells were kept in 30° C., 5% CO2 incubator. The cells were transfected with pGL3-HBV-Luc reporter plasmid using Boehringer's Lipofectin transfection kit. After 18 hours, the medium containing transfection reagents was removed and fresh medium was added with or without interferons. The cells were kept in culture for another 48 hours.
4. Luciferase Assay: Forty-eight hours after addition of interferon, the cells were harvested and cell lysis were prepared. The protein concentration of cell lysates were measured using Bio-Rad Protein Assay kit. The luciferase activity was measured using Promega's Luciferase Reporter Assay Systems according to the instructions of manufacturer.
Results
Expression of Luciferase Activity in Different Interferon-Treated Cell Lysates
[0342]
[0000]
No treatment
IFN-con1
rSIFN-co
IFNα-2b
100
65
32
73
[0343] This result shows that rSIFN-co inhibits most effectively on the expression of HBV gene expression of HB core Antigen. This data shows inhibitory effect of rSIFN-co is twice better than Infergen® and Intron A. See FIG. 10 .
Example 9
Recombinant Super-Compound Interferon Spray
[0344] Major component: Recombinant Super Compound Interferon
[0345] Characteristic: Liquid, no insoluble material
[0346] Pharmacology: Recombinant Super-Compound Interferon has a wide spectrum of anti-virus activity. Its effects are 5-20 times higher than those interferons (IFNs) which are available on the market. It can inhibit coronavirus growth in cell culture. In vitro test shows that rSIFN-co has an obvious anti-SARS virus activity. rSIFN-co effect to 10,000 and 1000 TCID 50 . The Inhibitory Indexes are 0.92 μg/ml and 0.18 μg/ml respectively. The Treatment Indexes (TI) are 151.28, 773.22 respectively. The mechanism is interruption of the combination reaction between the IFN and the correspondent receptor, and inducement of the expression of 2′5′-A synthesizenzyme, protein kinase R in the target cell, therefore inhibiting expression of the viral protein. IFN can induce expression of various anti-virus proteins to inhibit the reproduce of viral proteins, enhance the function of Natural Killer (NK) cell and other Immune regulative functions, and inhibit the invasion of viruses.
[0347] Acute toxicity: All mice are alive after the maximum dose (1000 times to human dose) subcutaneous injection, did not observe LD50.
[0348] Indication: Prevention of Severe Acute Respiratory Syndrome
[0349] Dosage and Administration: Spray to both nasal cavity and throat, three times a day.
[0350] Adverse reactions: There was no report of adverse reactions from the rSIFN-co spray. It did not induce allergy. If the stimulation is occasional, adverse gastrointestinal reaction is small, and no other obvious adverse reaction was noted during treatment, it is safe to continue use. All reactions will resolve themselves.
[0351] Warning: Patients allergic to IFN and productions of E. Coli . cannot use this product.
[0352] Precautions: Before first use, spray twice to expel the air. If there is any cloudy precipitation material, if the product is expired, or there is material on the vial, do not use it.
[0353] Pediatric Use: It is unclear.
[0354] Geriatric Use: It is unclear.
[0355] Nursing mothers and pregnant women: Use with care or under physician's supervision.
[0356] Drug Interactions: It is unclear.
[0357] Overdose: One-time dose of over 27 million of International Units have not produced any adverse effects.
[0358] Supplied: 1 spray/pack, 20 ug (1×10 7 IU)/3 ml. See FIGS. 11A-11D .
[0359] Storage: Store at 4-8° C. Do not freeze, protect from light.
[0360] Effective period: Approximately one year
[0361] Manufacture: Manufactured by Sichuan Huiyang life-engineering Ltd.
[0362] Address: 8 Yusa Road, Room 902, Building A
Chengdu, 610017 Sichuan, P.R. China
Example 9-A
In Vitro Effect of a New-Style Recombinant Compound Interferon on SARS-Associated Coronavirus
[0365] Sample supplied by: Huiyang Life Engineering Lt Company, SiChuan Province
[0366] Experimenter: Molecular Biology Department, microorganism and epidemiology Institute, Academy of Military Medical Science
[0367] Original data: Preserved in archive of Molecular Biology Department, microorganism and epidemiology Institute, Academy of Military Medical Science
1. Materials
[0368] Medicine: New-type recombinant compound interferon, 9 μg each, supplied by Huiyang Life Engineering Lt Company, SiChuan Province, Lot number: 20020501.
[0369] Cells: Vero E 6 , supplied by Molecular Biology Department of Microorganism and Epidemiology Institute, Academy of Military Medical Science.
[0370] Virus: SARS-associated coronavirus, BJ-01, supplied by Molecular Biology Department of Microorganism and Epidemiology Institute, Academy of Military Medical Science.
[0371] Cell medium: DMEM supplemented with 10% FBS.
2. Condition
[0372] Virus was measured in grade 3 rd laboratory of biosafety
3. Method
[0373] CPE (cytopathic effect) assay of TCID 50 : 100 μl of Vero E 6 cells were plated in 96-well plates at 2×10 4 cells per well. After 24 hr incubation at 37° C., Vero E6 monolayer cells were treated with 9 levels of SARS-associated coronavirus dilution by 10-fold dilution, 4 wells per dilution. The cells were incubated at 37° C. and 5% CO 2 . CPE (cytopathic effect) was examined daily by microscopy. CPE less than 25% was determined as +, 26-50% as ++, 51-75% as +++, 76-100% as ++++. CPE was recorded. Then TCID 50 was calculated by Reed-Muench method.
[0374] Cytotoxicity of medicine: Vero E 6 cells were inoculated into 96-well plates at 2×10 4 cells (100 ul) per well. After 24-hr incubation at 37° C., cells grew up to monolayer. The medicine was diluted into 36, 18, 9, 4.5, 2.259 μg/ml (final concentration) and added into wells each for 4 wells. The normal cells as control group were set. CPE of medicine group was daily observed during 5-day period, and then the concentration of medicine exhibiting no toxicity was determined.
[0375] CPE assay of the activity of the medicine against SARS-associated coronavirus: 100 μl of Vero E 6 cells were plated in 96-well plates at 2×10 4 cells per well. After 24 hr incubation at 37° C., cells grew up to monolayer. The medicine at the maximal concentration exhibiting no cytotoxicity was diluted into 5 levels by 2-fold dilution and added into wells (100 μl per well). By incubation with 5% CO 2 at 37° C. for 24-hour, different concentration of virus (10 −3 , 10 −4 , 10 −5 ) were added. After treatment with virus for 48-72 hours, CPE was examined (CPE less than 25% was determined as +, 26-50% as ++, 51-75% as +++, 76-100% as ++++, normal cell as −). The cells were divided into the normal group, the medicine control group, and the different dilution of virus control group, 4 wells per group. CPE was examined daily. Till cytopathic effect was obviously exhibited in the virus control group, the anti-virus activity of interferon was evaluated. The experiment was repeated. IC 50 of the medicine was calculated by Reed-Muench method.
4. Results
[0376] Toxicity of virus: TCID 50 of virus was 10 −8 .
[0377] Cytotoxicity of medicine: the concentration of Recombinant compound interferon exhibiting no cytotoxicity was 18 μg/ml, the cells shape was similar with the control group, and no cytopathic effect was exhibited.
[0378] The anti-virus effect of the medicine: Shown in Table 9-A.1 and Table 9-A.2
[0000]
TABLE 9
A.1, the anti-virus effect of new-type recombinant
compound interferon (first experiment)
Concentration of
CPE at different concentration
IFN
of virus
(μg/ml)
10 −3
10 −4
10 −5
18
−
−
−
9
−
−
−
4.5
+ +
−
−
2.25
+ + +
+ +
−
1.125
+ + + +
+ + + +
+ +
Virus control
+ + + +
+ + + +
+ + +
group
Normal group
−
−
−
Medicine control
−
−
−
group
[0000]
TABLE 9
A.2, the anti-virus effect of new-type recombinant
compound interferon (second experiment)
Concentration of
CPE at different concentration
IFN
of virus
(μg/ml)
10 −3
10 −4
10 −5
18
−
−
−
9
−
−
−
4.5
+
−
−
2.25
+ + +
+ +
−
1.125
+ + + +
+ + + +
+ +
Virus control
+ + + +
+ + + +
+ + + +
group
Normal group
−
−
−
Medicine control
−
−
−
group
5. Conclusion
[0379] The concentration of the new-type recombinant compound interferon exhibiting no cytotoxicity at 18 μg/ml. Its IC 50 were 1.27, 2.25, and 4.04 μg/ml respectively according to the concentration of 10 −5 (1000TCID 50 ), 10 −4 (1000TCID 50 ), 10 −3 (100000TCID 50 ) of SARS-associated coronavirus (Table 9-A.3).
[0000]
TABLE 9
A.3, IC 50 of IFN at different concentrations
of virus
Dilution of virus
IC50 of IFN (ug/ml)
10 −3
4.04
10 −4
2.25
10 −5
1.27
[0380] Principal: Jin-yan Wang
[0381] Laboratory assistant: Yan-hong Zhao, Xiao-guang Ji, Xiao-yu Li.
[0382] Original data: Preserved in archives of Molecular Biology Department, microorganism and epidemiology Institute, Academy of Military Medical Science
[0383] Date: From May 12th to 30th, 2003
Example 9-B
In Vitro Effect of a New-Type Recombinant Compound Interferon and Recombinant Interferon α-2b Injection on SARS-Associated Coronavirus
[0384] Sample (rSIFN-co) supplied by: Huiyang Life Engineering Ltd., Sichuan province
[0385] Experimenter: Molecular Biology Department, Institute of microbiology and epidemiology, Academy of Military Medical Science
[0386] Original data: Preserved in monument room of Molecular Biology Department, Institute of microbiology and epidemiology, Academy of Military Medical Science
1. Materials
[0387] Medicine: New-type recombinant compound interferon (rSIFN-co), 618 μg/ml, supplied by Huiyang Life Engineering Ltd., SiChuan Province; Alfaron (recombinant interferon α-2b injection), supplied by Tianjin Hualida Biotechnology Co., Ltd. 30 ug/vial (300,0000 IU/vial), Lot Number: 20030105.
[0388] Cells: Vero E 6 , supplied by Molecular Biology Department of Institute of microbiology and epidemiology, Academy of Military Medical Science.
[0389] Virus: SARS-associated coronavirus, BJ-01, supplied by Molecular Biology Department of Institute of microbiology and epidemiology, Academy of Military Medical Science.
[0390] Condition: Viruses were measured in grade 3 rd laboratory of biosafety
2. Method
[0391] TCID 50 was measured with CPE assay: Vero E 6 cells were inoculated in 96-well plates at 2×10 4 cells (100 μl) per well. After a 24-hr incubation at 37° C., Vero E6 monolayers were treated with 9 levels of SARS-associated coronavirus dilution by 10 times decreasing, each dilution per 4 wells. The cells were incubated at 37° C. and 5% carbon dioxide. CPE was examined daily by phase-contrast microscopy. CPE less than 25% was determined as +, 26-50% as ++, 51-75% as +++, 76-100% as ++++. CPE was recorded. Then TCID 50 was calculated by Reed-Muench method.
[0392] TC 50 of IFNs were measured by MTT assay: Vero E 6 cells were inoculated in 96-well plates at 2×10 4 cells per well (100 μl). After 24-hr incubation at 37° C., the supernatant liquid was removed when cells grew up to monolayer, then Vero E 6 was treated with different concentration of IFNs, each dilution per 4 wells. Normal group was set. After 5-day observation, the cells were mixed with MTT for 4 hours. After that, remove the liquid, and then thereafter DMSO were added into cells for 0.5 hour. The OD 570nm was measured by microplate reader. Finally, TC 50 was calculated by Reed-Muench method.
[0393] The activity of the INFs against SARS-associated coronavirus was measured with MTT assay: 100 μl of Vero E 6 cells were inoculated in 96-well plates at 2×10 4 cells per well. After 24-hr incubation 37° C., cells became monolayer. The medicine dilution at the concentration of exhibiting no cytotoxicity was 5 times decreasing and there were 5 levels of dilution. Then each dilution was added to 4 wells, 100 ul per well. After 24-hour incubation at 37° C. and 5% CO 2 , IFN solution was removed, then different concentrations of virus dilution (10000, 1000, 100 TCID 50 ) were added into dishes, 4 wells per dilution. The cells were divided into the normal group, the medicine control group, and the different dilution of virus control group (10000, 1000, 100 TCID 50 ). The cells were incubated at 37° C. and 5% CO 2 for 48-72 hr, until cytopathic effect was exhibited in the virus control group, CPE was recorded (CPE less than 25% was determined as +, 26-50% as ++, 51-75% as +++, 76-100% as ++++, normal cell as −). The growth ability of cells was measured with MTT assay, and then the antivirus effect of the INFs was evaluated. The experiment was repeated 3 times. IC 50 of the medicine was calculated by Reed-Muench method.
3. Results
[0394] TCID 50 of virus: TCID 50 of virus was 10 −7 .
[0395] TC 50 of IFNs: The concentration of new-type recombinant compound interferon (rSIFN-co) exhibiting no cytotoxicity was 100 μg/ml, and that of recombinant IFNα-2b was 12.5 μg/ml, the cells shape was identical with the normal group at that concentration. TC50 of new-type recombinant compound interferon (rSIFN-co) was 139.18 μg/ml, that of recombinant IFNα-2b was 17.18 μg/ml.
[0000]
TABLE 9
B.1 TC 50 of IFNs
TC 50 (μg/ml)
1 st
2 nd
3 rd
Mean value-
IFN
experiment
experiment
experiment
(X ± SD, n = 3)
new-type
141.42
125.96
150.08
139.18 ± 12.22
recombinant
compound
interferon
IFNα-2b
17.68
15.75
18.10
17.18 ± 1.25
[0396] The anti-virus effect of the medicine: The anti-virus effects of two IFNs were observed in vitro. The results of the experiments are shown on the Table 9-B.2, and the results of TI are shown on the Table 9-B.3.
[0000]
TABLE 9
B.2, The anti-virus activity of IFNs
Concentration
IC 50 (μg/ml)
of
1 st
2 nd
3 rd
Mean value-
IFNs
virus (TCID 50 )
experiment
experiment
experiment
(X ± SD, n = 3
new-type
10000
0.79
1.04
0.93
0.92 ± 0.12
recombinant
compound interferon
IFNα-2b
5.04
4.56
4.65
4.75 ± 0.25
new-type
1000
0.19
0.18
0.18
0.18 ± 0.01
recombinant
compound interferon
IFNα-2b
1.18
1.19
1.12
1.16 ± 0.04
new-type
100
0.08
0.10
0.11
0.10 ± 0.02
recombinant
compound interferon
IFNα-2b
0.33
0.21
0.30
0.28 ± 0.06
[0000]
TABLE 9
B.3, The anti-virus activity of IFNs
Concentration
of
TI
IFNs
virus (TCID 50 )
TC 50 (μg/ml)
IC 50 (μg/ml)
(TC 50 /IC 50 )
new-type
10000
139.18
0.92
151.28
recombinant
compound
interferon
IFNα-2b
17.18
4.75
3.62
new-type
1000
139.18
0.18
773.22
recombinant
compound
interferon
IFNα-2b
17.18
1.16
14.78
new-type
100
139.18
0.10
1391.80
recombinant
compound
interferon
IFNα-2b
17.18
0.28
61.36
4. Conclusion
[0397] The protection effect of new-type recombinant compound interferon (rSIFN-co) and IFNα-2b on Vero E 6 was observed in vitro, and the anti-virus ability of IFNs was manifested. IC 50 of new-type recombinant compound interferon on SARS-associated coronavirus at the concentration of 10000, 1000, and 100 was 0.92, 0.18, and 0.10 μg/ml in three experiments, TI of that was 151.28, 773.22, and 1391.80 respectively. IC 50 of IFNα-2b was 4.75, 1.16, and 0.28 μg/ml, TI (treatment index) of that was 3.62, 14.78, 61.36 respectively.
[0398] Most importantly, the two tests (See the above Examples 9A & 9B) of in vitro anti-SARS virus effect of rSIFN-co all testified that even the effective dose of rSIFN-co to inhibit SARS virus is 1/5 of that of Interferon α-2b which was used clinically in China at present, the Treatment Index (TI) of rSIFN-co is nearly 50 times of that of Interferon a-2b. (SEE: In vitro effect of a new-type recombinant compound interferon and recombinant interferon-α-2b injection on SARS-associated coronavirus. By The Institute of Microbiology & Epidemiology, Academy of Military Medical Science) Also, see FIG. 12 .
[0399] Thirty thousand sprays of rSIFN-co had been used among front-line nurses and doctors, and people at high risk in Sichuan province. The result shows that none of the nurses and doctors infected SARS in Sichuan Province.
[0400] Principal: Jin-yan Wang
[0401] Laboratory assistant: Yan-hong Zhao, Xiao-guang Ji, Min Zhang, Jing-hua, Zhao.
[0402] Date: From July 1st to 30th, 2003
Example 10
Side Effects and Changes in Body Temperature when Using rSIFN-co
[0403] There are usually more side effects to using interferon. The side effects includes: nausea, muscle soreness, loss of appetite, hair loss, hypoleucocytosis (hypoleukmia; hypoleukocytosis; hypoleukia), and decrease in blood platelet, etc.
Method
[0404] Sample patients are divided into two groups. 10 patients in Group A were injected with 9 μg rSIFN-co. 11 patients in Group B were injected with 9 μg Infergen®. Both groups were monitored for 48 hours after injections. First monitoring was recorded 1 hour after injection. After that, records were taken every 2 hours.
[0405] Table 11.1 is the comparison of side effects between patients being injected with 9 μg of rSIFN-co and 9 μg of Infergen®.
[0000]
TABLE 11.1
Side Effects
rSIFN-co
Infergen ®
9 μg (Group A)
9 μg (Group B)
Person: n = 10
Person: n = 11
Body Systems
Reactions
Headcount
Headcount
In General
Feeble
3
3
Fever
3
6
Sole heat
1
frigolabile
3
4
Leg
3
strengthless
Mild lumbago
2
1
Body soreness
4
5
Central Nervous
Headache
3
6
System/Peripheral
Dizziness
2
11
Nervous System
Drowsiness
3
Gastroenterostomy
Apoclesis
1
Celiodynia
1
Diarrhea
1
Musculoskeletal
Myalgia
1
2
system
Arthralgia
2
Respiratory
Stuffy nose
1
system
Paropsia
Swollen Eyes
1
Results
[0406] For those patients who were injected with rSIFN-co, the side effects were minor. They had some common symptoms similar to flu, such as: headache, feebleness, frigolability, muscle soreness, hidrosis, arthralgia (arthrodynia; arthronalgia). The side effects of those patients whom were injected with Infergen® were worse than those injected with rSIFN-co.
[0407] From FIGS. 13A-1 , 13 A- 2 , 13 B- 1 , and 13 B- 2 , it was obvious that the body temperatures of sample patients in Group B were higher than the patients in Group A. It also reflected that the endurance of rSIFN-co was much better than Infergen®.
Example 11
Effects of Recombinant Super-Compound Interferon (rSIFN-co) on Ebola Virus
[0408] Background: Ebola virus is a notoriously deadly virus that causes fearsome symptoms, the most prominent being high fever and massive internal bleeding. Ebola virus kills as many as 90% of the people it infects. It is one of the viruses capable of causing hemorrhagic (bloody) fever. There is no specific treatment for the disease. Currently, patients receive supportive therapy. This consists of balancing the patient's fluids and electrolytes, maintaining their oxygen level and blood pressure, and treating them for any complicating infections. Death can occur within 10 days of the onset of symptoms.
1. Materials
[0000]
1.1 Drugs: rSIFN-co, provided by Sichuan Biotechnology Research Center.
1.2 Virus: Ebola, supplied by The Academy of Military Medical Science, Institute of Microbiology Epidemiology.
1.3 Safety level of experiment: Viral experiments were carried under Biological Laboratory Safety System level 3.
1.4 Animals: 60 BALB/c mice
2 Method
[0000]
2.1 60 mice were randomly separated into 6 groups, each group consisting of 10 mice. Group 1 was treated with 1 μg/ of rSIFN-co on the day of inoculation with Ebola virus. Group 2 was treated with 1 μg/ of rSIFN-co day one (1) after inoculation with Ebola virus. Group 3 was treated with 1 μg/ of rSIFN-co on the day two (2) after inoculation with Ebola virus. Group 4 was treated with 1 μg/ of rSIFN-co on day three (3) after inoculation with Ebola virus. Group 5 was treated with 1 μg/ of rSIFN-co on day four (4) after inoculation with Ebola virus. Group 6 was not treated with rSIFN-co and this is designated as the control group.
2.2 Administration of the medication: 1 μg/ of rSIFN-co was administered once a day for six (6) consecutive days.
3 Results
[0000]
All ten (10) mice in group 6 (control group) died. All mice in groups one (1), two (2) and three (3) survived with no observable toxic effect. In groups four (4) and five (5), showed some effects.
4 Conclusion
[0000]
Clearly these result show effectiveness of rSIFN-co against Ebola virus.
Example 12
Anti-HIV Effects of Recombinant Super-Compound Interferon (rSIFN-co)
1. Materials
[0000]
1.1 Wild-Type HIV
1.2 Drug Resistant HIV
1.3 293-CD4-CCR5 cells
1.4 DMEM, Gibco
1.5 Fetal Bovine Seru, Gibco
1.6 rSIFN-co provided by Sichuan Biotechnology Research Center
[0423] 1.7 96-well plate, NUNC
1.8 CO 2 incubator 1.9 Laminar Flow Hood 1.10 Fluorometer 1.1 IU V Absorbance Meter 1.12 Others
2. Method
[0000]
2.1 293-CD4-CCR5 cells in exponential (log) phase were obtained, digested with 0.25% pancreatin, stained with Trypan blue stain to determine cell number and diluted with DMEM to concentration of 2.0×10 5 cells per milliliter (cell/ml).
2.2 Each well of 96-well plate was filled with 100 μl (microliters) of 293-CD4-CCR5-DMEM suspension solution. The plate was placed into 5% carbon dioxide incubator at 37 degrees Celsius and observed the next day seventy percent (70%) of basal area of the well were recovered.
2.3 After supernatant was removed, 100 μl (microliters) of different concentrations of rSIFN-co were added to each well. Two controls were used: Phosphate Buffered Saline (PBS) and Growth Media.
2.4 The plate was placed into carbon dioxide incubator at 37 degrees Celsius for approximately 18 to 20 hours.
2.5 Experimental wells: Different concentrations of the Wild-Type HIV and Drug Resistant HIV viruses were placed into each well at 100 μl (microliters) per well.
Control wells: No virus was added, only 100 μl (microliters) of DMEM per well.
2.6 The plate was placed into carbon dioxide incubator at 37 degrees Celsius for approximately 24 hours.
2.7 Routine Luciferase assay was performed and protein concentrations of the supernatants were measured. Luciferase was measured in RLU/mg units.
3 Results
[0000]
rSIFN-co can inhibit HIV at level of ≧4 nanograms per milliliter (ng/ml). See Table 4 and FIGS. 14-15 . When using Luciferase as Y axis and concentration of rSIFN-co as X axis, using EXCEL, it is clear that at level of rSIFN-co ≧4 nanograms per milliliter (ng/ml), the level of Luciferase activities are obviously lower than in PBS and Medium controls. A clear inverse dose-dependent response has been shown.
[0000]
TABLE 4
Comparison of Inhibition of Wild-Type HIV and Drug
Resistant HIV by rSIFN-co
Concentration
Luciferase Assay
of rSIFN-co
Wild-Type HIV
Drug Resistant HIV
Medium
13500 + 2000
18000 + 2000
1 μg/ml
3000 + 200
2800 + 800
500 ng/ml
3000 + 600
2800 + 900
250 ng/ml
3400 + 400
4000 + 600
125 ng/ml
4300 + 200
4100 + 600
62.5 ng/ml
4300 + 400
4100 + 1000
31 ng/ml
5000 + 800
5100 + 800
15 ng/ml
7200 + 400
6000 + 1500
7.5 ng/ml
7000 + 800
7700 + 1300
4 ng/ml
9000 + 2000
8900 + 2000
PBS
13000 + 3000
15100 + 2300
Medium
16000 + 3600
19000 + 2500
4 Conclusion: rSIFN-co is effective against both: Wild-Type HIV and Drug Resistant HIV.
Example 13
Anti-Influenza Effects of Recombinant Super-Compound Interferon (rSIFN-co)
1. Materials
[0000]
1.1. 10-day old chick embryonic membrane cells
1.2. SIFN-co provided by Sichuan Biotechnology Research Center
1.3. Influenza virus provided by Molecular Biology Department of Institute of microbiology and epidemiology, Academy of Military Medical Science.
1.4. DMEM, Gibco
1.5. Newborn Calf Serum
1.6. 96-well plate, NUNC
1.7. CO 2 incubator
1.8. Laminar Flow Hood
1.9. Inverted Microscope
1.10. Others
2. Method
[0000]
2.1 10-day old chick embryonic membrane cell in exponential (log) phase were obtained, digested with 0.25% pancreatin, stained with Trypan blue stain to determine cell number and diluted with DMEM to concentration of 2.0×10 5 cells per milliliter (cell/ml).
2.2 Each well of 96-well plate was filled with 100 μl (microliters) of 293-CD4-CCR5-DMEM suspension solution. The plate was placed into carbon dioxide incubator at 37 degrees Celsius. The next day cells grew to a monolayer.
2.3 After supernatant was removed, 100 μl (microliters) of different concentrations of rSIFN-co were added to each well. Two control wells: No rSIFN-co was added
2.4 The plate was placed into carbon dioxide incubator at 37 degrees Celsius for approximately 18 to 20 hours.
2.5 Experimental wells: Different concentrations of the Influenza virus were placed into each well at 100 microliters (μl) per well.
Control wells: No Influenza virus was added, only 100 μl (microliters) of DMEM per well.
2.6 The plate was placed into carbon dioxide incubator at 37 degrees Celsius for approximately 24 hours.
2.7 Cells were observed under inverted microscope.
3. Results
[0000]
3.1 Under inverted microscope, the cells in the control well with Influenza virus added and without interferon had obvious CPE, such as rounding of cells, cell necroses, decrease in reflective light and sloughing off.
3.2 Cells from the experimental wells containing rSIFN-co at concentration ≧10 nanogram per milliliter (ng/ml) had no CPE and morphology comparable to normal cells. See FIG. 16 .
3.3 Control Wells without Influenza virus added and without interferon did not have any CPE.
4 Conclusion
[0000]
At concentration ≧10 nanogram per milliliter (ng/ml) rSIFN-co is effective against Influenza virus. | This invention provides a method for treating tumors in a subject, comprising administering to the subject an effective amount of a recombinant interferon, wherein the interferon has the amino acid sequence of SEQ ID NO:2 and is encoded by the nucleotide sequence SEQ ID NO:1, wherein the tumors are selected from the group consisting of skin cancer, basal cell carcinoma, liver cancer, thyroid cancer, rhinopharyngeal cancer, solid carcinoma, prostate cancer, esophageal cancer, pancreatic cancer, superficial bladder cancer, hemangioma, epidermoid carcinoma, cervical cancer, glioma, leucocythemia, acute leucocythemia, chronic leucocythemia, lymphadenoma, and polycythemia vera. | 2 |
PRIORITY APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 13/453,312, filed 23 Apr. 2012 (now U.S. Pat. No. 8,891,312) entitled Method and Apparatus for Reducing Erase Time of Memory By Using Partial Pre-Programming. This application is incorporated herein by reference.
BACKGROUND
Description of Related Art
U.S. Pat. Nos. 6,094,373 and 6,842,378 discuss an erase procedure of a group of memory cells, in which the actual erase step follows a pre-program step. In the group of memory cells, some memory cells may be in the programmed state, and other memory cells may be in the erased state. Prior to erasing all of the memory cells in the group of memory cells, the memory cells in the group that are already in the erased state are pre-programmed to a programmed state. Such pre-programming brings all of the memory cells in the group of memory cells to a shared programmed state, and prevents memory cells in the erased state from being erased again. The erase which follows pre-program then brings all of the memory cells in the group of memory cells from the programmed state to a shared erased state. Accordingly, pre-program prevents an undesirably wide distribution of threshold voltages in the group of memory cells following the erase, by bringing the threshold voltages of all memory cells in the group to the programmed state prior to the erase.
A disadvantage with pre-program is its time consuming nature, compared to erase. Erase is relatively quick compared to pre-program, and all memory cells in the group are erased. However, not all memory cells in the group are pre-programmed; memory cells in the erased state and memory cells in the programmed state are treated differently. Memory cells in the group that are in the erased state are pre-programmed to a programmed state, and memory cells in the group that are in the programmed state are not pre-programmed. This difference in treatment of memory cells in different states results in pre-program taking significantly longer than erase. Although pre-program results in a narrowed distribution of threshold voltages for the group of memory cells, pre-program also results in a lengthy erase procedure.
SUMMARY
The technology described here includes an integrated circuit with a nonvolatile memory array and control circuitry. Memory cells of the nonvolatile memory array are characterized by one of multiple threshold voltage ranges including at least an erased threshold voltage range and a programmed threshold voltage range. The control circuitry is responsive to an erase command to erase a group of memory cells of the nonvolatile memory array, with a plurality of phases including at least a pre-program phase and an erase phase. In the pre-program phase, the control circuitry programs a first set of memory cells in the group having threshold voltages within the erased threshold voltage range, and does not program a second set of memory cells in the group having threshold voltages within the erased threshold voltage range in the group. By not programming the second set of memory cells, the pre-program phase is performed more quickly than if the second set of memory cells were programmed along with the first set of memory cells. In the erase phase after the pre-program phase, the control circuitry erases the group.
In some embodiments of the described technology, the erase command selects the group of memory cells to erase from a plurality of erase groups dividing the nonvolatile memory array.
In some embodiments of the described technology, the group of memory cells specified in the erase command, is divided into a plurality of pre-program regions. The first set of memory cells programmed in the pre-program phase, is limited to a pre-program region of the plurality of pre-program regions. Memory cells in other pre-program regions are not programmed, regardless of whether the memory cells have threshold voltages within the erased threshold voltage range. The pre-program region can be determined by pre-program location data stored in a memory. The pre-program region can also be selected from the plurality of pre-program regions. The pre-program region can also be changed to a next pre-program region of the pre-program regions each time the control circuitry is responsive to the erase command to erase the group. In some embodiments of the described technology, the pre-program region is selected a first time the control circuitry is responsive to the erase command to erase the group after the integrated circuit is turned on, and in second and later times the control circuitry is responsive to the erase command to erase the group after the integrated circuit is turned on, the pre-program region is changed to a next pre-program region.
In some embodiments of the described technology, the erase phase erases at least the first set of memory cells (programmed in the pre-program phase) and the second set of memory cells (not programmed in the pre-program phase). The first set of memory cells (programmed in the pre-program phase) and the second set of memory cells (not programmed in the pre-program phase) have threshold voltages within the erased threshold voltage range prior to the pre-program phase. The group of memory cells selected for erase by the erase command, can further include a third set of memory cells having threshold voltages within the programmed threshold voltage range prior to the pre-program phase. The third set of memory cells is not programmed during the pre-program phase, and is erased during the erase phase along with the first set of memory cells and the second set of memory cells.
Additional technology described here includes a method. The method comprises at least the following step: responsive to an erase command to erase a group of memory cells of a nonvolatile memory array, the data in the memory cells characterized by one of a plurality of threshold voltage ranges including at least an erased threshold voltage range and a programmed threshold voltage range:
(i) performing a pre-program phase that programs a first set of memory cells in the group having threshold voltages within the erased threshold voltage range, and that does not program a second set of memory cells in the group having threshold voltages within the erased threshold voltage range in the group, and (ii) performing an erase phase after the pre-program phase, the erase phase erasing the group.
Other embodiments of the described technology are disclosed herein.
In another aspect of the described technology, during the pre-program phase, the control circuitry programs a first set of memory cells having threshold voltages within the erased threshold voltage range in only a pre-program region of a plurality of pre-program regions dividing the group, regardless of whether other memory cells have threshold voltages within the erased threshold voltage range in other pre-program regions of the plurality of pre-program regions dividing the group.
Further technology described here includes an integrated circuit with a nonvolatile memory array and control circuitry. The nonvolatile memory array has memory cells each having a threshold voltage in one of an erased state and a programmed state. The control circuitry erases a group of memory cells of the nonvolatile memory array in an erase cycle. The erase cycle includes at least: (i) a pre-program phase that programs only part of the memory cells in the erased state, and (ii) an erase phase after the pre-program phase, the erase phase erasing the group.
Further technology described here includes a method of erasing memory cells in an erase cycle, the memory cells arranged in a memory array having a plurality of word lines. The method of the erase cycle comprises at least the following:
performing in the erase cycle, a pre-program phase that program only part of a set of memory cells each in an erase state; and performing in the erase cycle, an erase phase after the pre-program phase, the erase phase erasing all of the set of memory cells.
In some embodiments of the described technology, the set of memory cells is allocated a plurality of word lines, and the part of the set of memory cells is allocated a part of the plurality of word lines.
In some embodiments of the described technology, the method is responsive to an erase command to erase a group of the memory cells of the memory array, and data in the memory cells are characterized by one of a plurality of threshold voltage ranges including at least an erased threshold voltage range of the erased state and a programmed threshold voltage range of a programmed state.
In some embodiments of the described technology, the part of the set of memory cells programmed in the pre-program phase is limited to a pre-program region of a plurality of pre-program regions dividing the group. Some embodiments of the described technology further comprise, reading pre-program location data stored in a memory to determine the pre-program region. Some embodiments of the described technology further comprise, selecting the pre-program region from the plurality of pre-program regions. Some embodiments of the described technology further comprise, a first time the erase command is received after an integrated circuit with the nonvolatile memory array is turned on, selecting the pre-program region from the plurality of pre-program regions. Some embodiments of the described technology further comprise, each time the erase command is received, changing the pre-program region to a next pre-program region. Some embodiments of the described technology further comprise, a first time the erase command is received after an integrated circuit with the nonvolatile memory array is turned on, selecting the pre-program region from the plurality of pre-program regions, and a second and later times the erase command is received after the integrated circuit with the nonvolatile memory array is turned on, changing the pre-program region to a next pre-program region.
In some embodiments of the described technology, the pre-program phase does not program a second set of memory cells in the group having threshold voltages within the programmed threshold voltage range in the group, and the erase phase erases the part of the set of memory cells, other memory cells in the set of memory cells that are not in the part of set of memory cells, and the second set of memory cells.
Other embodiments of the described technology are disclosed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an example flowchart of an erase procedure showing a series of threshold voltage distributions of memory cells during an erase procedure featuring repeated erase without pre-program.
FIG. 2 is an example flowchart of an erase procedure showing a series of threshold voltage distributions of memory cells during an erase procedure featuring complete pre-program.
FIG. 3 is a block diagram of a memory cell, showing the division of a memory array into multiple erase groups, and the division of an erase group into multiple pre-program regions.
FIG. 4 is an example flowchart of an erase procedure with selective pre-programming on memory cells in the erased state in a particular pre-program region, such as in FIG. 3 .
FIG. 5 is an example flowchart of part of an erase procedure with selection of the particular pre-program region that is pre-programmed.
FIG. 6 is a block diagram of an integrated circuit with a memory array and improvements described herein.
FIG. 7 is a block diagram of sets of word lines allocated to the pre-program regions of an erase group.
FIG. 8 is a block diagram of sets of bit lines allocated to the pre-program regions of an erase group.
DETAILED DESCRIPTION
FIG. 1 is an example flowchart of an erase procedure showing a series of threshold voltage distributions of memory cells during an erase procedure featuring repeated erase procedures without pre-program.
In the series of graphs showing the threshold voltage distribution of a group of memory cells, two threshold voltage distributions are shown. The dotted line shows the threshold voltage distribution of memory cells in the group which begin the erase procedure in the erased state, with threshold voltages within a low erased threshold voltage range The solid line shows the threshold voltage distribution of memory cells in the group which begin the erase procedure in the programmed state, with threshold voltages within a high programmed threshold voltage range.
At 10 , two distinct threshold voltage distributions are shown. The memory cells represented by the two distinct threshold voltage distributions can represent, in combination, the threshold voltage distribution of memory cells in an erase group. The dotted line threshold voltage distribution represents memory cells in the group which begin the erase procedure with a low threshold voltage erased state. The solid line threshold voltage distribution represents memory cells in the group which begin the erase procedure with a high threshold voltage programmed state.
At 12 , the group of memory cells undergoes the erase step repeatedly without pre-program. The erase step is repeated in the sense that multiple erase procedures without pre-program are the cause of an undesirably wide threshold voltage distribution, as discussed in the following. Any single particular erase procedure can have a single erase step (or multiple erase steps if erase verify fails).
At 14 , two overlapping threshold voltage distributions are shown. Again, the memory cells represented by the two overlapping threshold voltage distributions can represent, in combination, the threshold voltage distribution of memory cells in an erase group. The dotted line threshold voltage distribution represents memory cells in the group which began the erase procedure with a low threshold voltage erased state, but now has an undesirably wide threshold voltage distribution, spreading even into negative threshold voltages. The dotted line threshold voltage distribution has been erased repeatedly, despite beginning with a low threshold voltage erased state already. Because the pre-program step has been skipped repeatedly over multiple erase procedures, the threshold voltage distribution has been stretched in the negative threshold voltage direction. The solid line threshold voltage distribution represents memory cells in the group which began the erase procedure with a high threshold voltage programmed state.
At 16 , the group of memory cells undergoes soft program. The effect of soft program on the over-erased and low threshold voltages cells, is to tighten threshold voltage distribution of the group of memory cells.
At 18 , two overlapping threshold voltage distributions are shown. Soft program only partly successful in correcting the undesirably wide threshold voltage distribution. The solid line threshold voltage distribution represents memory cells in the group which began the erase procedure with a high threshold voltage programmed state. Soft program is sufficient to correct this solid line threshold voltage distribution. The dotted line threshold voltage distribution represents memory cells in the group which began the erase procedure with a low threshold voltage erased state, but now has an undesirably wide threshold voltage distribution, spreading even into negative threshold voltages. Soft program is insufficient to correct this dotted line threshold voltage distribution.
The erase procedure of as shown in 10 - 18 is relatively quick, due to skipping the pre-program step. However, the resulting threshold voltage distribution is wide, even stretching into negative threshold voltages, which is problematic for a NOR array.
FIG. 2 is an example flowchart of an erase procedure showing a series of threshold voltage distributions of memory cells during an erase procedure featuring complete pre-program.
At 20 , two distinct threshold voltage distributions are shown. The memory cells represented by the two distinct threshold voltage distributions can represent, in combination, the threshold voltage distribution of memory cells in an erase group. The dotted line threshold voltage distribution represents memory cells in the group which begin the erase procedure with a low threshold voltage erased state. The solid line threshold voltage distribution represents memory cells in the group which begin the erase procedure with a high threshold voltage programmed state.
At 22 , the group of memory cells undergoes full pre-program. In full pre-program, every memory cell in the dotted line low threshold voltage distribution is programmed. At 24 , two overlapping threshold voltage distributions are shown, which in combination, represent the threshold voltage distribution of memory cells in the erase group. The dotted line threshold voltage distribution, which represents memory cells in the group that began the erase procedure with a low threshold voltage erased state, is programmed. The solid line threshold voltage distribution, which represents memory cells in the group that began the erase procedure with a high threshold voltage programmed state, is unchanged. As a result, both the dotted line and solid line threshold voltage distributions are high threshold voltage distributions.
At 26 , the group of memory cells undergoes the erase step. A result of the erase step is a widening of the threshold voltage distribution. At 28 , two overlapping threshold voltage distributions are shown, which in combination, represent the threshold voltage distribution of memory cells in the erase group. At the conclusion of pre-program at 24 , both the dotted line and solid line threshold voltage distributions had high threshold voltage distributions. Following erase, at 28 both the dotted line and solid line threshold voltage distributions have low threshold voltage distributions.
At 30 , the group of memory cells undergoes soft program. The effect of soft program on the over-erased and low threshold voltages cells, is to tighten threshold voltage distribution of the group of memory cells. At 32 , two overlapping threshold voltage distributions are shown, which in combination, represent the threshold voltage distribution of memory cells in the erase group. At the conclusion of erase at 28 , both the dotted line and solid line threshold voltage distributions had undesirably wide, low threshold voltage distributions. Following soft program, at 32 both the dotted line and solid line threshold voltage distributions have narrow, low threshold voltage distributions.
The erase procedure of as shown in 20 - 32 has an acceptable threshold voltage distribution of memory cells in the erase group. However, the erase procedure is time consuming, because of the full pre-program at step 22 , in which every memory cell in the low threshold voltage distribution is programmed to a high threshold voltage distribution.
FIG. 3 is a block diagram of a memory cell, showing the division of a memory array into multiple erase groups, and the division of an erase group into multiple pre-program regions.
The memory array 48 is divided into multiple erase groups 1 , 2 , . . . , i, . . . , M. An erase group can be a contiguous group of memory cells such as a segment, block, or sector, that are collectively erased together in response to an erase command. The erase group of memory cells can be the whole memory array, in response to an erase command to erase the whole memory array.
The erase groups are further divided into multiple pre-program regions. Erase group i (shown in expanded view 50 ) is divided into pre-program regions 1 , 2 , . . . , N- 2 , N- 1 , N. With the division of an erase group into multiple pre-program groups, pre-program can be performed on part of an erase group instead of the entire erase group. Over multiple erase procedures, a different pre-program region is selected for pre-program during each subsequent erase procedure, such that each pre-program region has a chance to be pre-programmed.
FIG. 4 is an example flowchart of an erase procedure, or erase cycle, with selective pre-programming on memory cells in the erased state in a particular pre-program region, such as in FIG. 3 .
At 34 , the erase command is received by the integrated circuit with the memory array. The erase command identifies an erase group of memory cells to be erased. An erase group can be a contiguous group of memory cells such as a segment, block, or sector, that are collectively erased together in response to an erase command. The erase group of memory cells can be the whole memory array.
At 36 , selective pre-program is performed on the erase group of memory cells identified to be erased. The pre-program is selective in that the pre-program is performed on only part of the erase group of memory cells. As shown in FIG. 3 , the erase group is divided into multiple pre-program regions. The pre-program is performed on only memory cells in at least one particular pre-program region. Such selective pre-program is different from a full pre-program, in which all memory cells in the erase group which are already in the erased state are pre-programmed. In selective pre-program, memory cells which are already in the erased state must be in a particular pre-program region of the erase group, in order to undergo pre-program. Even if the erase group has memory cells in the erased state that are outside of the particular pre-program region of the erase group, such memory cells do not undergo pre-program.
Because pre-programming is performed on only part of the erase group of memory cells, pre-programming is faster than if performed on the entire erase group of memory cells.
At 38 , erase is performed on all of the memory cells in the erase group of memory cells. At 40 , erase verify is performed to check whether the preceding erase step sufficiently erased the memory cells in the group of memory cells selected for erase. At 42 , if erase verify fails, then the erase algorithm returns to step 38 to repeat erase. At 42 , if erase verify passes, then the erase algorithm proceeds. At 44 , soft program is performed on over-erased low threshold voltage cells in the memory group selected for erase, which. At 46 , the erase command ends.
In the erase procedure of FIG. 4 , at 36 pre-program is not performed on memory cells already in the erased state, in the erase group of memory cells identified to be erased. Over multiple erase procedures, if the same memory cells were repeatedly erased without pre-program, then the memory cells would have unacceptably low threshold voltage. However, this problem is prevented by changing the pre-programmed memory cells, as discussed in connection with FIG. 5 .
FIG. 5 is an example flowchart of part of an erase procedure with selection of the particular pre-program region that is pre-programmed.
At 52 , the erase command is received by the integrated circuit with the memory array. The erase command identifies an erase group of memory cells to be erased.
Step 54 determines whether the erase procedure is the first erase procedure performed after power on. In various embodiments, the erase procedure is the first performed on the entire array, or on the particular erase group which is identified to be erased by the erase command.
If the erase procedure is the first erase procedure performed after power on, then at 56 a pre-program region is randomly, or arbitrarily, selected out of the erase group. In another embodiment, during power on, the first pre-program region is determined. If the erase procedure is the second or subsequent erase procedure performed after power on, then at 58 the next pre-program region is selected out of the pre-program regions of the erase group.
At 60 , pre-program is performed on the selected pre-program region. At 62 , erase is performed on the entire erase group of memory cells. The ellipsis indicates other steps being performed on memory cells after erase, such as erase verify and soft program as discussed in connection with FIG. 4
FIG. 6 is a block diagram of an integrated circuit with a memory array and improvements described herein. An integrated circuit 150 includes a memory array 100 . A word line (or row) and block select decoder 101 is coupled to, and in electrical communication with, a plurality of word lines 102 , and arranged along rows in the memory array 100 . A bit line (column) decoder and drivers 103 are coupled to and in electrical communication with a plurality of bit lines 104 arranged along columns in the memory array 100 for reading data from, and writing data to, the memory cells in the memory array 100 . Addresses are supplied on bus 105 to the word line decoder and drivers 101 and to the bit line decoder 103 . Sense amplifiers and data-in structures in block 106 , are coupled to the bit line decoder 103 via the bus 107 . Data is supplied via the data-in line 111 from input/output ports on the integrated circuit 150 , to the data-in structures in block 106 . Data is supplied via the data-out line 115 from the sense amplifiers in block 106 to input/output ports on the integrated circuit 150 , or to other data destinations internal or external to the integrated circuit 150 . Program, erase, and read bias arrangement state machine circuitry 109 controls biasing arrangement supply voltages 108 , and performs selective pre-program during erase. State machine circuitry 109 also includes memory 140 that determines a next pre-program region of an erase group that is pre-programmed. Memory 140 can be a nonvolatile memory, counter, or register in control circuitry.
FIG. 7 is a block diagram of sets of word lines allocated to the pre-program regions of an erase group.
In particular, a row decoder 201 is coupled to different pre-program regions via different sets of word lines. Word lines 1 211 couple the row decoder 201 to pre-program region 1 221 . Word lines 2 212 couple the row decoder 201 to pre-program region 2 222 . Word lines N- 2 214 couple the row decoder 201 to pre-program region N- 2 224 . Word lines N- 1 215 couple the row decoder 201 to pre-program region N- 1 225 . Word lines N 216 couple the row decoder 201 to pre-program region N 226 .
The different sets of word lines 211 , 212 , 214 , 215 , and 216 contain one or more word lines. The shown pre-program regions 221 , 222 , 224 , 225 , and 226 belong to a same erase group, such as shown in FIG. 3 . Additional erase groups with additional pre-program regions are coupled to the row decoder 201 via additional sets of word lines that are allocated to the additional pre-program regions of the additional erase groups.
FIG. 8 is a block diagram of sets of bit lines allocated to the pre-program regions of an erase group.
In particular, a column decoder 251 is coupled to different pre-program regions via different sets of bit lines. Bit lines 1 251 couple the column decoder 251 to pre-program region 1 261 . Bit lines 2 252 couple the column decoder 251 to pre-program region 2 262 . Bit lines N- 1 255 couple the column decoder 251 to pre-program region N- 1 265 . Bit lines N 256 couple the column decoder 251 to pre-program region N 266 .
The different sets of bit lines 251 , 252 , 255 , and 256 contain one or more bit lines. The shown pre-program regions 261 , 262 , 265 , and 266 belong to a same erase group, such as shown in FIG. 3 . The same erase group can include memory cells on a single word line, or multiple word lines. Multiple pre-program regions can include memory cells on a single word line, or multiple word lines. Additional erase groups with additional pre-program regions are coupled to the column decoder 251 via additional sets of bit lines that are allocated to the additional pre-program regions of the additional erase groups.
One programmed state is shown, but other embodiments cover multiple programmed states, such as multi-level cells with 2 bits and 3 levels of programming per memory location, triple level cell cells with 3 bits or 7 levels of programming per memory location.
The disclosed technology is applicable to nonvolatile memory arrays such as a NOR array. Example nonvolatile memory elements are floating gate elements and dielectric charge trapping memory elements.
While the present invention is disclosed by reference to the preferred embodiments and examples detailed above, it is to be understood that these examples are intended in an illustrative rather than in a limiting sense. It is contemplated that modifications and combinations will readily occur to those skilled in the art, which modifications and combinations will be within the spirit of the invention and the scope of the following claims. | Memory cells of a nonvolatile memory array are characterized by one of multiple threshold voltage ranges including at least an erased threshold voltage range and a programmed threshold voltage range. Responsive to an erase command to erase a group of memory cells of the nonvolatile memory array, a plurality of phases are performed, including at least a pre-program phase and an erase phase. The pre-program phase programs a first set of memory cells in the group having threshold voltages within the erased threshold voltage range, and does not program a second set of memory cells in the group having threshold voltages within the erased threshold voltage range in the group. By not programming the second set of memory cells, the pre-program phase is performed more quickly than if the second set of memory cells were programmed along with the first set of memory cells. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of International Application No. PCT/EP2014/060993, published in German, with an International filing date of May 27, 2014, which claims priority to DE 10 2013 009 184.5, filed May 31, 2013; the disclosures of which are hereby incorporated in their entirety by reference herein.
TECHNICAL FIELD
[0002] The present invention relates to a contact element for making a shield connection to a cable provided with a braided shield, the contact element including (i) a spring contact sleeve having an annular ring and spring contacts connected circumferentially to the annular ring and (ii) a crimp sleeve that can be connected to the annular ring.
BACKGROUND
[0003] DE 10 2011 102 566 A1 describes a contact element having a spring contact sleeve and a crimp sleeve. The spring contact sleeve has an annular ring and spring contacts arranged circumferentially on the annular ring. Each spring contact is respectively formed of a substantially linear supporting arm. The supporting arm of each spring contact is connected to a respective spring arm through a U-shaped curved section.
[0004] The connection of the contact element to a braided cable is accomplished by pushing the spring contact sleeve onto the cable sheath of the cable whereby the supporting arms rest against the cable sheath. Since a fixed connection has not yet been achieved, the spring contact sleeve can be rotated and moved into a desired position on the cable sheath. The braided shield of the cable is folded back in such a manner that the braided shield contacts the supporting arms to complete the connection to the braided shield. In a subsequent assembly step the crimp sleeve is pushed over the supporting arms so that the crimp sleeve surrounds the braided shield from the outside. The crimp sleeve is then pressed together with the supporting arms and the braided shield located between them.
[0005] A disadvantage of this contact element is the relatively elaborate design that is required to bend the supporting arms and the spring arms. A particular drawback is that the crimp sleeve, which is cylindrical shaped, cannot completely enclose the braided shield from all sides. This is disadvantageous for high voltage contacts since individual loose braided shield strands, which can result from stripping the cable, and exposure of the braided shield can cause dangerous short circuits.
SUMMARY
[0006] An object is a contact element that is characterized by a relatively simple and cost-effective design and is relatively simple to assemble to a cable having cable shielding and can produce a safe electrically shielded connection.
[0007] In carrying out at least one of the above and/or other objects, a contact element for connecting to a cable having a braided shield is provided. The contact element includes a spring contact sleeve and a crimp sleeve. The spring contact sleeve has an annular ring and spring contacts arranged circumferentially on one end of the annular ring. The spring contact sleeve and the crimp sleeve form an enclosed hollow cavity between one another when the crimp sleeve is joined to the annular ring. The hollow cavity is configured to fully receive therein an exposed portion of the braided shield provided for connection of the contact element to the cable.
[0008] Further, in carrying out at least one of the above and/or other objects, a cable assembly is provided. The cable assembly includes a cable and a contact element. The cable has a braided shield. The contact element has a spring contact sleeve and a crimp sleeve. The spring contact sleeve has an annular ring and spring contacts arranged circumferentially on one end of the annular ring. The spring contact sleeve and the crimp sleeve form an enclosed hollow cavity between one another when the crimp sleeve is joined to the annular ring. The spring contact sleeve and the crimp sleeve are placed on the cable with the cable extending through aperture passages of the spring contact sleeve and the crimp sleeve and the crimp sleeve is joined to the annular ring to thereby form the enclosed hollow cavity between the spring contact sleeve and the crimp sleeve. The hollow cavity fully receives therein in a physical contact manner an exposed portion of the braided shield to thereby electrically connect the contact element to the cable.
[0009] An embodiment provides a contact element for contacting the cable shielding (e.g., braided shield) of a cable in a shielded manner. The contact element includes a spring contact sleeve and a crimp sleeve. The spring contact sleeve has an annular ring and spring contacts. The spring contacts are circumferentially arranged on one end of the annular ring. The spring contact sleeve and the crimp sleeve are placed on the cable with the cable extending through aperture passages of the spring contact sleeve and the crimp sleeve. The spring contact sleeve and the crimp sleeve form a hollow cavity (i.e., receptacle chamber) between one another when the crimp sleeve is joined to the spring contact sleeve. The hollow cavity is enclosed by the spring contact sleeve and the crimp sleeve. The hollow cavity can completely accommodate therein an exposed portion of the braided shield. The exposed portion of the braided shielded accommodated within the cavity is in physical contact with the spring contact sleeve and the crimp sleeve thereby contacting the contact element and the cable together in a shielded manner.
[0010] In embodiments, the spring contact sleeve and the crimp sleeve form a hollow cavity when joined together. The hollow cavity is formed between the spring contact sleeve and the crimp sleeve. An exposed section of the braided shield of the cable, which is provided for the connection of the cable to the contact element, is accommodated within the hollow cavity. That is, the hollow cavity completely encloses in a physical contacting manner the exposed section of the braided shield thereby connecting the contact element and the braided shield of the cable together.
[0011] In embodiments, the crimp sleeve is in the shape of a cap. The cap includes a base plate having a circularly shaped aperture passage extending therethrough. The crimp sleeve is pushed onto the cable with the cable extending through the aperture passage of the crimp sleeve. The diameter of the aperture passage of the crimp sleeve corresponds closely to the outer dimension of the inner insulation of the cable. Thus, the crimp sleeve tightly seals to the portion of the cable extending through the aperture passage of the crimp sleeve. That is, the crimp sleeve tightly seals to the inner insulation of this portion of the cable.
[0012] Because of the complete enclosure of the stripped braided shield of the cable within a receptacle chamber formed by the hollow cavity and a part of the crimp sleeve that surrounds it and the spring contact sleeve, no loose sections of the braided shield can move around and give rise to short circuits. This is advantageous when the conductor contact is made to a high voltage cable carrying high currents and voltages, as for example in an electric vehicle.
[0013] In embodiments, the crimp sleeve has an integrally molded structured (i.e., gripping) inner contour on its inner surfaces. The inner contour can be designed, for example, as a spiral, helix, diamond shaped, or corrugated pattern. The gripping inner contour enables the braided shield of the cable to be pulled completely under the crimp sleeve with rotational movements while the crimp sleeve is being attached to the spring contact sleeve. The stripped sections of the braided shield are thereby completely enclosed in the hollow cavity formed by the spring contact sleeve and the crimp sleeve.
[0014] In embodiments, the spring contact sleeve assumes a relatively simple shape that does not require U-shaped bending of the spring contacts of the spring contact sleeve. The spring contact sleeve can thus be manufactured in a relatively simple and cost-effective manner as a single molded part, in particular through a thermoforming process.
[0015] In embodiments, the spring contacts of the spring contact sleeve are a cover surface whose free end sections extend away from the annular ring of the spring contact sleeve. The spring contacts can form an ascending section with respect to the axis of symmetry of the spring contact sleeve and an adjoining section that is parallel to the axis of symmetry or at least ascends noticeably less steeply. The ascending sections deflect when a cylindrically shaped section of a metal housing is pushed over the spring contact sleeve. The parallel or slightly ascending sections, possibly using integrally molded contact points, lie against the inner surface of the metal housing and thereby produce well-defined contact junctions making a good electrical connection.
[0016] In embodiments, the annular ring of the spring contact sleeve has an uninterrupted annular surface. As a result of this an increase in stability is achieved as compared to an interrupted lamellar structure, especially for the attachment of the crimp sleeve.
[0017] In embodiments, the annular ring of the spring contact sleeve has a collar on its end section. (The spring contacts are arranged on the other end section of the annular ring.) The diameter of the collar is smaller than the inner diameter of the spring contact sleeve. The inner diameter of the spring contact sleeve is determined so that the spring contact sleeve rests snugly on the exterior cable sheath when the spring contact sleeve is pushed over the cable. The collar of the annular ring thereby strikes the front edge of the cable sheath, which is formed as a result of a portion of the cable sheath being stripped off the cable. The collar thus determines the position of the spring contact sleeve on the cable.
[0018] In embodiments, the contact element can be used on a high voltage coaxial cable, for example in electrically powered motor vehicles or in energy supply systems that use regenerative energy sources.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 illustrates a contact element having a spring contact sleeve and a crimp sleeve, the contact element being in a disassembled state in which the spring contact sleeve and the crimp sleeve are not joined together;
[0020] FIGS. 2 , 3 , 4 , 5 , 6 , and 7 respectively illustrate steps in the assembly of the contact element on a shielded cable shown with each of FIGS. 2 , 3 , 4 , 5 , 6 , and 7 having a cross-sectional view a) and a plan view b); and
[0021] FIGS. 8 and 9 illustrate an application example of the shield connection of the contact element to the shielded cable.
DETAILED DESCRIPTION
[0022] Detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
[0023] Referring now to FIG. 1 , a contact element for contacting braided shield 4 of a cable 5 (not shown in FIG. 1 ) in a shielded manner is shown. The contact element includes a spring contact sleeve 1 and a crimp sleeve 6 . Spring contact sleeve 1 and crimp sleeve 6 can be joined together to form the assembled contact element. As shown in FIG. 1 , the contact element is in a disassembled state in which spring contact sleeve 1 and crimp sleeve 6 are not joined together.
[0024] Spring contact sleeve 1 is a unitary molded component. Spring contact sleeve 1 includes an annular ring 3 and a plurality of flat surface spring contacts 2 . Spring contacts 2 are integrally molded circumferentially on an end section of annular ring. Spring contacts 2 form a lamellar crown that opens in a direction extending away from the end section of annular ring 3 .
[0025] Each spring contact 2 has a first spring contact portion 14 , a second spring contact portion 15 , and a contact point 23 . First spring contact portion 14 steeply ascends relative to the axis of symmetry of spring contact sleeve 1 . Second spring contact portion 15 is parallel to or ascends at a noticeably flatter rate to the axis of symmetry of spring contact sleeve 1 . The more steeply ascending first spring contact portions 14 deflect while being pushed radially inward by a cylindrically shaped socket section 18 of a metal housing 21 pushed over the assembled contact element (shown in FIG. 9 ). The flatter second spring contact portions 15 lie against the inner surface of socket section 18 of metal housing 21 pushed over the assembled contact element (shown in FIG. 9 ). Contact points 23 of spring contacts 2 are respectively integrally molded on second spring contact portions 15 . Contact points 23 provide well-defined contact junctions to metal housing 21 (shown in FIG. 9 ).
[0026] Crimp sleeve 6 is formed as a cap having a base plate 8 and inner surfaces provided with a structured (e.g., gripping) inner contour 7 . Base plate 8 has a circularly shaped aperture passage 16 extending therethrough and bordered by inner contour 7 .
[0027] Referring now to FIGS. 2 , 3 , 4 , 5 , 6 , and 7 , with continual reference to FIG. 1 , sequential steps in the assembly of the contact element on cable 5 are respectively shown. Each of FIGS. 2 , 3 , 4 , 5 , 6 , and 7 includes a cross-sectional view a) and a plan view b) of a respective assembly step.
[0028] FIGS. 2 , 3 , 4 , 5 , 6 , and 7 clarify the mounting of the two-component contact element on cable 5 . Cable 5 has a cable shield formed as a braided shield 4 . Cable 5 is shown as a high-voltage coaxial cable. Such high-voltage coaxial cables 5 are used, for example, in electrically powered motor vehicles and carry both relatively high currents and voltages.
[0029] Cable 5 further has an inner conductor 9 , an inner insulation 11 , and an outer cable sheath 10 Inner insulation 11 is between braided shield 4 and inner conductor 9 and lies beneath the braided shield. Cable sheath 10 lies above braided shield 4 and forms an exterior insulating layer of cable 5 . Inner conductor 9 is shown in FIGS. 2 , 3 , 4 , 5 , 6 , and 7 as a simplified solid object made of a plurality of individual strands in order to increase the flexibility of cable 5 . Braided shield 4 surrounding inner insulation 11 is primarily responsible for keeping interference radiation in cable 5 as small as possible. In this application it is important that while preparing cable 5 no part of inner conductor 9 or braided shield 4 is accessible, or that no leftover part remains, which could give rise to dangerous short circuits when detached from cable 5 .
[0030] FIG. 2 illustrates the first assembly step as the pushing of spring contact sleeve 1 onto a free cable 5 whose end section has already been stripped. Collar 13 of annular ring 3 of spring contact sleeve 1 constricts the aperture passage of the annular ring on the one end section of cable 5 .
[0031] FIG. 3 illustrates the second assembly step. As shown in FIG. 3 , to further connect spring contact sleeve 1 to cable 5 , annular ring 3 of spring contact sleeve 1 is pushed onto cable 5 until collar 13 of annular ring 3 strikes the front edge of cable sheath 10 . Because of this an exact and secure positioning of spring contact element 1 with respect to cable 5 is obtained.
[0032] As further shown in FIG. 3 , braided shield 4 and inner insulation 11 are cut to the same length. This length is chosen so that in the next sequential assembly step, shown in FIG. 4 , the folding back of braided shield 4 in the direction of spring contact sleeve 1 is such that braided shield 4 covers annular ring 3 of spring contact sleeve 1 .
[0033] In the next sequential assembly step, shown in FIG. 5 , crimp sleeve 6 is pushed over the free end of cable 5 . The cap-shaped crimp sleeve 6 has aperture 16 in its base plate 8 . The diameter of aperture 16 of crimp sleeve 6 corresponds as precisely as possible to the cross-section of cable 5 in the region of inner insulation 11 of cable 5 . The edge of aperture 16 of crimp sleeve 6 thereby lies tightly on inner insulation 11 of cable 5 .
[0034] In contrast, the open side of crimp sleeve 6 is wider than annular ring 3 of spring contact sleeve 1 . As a result, crimp sleeve 6 can be pushed over annular ring 3 and braided shield 4 that lies on it.
[0035] Pushing of crimp sleeve 6 onto cable 5 is accomplished by using a superimposed rotational motion. The inner surface of crimp sleeve 6 has integrally molded structured inner contour 7 Inner contour 7 is designed as a screw like inner thread, as indicated to some extent in the figures. When crimp sleeve 6 is rotated, braided shield 4 is carried with crimp sleeve 6 by its inner contour 7 in the direction of motion and is pulled completely under crimp section 6 .
[0036] In the next sequential assembly step, shown in FIG. 6 , crimp sleeve 6 is already partially pushed over annular ring 3 of spring contact sleeve 1 . Flared cams 12 on crimp sleeve 6 function as catches during the rotational motion for sections of wire of braided shield 4 protruding between crimp sleeve 6 and annular ring 3 of spring contact sleeve 1 . Crimp sleeve 6 is rotated until cams 12 insert into matching shaped wells 22 in annular ring 3 of spring contact sleeve 1 (shown in FIG. 1 ).
[0037] The finished assembly, shown in FIG. 7 , is hereby produced in which crimp sleeve 6 has arrived at its final position. In this final position, the leading edge of crimp sleeve 6 now rests against spring contact sleeve 1 . A hollow cavity 17 whose boundary walls completely encapsulate braided shield 4 remains because of its shape between crimp sleeve 6 and spring contact sleeve 1 .
[0038] Crimp sleeve 6 is then connected to spring contact sleeve 1 so that it cannot be released by a crimp (not shown). A secure mechanical and electrical connection is produced in this manner between braided shield 4 of cable 5 and spring contact sleeve 1 .
[0039] The arrangement described thus far can be supplemented by connecting to a screened plug-in connector. To this end, a socket contact 19 can be crimped to inner conductor 9 of cable 5 , as is shown in FIG. 8 . Socket contact 19 , shown as an example in FIGS. 8 and 9 , is provided to accommodate flat connector pins. To achieve a moisture-proof seal, a sealing gasket 20 can be attached to cable 5 .
[0040] The preassembled component is then inserted into a metal housing 21 , as shown in FIG. 9 in a sectional view. Spring contacts 2 of spring contact sleeve 1 resting against the inside of socket section 18 produce an electrical connection between braided shield 4 of cable 5 and metal housing 21 .
REFERENCE SYMBOL LIST
[0041] 1 spring contact sleeve
[0042] 2 spring contacts of spring contact sleeve
[0043] 3 annular ring of spring contact sleeve
[0044] 4 braided shield of cable
[0045] 5 cable (high-voltage coaxial cable)
[0046] 6 crimp sleeve
[0047] 7 inner contour of crimp sleeve
[0048] 8 base plate of crimp sleeve
[0049] 9 inner conductor of cable
[0050] 10 cable sheath
[0051] 11 inner insulation of cable
[0052] 12 cams
[0053] 13 collar
[0054] 14 first portion of a spring contact
[0055] 15 second portion of a spring contact
[0056] 16 aperture passage
[0057] 17 hollow cavity
[0058] 18 socket section
[0059] 19 socket contact
[0060] 20 seal
[0061] 21 metal housing
[0062] 22 wells
[0063] 23 contact point of a spring contact
[0064] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the present invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the present invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the present invention. | A contact element for connecting to a cable having a braided shield includes a spring contact sleeve and a crimp sleeve. The spring contact sleeve has an annular ring and spring contacts arranged circumferentially on one end of the annular ring. The spring contact sleeve and the crimp sleeve form an enclosed hollow cavity between one another when the crimp sleeve is joined to the annular ring. The hollow cavity is configured to fully receive therein an exposed portion of the braided shield provided for connection of the contact element to the cable. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
BACKGROUND OF THE INVENTION
[0001] The invention relates generally to industrial control systems, and more specifically to an industrial control system having a battery backed solid-state memory, the battery preventing loss of data during momentary power interruptions.
[0002] Industrial controllers are special purpose computers used for the control of industrial processes and the like. While executing a stored program, they read inputs from the controlled process and, according to the logic of a contained control program, provide outputs to the controlled process.
[0003] Industrial controllers differ from regular computers both in that they provide “real-time” control (i.e., control in which control outputs are produced predictably and rapidly in response to given control inputs) and in that they provide for extremely reliable operation. In this latter regard, the volatile memory used by the industrial controller is often backed up with a battery so that data needed for the control program is not lost during momentary power outages. Volatile memory is that which requires power to maintain its stored data.
[0004] Such “battery backed” memory, using a combination of static random access memory (SRAM) and a long life battery such as a lithium cell, is well known. In current control applications, synchronous dynamic random access memory (SDRAM) may be preferred to SRAM because of its higher density, faster speed, and lower cost. Unfortunately, the amount of power needed for SDRAM can be thirty times greater than that needed for conventional SRAM devices. The voltage requirements of SDRAM require that the lithium cell voltage be stabilized with a DC-to-DC converter, introducing additional power losses of about 25 percent. High speed SRAM is one alternative, but high-speed SRAM still draws about ten times as much current as the older SRAM devices, has much lower density than SDRAM in number of bits of storage per device, and costs much more than SDRAM per device.
[0005] Many customers wish to disconnect power from their industrial controllers during the night, over weekends, and during scheduled factory shutdowns. The high power requirements of SDRAM and high speed SRAM produce unacceptable battery drain in these situations. At times, it may be desirable to ship an industrial controller preprogrammed from the factory. The one-month or more of transport time make battery back-up of the programmed data impractical.
BRIEF SUMMARY OF THE INVENTION
[0006] The present invention allows automatic deactivation of the battery backup for periods of planned power outage. In this way, memory devices having high power consumption may be provided with battery back up during short periods of unexpected power loss, without risk of high battery discharge levels during longer scheduled shutdowns. The invention may include nonvolatile (e.g., Flash) memory into which selected data from the volatile memory may be saved prior to a planned shut down.
[0007] Specifically, the present invention provides a battery backed memory system having a first line receiving a source of line voltage and a second line receiving a source of battery voltage to provide backup voltage when the line voltage is lost. A volatile solid-state memory receives voltage from the first line, and from the second line via an electronically controlled switch. A microprocessor communicating with the volatile solid-state memory and the electronically controlled switch, executes a program to open the electronically controlled switch in response to a signal indicating a planned cessation of line voltage.
[0008] Thus it is an object of the invention to distinguish between and respond differently to power outages that are unexpected and that require battery backup and those which are planned in which battery backup may not be required.
[0009] The system may further include nonvolatile solid state memory communicating with the microprocessor and the executed program may operate to transfer predetermined data from the volatile solid state memory to the nonvolatile solid state memory in response to the signal indicating a planned cessation of line voltage and prior to opening of the electronically controlled switch.
[0010] Thus it is an object of the invention to allow storage of data in nonvolatile memory when a planned power outage is incurred, thus eliminating loss of critical data, and to allow for such a transfer while line voltage is present to ameliorate the power demands of programming common non-volatile memories.
[0011] The invention may include a latch connected between the microprocessor and the electronically controlled switch so that the electronically controlled switch is latched open even after loss of power to the microprocessor.
[0012] Thus it is another object of the invention to allow the microprocessor to be fully powered down during loss of line voltage without affecting the disconnection of the battery from the volatile memory.
[0013] The invention may include circuitry for resetting the latch upon restoration of line voltage to the first line.
[0014] Thus it is another object of the invention to ensure that battery backup is reestablished on next power up after an unplanned power outage without the necessity of resetting by the microprocessor.
[0015] The volatile memory may include static and dynamic random access memory.
[0016] Thus it is another object of the invention to provide a system that works not only with high current dynamic memories but also faster, higher current static memory systems.
[0017] The system may include a DC-to-DC converter for use with the dynamic access memory and a voltage regulator for use with the static memory.
[0018] Thus it is another object of the invention to provide improved battery backup operation for memory systems that include efficiency decreasing, regulation, or DC-to-DC conversions.
[0019] The foregoing objects and advantages may not apply to all embodiments of the inventions and are not intended to define the scope of the invention, for which purpose claims are provided. In the following description, reference is made to the accompanying drawings, which form a part hereof, and in which there is shown by way of illustration, a preferred embodiment of the invention. Such embodiment also does not define the scope of the invention and reference must be made therefore to the claims for this purpose.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1 is a simplified perspective view in phantom showing a processor board within an industrial controller, the former which may include a battery backing up a volatile memory;
[0021] [0021]FIG. 2 is a schematic representation of the present invention showing a microprocessor having an output communicating through a latch with a switch connected to disconnect battery backup from volatile memory during a planned power outage; and
[0022] [0022]FIG. 3 is a timing diagram showing the signals at specific locations on the schematic of FIG. 2 during initial application of power to the industrial controller, an unanticipated power loss, and a planned shut down according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Referring now to FIG. 1, an industrial controller 10 may include a chassis 12 incorporating a number of modules 14 , 16 , 18 , and 20 interconnected by means of backplane 22 .
[0024] In particular, a power supply module 14 provides power from a line source 24 and regulates the power for distribution along the backplane 22 to the other modules 16 , 18 , and 20 . A processor module 16 receives data along the backplane 22 from a network module 18 or an I/O module 20 . The network module 18 provides an interface with a communication network 34 such as EtherNet, or ControlNet to receive system control data or data from other I/O modules. The I/O module 20 provides an interface for input and output signals along I/O lines 27 communicating with the controlled process or machine. Generally, during operation of the industrial controller 10 , a program executed by the processor module 16 reads this input data to create output data that is then returned along the backplane 22 from a network module 18 or an I/O module 20 .
[0025] The processor module 16 includes an internal processor circuit board 26 containing a battery 28 , volatile memory 30 , and processor circuitry 32 .
[0026] Referring now to FIG. 2, the battery may be a lithium battery as is generally known in the art. Such batteries are not rechargeable and hence must be replaced when their power is exhausted. The volatile memory 30 may include static random access memory (RAM) 42 and synchronous dynamic random access memory (SDRAM) 44 , both of which require application of power to maintain their memory states. The processor circuitry 32 includes a microprocessor 36 communicating via an internal data and address bus 38 with the volatile memory 30 and nonvolatile memory 40 which together contain control data and the control program. The non-volatile memory may be so called “flash” memory well known in the art.
[0027] According to methods well known in the art, the microprocessor 36 reads or writes to the volatile memory 30 or non-volatile memory 40 as is necessary to execute the control program. The microprocessor 36 may also communicate over bus 38 , or via a similar mechanism, with the backplane 22 and hence with I/O modules 20 or network module 18 .
[0028] Referring still to FIG. 2, power for the SRAM 42 is received through a transistor 46 , which in turn receives power from a voltage regulator 48 of conventional design, connected to battery 28 . The regulator voltage is adjusted to the necessary voltage for the particular SRAM 42 . Generally voltage regulators operate to controllably reduce voltage. Similarly, power for the SDRAM 44 is received through a transistor 50 which in turn receives power from DC-to-DC converter 52 of conventional design, connected to battery 28 . Again, the DC-to-DC converter 52 is adjusted to the necessary voltage for the particular SDRAM 44 . The DC-to-DC converter operates to maintain the desired voltage to the memory with an input battery voltage above or below the desired voltage to the memory.
[0029] The SRAM 42 and SDRAM 44 also have a connection to line power 56 obtained from the power supply module 14 through the backplane 22 . Thus, when line power 56 is available, no current need be or is drawn through transistors 46 and 50 preventing current drain on battery 28 and saving its capacity instead for periods of unexpected interruption of line power 56 .
[0030] The non-volatile memory 40 is connected to line power 56 , as it does not require battery back up because it does not lose data when power is lost.
[0031] The transistors 46 and 50 receive at their controlling inputs the output of an inverter 90 whose input is a signal (D) output from a latch 58 . In the example shown, the transistors 46 and 50 may be p-channel field effect transistors passing current from their drain to source upon application of a low state voltage at their gates. Thus, a high or set state of the output of the latch 58 will turn on transistors 46 and 50 allowing current flow to the SRAM 42 and SDRAM 44 , whereas a low or reset state of the output of the latch 58 will turn off transistors 46 and 50 preventing current flow to the SRAM 42 and SDRAM 44 . It will be understood that the particular voltage considered to be the “set” state is arbitrary and for the purposes of the claims herein, the terms “set” and “reset” should be construed to embrace either high or low voltages according to the necessary logic to be effected by the present invention.
[0032] Latch 58 and inverter 90 may be powered directly from the battery 28 , bypassing transistors 46 and 50 so as to maintain their states even with loss of line power 56 or switching of the transistors 46 and 50 .
[0033] The microprocessor 36 provides two output lines 66 and 68 which may be controlled by the program executed by the microprocessor 36 . Each output line 66 and 68 is received, respectively, by one inverter 70 and 72 . The output of inverter 70 is received by a first input of a dual input AND gate 64 .
[0034] Associated with the microprocessor 36 of the processor circuitry 32 is reset timing circuitry 60 receiving line power 56 to provide a series of reset signals 62 needed to properly initialize the microprocessor 36 and other circuitry when power is first applied to the processor circuitry 32 . Such circuitry is well known in the art. The reset signal 62 of the reset timing circuitry 60 rises shortly after power is first applied to the processor circuitry 32 and is received by the second input of the dual input AND gate 64 .
[0035] The output of the dual input AND gate 64 is received by the clock input of a standard D-type latch 58 whereas the output of inverter 72 is received by the data input of the latch 58 . Thus generally, control of the latch 58 is provided by the reset signal 62 and the two output lines 66 and 68 .
[0036] Referring now to FIG. 3, at a time prior to the application of line power 56 to the processor circuitry 32 , indicated by interval 76 , reset signal 62 indicated as waveform (C), output line 66 indicated as waveform (A) and, output line 68 indicated as waveform (B) will all be low. Upon application of line power 56 , indicated by a vertical dotted line 78 , power to the volatile memory 30 (shown in FIG. 3) will rise indicated by waveform (P) to a predetermined normal voltage necessary for supplying power to the non-volatile memory 40 , the microprocessor 36 , and the reset timing circuitry 60 . Whereas a single power level is indicated, more generally different voltages will be provided by power supply module 14 to the various devices of SRAM 42 and SDRAM 44 .
[0037] At a predetermined interval 80 after the application of power, a rising edge of reset signal 62 (waveform (C)) will occur. Insofar as microprocessor output lines 66 and 68 remain low during normal start-up of the microprocessor, the output of the AND gate 64 will provide a rising edge clocking the latch 58 while a high value will be applied to latch input D from inverter 72 .
[0038] The result is a high or set latch output which, through the operation of transistors 46 and 50 , will connect the SRAM 42 and the SDRAM 44 to battery power from battery 28 as has been described above in addition to their connection to line power 56 . Line power 56 may be attached to SRAM 42 and SDRAM 44 in a manner so as to inhibit power being drained from the battery so long as line power 56 is present. For example, this may be done by back biasing a diode junction or the like.
[0039] Referring again to FIG. 3, after this time, a power interruption 82 causing a loss of line power 56 will cause power from battery 28 to be conducted by transistors 46 and 50 through to the SRAM 42 and SDRAM 44 preventing loss of data on these devices. After this time, as indicated by vertical dotted line 84 , a planned shutdown signal may be received by the microprocessor 36 . The planned shutdown signal may, for example, be received as a dedicated input from a front panel control (not shown) or received through bus 38 on the industrial controller (and thus from the network 34 or an I/O line 27 or as a software command implemented as a portion of the controlled program executed by the microprocessor. The planned shutdown signal, as the name implies, indicates that a planned interruption of line power 56 will occur.
[0040] At this time, during a data storage interval 86 , the microprocessor 36 may cause a transfer of predetermined data from SRAM 42 and SDRAM 44 to the non-volatile memory 40 using the available line power 56 to implement the writing to the non-volatile memory 40 . The predetermined data is that selected by the programmer based on the particular application of the industrial controller, but may include programs and program data values and or I/O values.
[0041] At the conclusion of the data storage interval 86 , the microprocessor 36 may change output line 68 and may pulse output line 66 to cause the output of the latch 58 (signal (D)) to be reset at vertical line 88 turning off transistors 46 and 50 . In this way, when line power 56 is lost, unlike during interruption 82 , there is no drain on battery 28 .
[0042] The latch 58 is connected directly to the battery 28 and so remains powered during the turning off of transistors 46 and 50 . The relatively low power requirements of the latch 58 do not cause a significant drain on the battery 28 . With the latch 58 holding the transistors 46 and 50 off, power may be cut to the microprocessor 36 with or without transistors 46 and 50 turning on again. Thus the circuit allows current drain on the battery 28 to be minimized.
[0043] Generally, the planned shutdown signal precedes a controlled shut down of the industrial controller 10 , for example, in evenings or at night so as to save power or may be powering down prior to shipping of the industrial controller 10 to a customer with critical data stored in the non-volatile memory 40 . By eliminating the drain of the volatile memory 30 on the battery 28 , battery life can be increased dramatically, typically from one week to one year or more. It will be understood, however, that all current drain on the battery is not necessarily prohibited. For example, a real-time clock may also be connected to the battery 28 on a permanent basis.
[0044] It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but that modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments also be included as come within the scope of the following claims. | Battery backed memory for use in an industrial controller allows software disconnect of the battery and memory so that unplanned power outages may receive the benefit of battery backup, but battery power is not unduly wasted during planned power outages when data loss may be accommodated or other provisions may be made for saving data in nonvolatile memory. | 6 |
TECHNICAL FIELD
This invention relates to inkjet printheads and to a method of fabricating such printheads.
BACKGROUND ART
Inkjet printers operate by ejecting small droplets of ink from individual orifices in an array of such orifices provided on a nozzle plate of a printhead. The printhead forms part of a print cartridge which can be moved relative to a sheet of paper and the timed ejection of droplets from particular orifices as the printhead and paper are relatively moved enables characters, images and other graphical material to be printed on the paper.
A typical conventional printhead is fabricated from a silicon substrate having thin film resistors and associated circuitry deposited on a front surface of the substrate. The resistors are arranged in an array relative to one or more ink supply slots in the substrate, and a barrier material is formed on the substrate around the resistors to isolate each resistor inside a thermal ejection chamber. The barrier material is shaped both to form the thermal ejection chambers, and to provide fluid communication between the chambers and the ink supply slot. In this way, the thermal ejection chambers are filled by capillary action with ink from the ink supply slot, which itself is supplied with ink from an ink reservoir in the print cartridge of which the printhead forms part.
The composite assembly described above is typically capped by a metallic nozzle plate having an array of drilled orifices which correspond to and overlie the ejection chambers. The printhead is thus sealed by the nozzle plate, but permits ink flow from the print cartridge via the orifices in the nozzle plate.
The printhead operates under the control of printer control circuitry which is configured to energise individual resistors according to the desired pattern to be printed. When a resistor is energised it quickly heats up and superheats a small amount of the adjacent ink in the thermal ejection chamber. The superheated volume of ink expands due to explosive evaporation and this causes a droplet of ink above the expanding superheated ink to be ejected from the chamber via the associated orifice in the nozzle plate.
Many variations on this basic construction will be well known to the skilled person. For example, a number of arrays of orifices and chambers may be provided on a given printhead, each array being in communication with a different coloured ink reservoir. The configurations of the ink supply slots, printed circuitry, barrier material and nozzle plate are open to many variations, as are the materials from which they are made and the manner of their manufacture.
The typical printhead as described above is normally manufactured simultaneously with many similar such printheads on a large area silicon wafer which is only divided up into the individual printheads at a late stage in the manufacture. The silicon wafer is typically several hundred microns (μm) in depth, for example 675 μm, which is necessary to allow robust handling. This leads to the following disadvantage.
The ink supply slots are usually cut using laser milling. This is a slow process and typically removes material 50 μm wide by 50 μm deep at a rate of 1.5 mm/sec. A typical ink supply slot 675 μm deep by 100 μm wide by several millimeters long may require 28 milling passes. To cut the ink supply slots in an entire wafer using a two-head laser slotting machine takes about 6 hours.
It is an object of the invention to provide a new construction of inkjet printhead, and a method of making such a printhead, in which this disadvantage is avoided or mitigated.
DISCLOSURE OF THE INVENTION
According to one aspect of the invention there is provided a method of making an inkjet printhead comprising providing a substrate having first and second opposite surfaces, providing a support member, bonding the second surface of the substrate to the support member, and, after the substrate and support member are bonded together, forming a plurality of ink ejection elements on the first surface of the substrate, the method further including forming communicating ink supply slots passing respectively through the substrate and support member to provide fluid communication between an ink supply and the ink ejection elements.
The invention further provides a print cartridge comprising a cartridge body having an aperture for supplying ink from an ink reservoir to a printhead, and a printhead as specified above mounted on the cartridge body with said aperture in fluid communication with said ink supply slot.
The invention further provides an inkjet printer including a print cartridge according to the preceding paragraph.
A further disadvantage with the conventional construction of printhead results from the trend towards printheads with smaller geometries (i.e. higher nozzle densities) to provide higher resolution and operating frequencies. This entails, inter alia, the use of very narrow ink supply slots, for example, 30 μm wide. However, the depth of the conventional silicon wafer (675 μm) provides a significant resistance to ink flow in the case of narrow ink supply slots, placing a limit on the speed at which ink can be supplied to the thermal ejection chamber and correspondingly limiting the speed of operation of the printhead.
Accordingly, in a preferred embodiment of the invention, the ink supply slot comprises individual ink supply slots extending through the substrate and support member respectively, the ink supply slot in the support member being in register with but of greater width than the ink supply slot in the substrate.
Even if it were practical to use thin wafers, say 50 μm thick, a high operating frequency generates more heat due to the increased resistor firing. It is necessary to dissipate this heat quickly after firing the resistor, as if it does not dissipate quickly, drive bubble collapse time is long. Drive bubble collapse time is dead-time and by reducing dead-time faster operation can be provided. However, the thin silicon substrate may not in all cases constitute an efficient heat sink, and in such circumstances this again places a limit on the frequency of operation.
Accordingly, in an embodiment, the support member acts as a heat sink.
As used herein, the terms “inkjet”, “ink supply slot” and related terms are not to be construed as limiting the invention to devices in which the liquid to be ejected is an ink. The terminology is shorthand for this general technology for printing liquids on surfaces by thermal, piezo or other ejection from a printhead, and while the primary intended application is the printing of ink, the invention will also be applicable to printheads which deposit other liquids in like manner.
Furthermore, the method steps as set out herein and in the claims need not necessarily be carried out in the order stated, unless implied by necessity.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view of a silicon wafer undergoing a reduction in thickness for use in a printhead according to an embodiment of the invention;
FIG. 2 is a plan view of a carrier for the thinned wafer of FIG. 1 ;
FIG. 3 is cross-section through part of the carrier of FIG. 2 ;
FIGS. 4 to 7 show successive steps in making a printhead according to an embodiment of the invention;
FIG. 8 is a cross-section of the final printhead made by the method of FIGS. 4 to 7 ; and
FIG. 9 is a cross-sectional view of a print cartridge incorporating the printhead of FIG. 8 .
In the drawings, which are not to scale, the same parts have been given the same reference numerals in the various figures.
DETAILED DESCRIPTION OF THE INVENTION
There will now be described, by way of example only, the best mode contemplated by the inventors for carrying out embodiments of the invention.
The left hand side of FIG. 1 shows, in side view, a substantially circular silicon wafer 10 of the kind typically used in the manufacture of conventional inkjet printheads, the wafer 10 having a thickness of 675 μm and a diameter of 150 mm (the thickness of the wafer is greatly exaggerated in FIG. 1 ). The wafer 10 has opposite, substantially parallel front and rear major surfaces 12 and 14 respectively, the front surface 12 being flat, highly polished and free of contaminants in order to allow ink ejection elements to be built up thereon by the selective application of various layers of materials in known manner.
The first step in the manufacture of a printhead according to the embodiment of the invention is to grind the rear surface 14 of the wafer by conventional techniques to reduce the thickness of the wafer 10 to 50 μm. This is shown on the right hand side of FIG. 1 , where the front surface 12 remains undisturbed while the ground rear surface is indicated at 14 ′. The reduced thickness wafer is referenced 100 .
The next step is to bond the rear surface 14 ′ of the reduced thickness wafer 100 to a substantially circular support member, herein referred to as a wafer carrier 16 . The wafer carrier 16 is shown in plan view in FIG. 2 , and it has a diameter substantially the same as that of the wafer 100 . The wafer carrier 16 is moulded using a standard injection moulding process and has a thickness of 625 μm so that the combined thickness of the carrier 16 and wafer 100 is substantially the same as the original wafer 10 so that the same wafer handling apparatus as is used for conventional wafers 10 can be used in subsequent manufacturing steps.
The carrier 16 is preferably made of aluminium nitride which has a high thermal conductivity and allows the carrier to act as a heat sink in the finished printhead. In the moulding process, aluminium nitride powder is mixed with a standard polymer carrier to allow moulding, after which the polymer is burned off at high temperature which also sinters the aluminium nitride particles together to give the final carrier 16 . Silicon nitride particles may be used instead of aluminium nitride.
As seen in FIG. 2 , the carrier 16 has a large number of slots 18 grouped in threes, each slot 18 extending fully through the thickness of the carrier. The bottom surface (not seen in FIG. 2 ) of the carrier 16 has grooves running vertically between each group of three slots 18 and horizontally between each row of slots 18 so that ultimately the carrier can be divided up using a conventional dicing saw into individual “dies” each containing one group of three slots 18 . FIG. 3 is a cross-section through the carrier 16 showing one of the dies prior to separation from the carrier. The grooves 20 are the vertical grooves between adjacent groups of slots; the horizontal grooves are similar but run perpendicular to the grooves 20 .
The wafer 100 is bonded to the top surface of the carrier 16 (i.e. the surface not containing the grooves 20 ), using a lead borate glass frit at 390 deg C. The result is an intimately bonded composite structure in which the upper part is a 50 μm thick layer of silicon 100 and the lower part is a 625 μm thick aluminium nitride carrier 16 containing slots 18 grouped in threes and each group of three being separated from its neighbors by horizontal and vertical grooves 20 .
This is shown in FIG. 4 for a single die of three slots 18 , such die being shown as a separate entity in FIG. 4 but actually still at this point forming an undivided part of the composite structure. However, from this point on, the method will be described for a single die for simplicity, but it will be understood that in practice the further steps required to complete the printhead, as described below, will be carried out at the wafer level simultaneously for all dies, and the individual printheads will be cut from the wafer along the grooves 20 after the printheads are substantially complete.
Next, the front surface 12 of the wafer is processed in conventional manner to lay down an array of thin film heating resistors 22 ( FIG. 8 ) which are connected via conductive traces to a series of contacts which are used to connect the traces via flex beams with corresponding traces on a flexible printhead-carrying circuit member (not shown), which in turn is mounted on a print cartridge. The flexible printhead-carrying circuit member enables printer control circuitry located within the printer to selectively energise individual resistors under the control of software in known manner. As discussed, when a resistor 22 is energised it quickly heats up and superheats a small amount of the adjacent ink which expands due to explosive evaporation. The resistors 22 , and their corresponding traces and contacts, are not shown in FIGS. 5 to 7 due to the small scale of these figures, but methods for their fabrication are well-known.
After laying down the resistors 22 , a blanket barrier layer 24 of, for example, dry photoresist is applied to the entire front surface 12 of the wafer 100 , FIG. 5 . Then, selected regions 26 of the photoresist are removed and the remaining portions of photoresist are hard baked. Each region 26 is centered over a respective slot 18 and extends along substantially the full length thereof. In the finished printhead, the regions 26 define the lateral boundaries of a plurality of ink ejection chambers 28 , FIG. 8 , as will be described. Again, the formation of the barrier layer is part of the state of the art and is familiar to the skilled person.
Next, FIG. 6 , slots 30 ( FIG. 7 ) are laser machined fully through the thickness of the wafer 100 using one or more narrow laser beams 32 (not all the slots 30 are necessarily machined simultaneously as suggested by the presence of beams 32 in all three slots 18 in FIG. 6 ). In this embodiment each slot 30 is 30 μm wide and is centered over, and extends substantially the full length of, a respective slot 18 in the carrier 16 . The slots 30 could alternatively be cut by reactive ion etching. In the preferred embodiment, in either case the machining or etching is performed from below, i.e. on the rear surface 14 ′ upwardly through the slots 18 , while maintaining a greater air pressure at the front surface 12 of the wafer than at the rear surface 14 ′ to prevent contamination reaching the front surface.
The result is shown in FIG. 7 . Clearly, wafer slotting time is significantly reduced compared to the conventional 675 μm thick wafer; typically processing is twenty times faster.
Next, FIG. 8 , a pre-formed metallic nozzle plate 42 is applied to the top surface of the barrier layer 24 in a conventional manner, for example by bonding. The final composite carrier/wafer structure, whose cross-section is seen in FIG. 8 , comprises a plurality of ink ejection chambers 28 disposed along each side of each slot 30 although, since FIG. 8 is a cross-section, only one chamber 28 is seen on each side of each slot 30 . Each chamber 28 contains a respective resistor 22 , and an ink supply path 34 extends from the slot 30 to each resistor 22 . Finally, a respective ink ejection orifice 36 leads from each ink ejection chamber 28 to the exposed outer surface of the nozzle plate 42 . It will be understood that the manufacture of the structure above the wafer surface 12 , i.e. the structure containing the ink ejection chambers 28 , the ink supply paths 34 and the ink ejection orifices 36 as described above, can be entirely conventional and well known to those skilled in the art.
Finally, FIG. 9 , the composite carrier/wafer processed as above is diced by cutting along the grooves 20 to separate the individual printheads and each printhead is mounted on a print cartridge body 38 having respective apertures 40 for supplying ink from differently coloured ink reservoirs (not shown) to the printhead. To this end the printhead is mounted on the cartridge body 38 with each aperture 40 in fluid communication with a respective slot 18 in the carrier 16 .
It will be evident that each pair of registered slots 18 and 30 together supply ink of the relevant colour to the printhead, and replace the single ink supply slot in the much thicker (675 μm) substrate used in the prior art. However, due to the small depth (50 μm) of the narrow ink supply slot 30 in the substrate 100 compared to the much wider ink supply slot 18 in the carrier 16 , the resistance to ink flow is much less and so faster operating frequencies can be achieved. Furthermore, the aluminium nitride carrier 16 , which is directly below the resistors 22 and separated therefrom only by the thin substrate 100 , has a high thermal conductivity and thus acts as a good heat sink to dissipate the heat quickly after firing the resistors 22 .
Although the slots 18 in each group of three slots are shown as disposed side by side, they could alternatively be disposed end to end or staggered or otherwise offset without departing from the scope of this invention. Also, in the case of a printhead which uses a single colour ink, usually black, only one ink supply slot 18 , and correspondingly only one ink supply slot 30 , will be required per printhead.
The invention is not limited to the embodiment described herein and may be modified or varied without departing from the scope of the invention. | A method of making an inkjet printhead comprising providing a substrate having first and second opposite surfaces, providing a support member, bonding the second surface of the substrate to the support member, and, after the substrate and support member are bonded together, forming a plurality of ink ejection elements on the first surface of the substrate, the method further including forming communicating ink supply slots passing respectively through the substrate and support member to provide fluid communication between an ink supply and the ink ejection elements. | 8 |
This is a divisional application of U.S. Ser. No. 10/003,640, filed Nov. 2, 2001, now abandoned which is a continuation-in-part of U.S. Ser. No. 09/698,527, filed Oct. 27, 2000, now U.S. Pat. No. 6,462,169.
BACKGROUND OF THE INVENTION
Since the successful development of crystalline thermoplastic polyglycolide as an absorbable fiber-forming material, there has been a great deal of effort directed to the development of new linear fiber-forming polyesters with modulated mechanical properties and absorption profiles. Such modulation was made possible through the application of the concept of chain segmentation or block formation, where linear macromolecular chains comprise different chemical entities with a wide range of physicochemical properties, among which is the ability to crystallize or impart internal plasticization. Typical examples illustrating the use of this strategy are found in U.S. Pat. Nos. 5,554,170, 5,431,679, 5,403,347, 5,236,444, and 5,133,739, where difunctional initiators were used to produce linear crystallizable copolymeric chains having different microstructures.
On the other hand, controlled branching in crystalline, homochain polymers, such as polyethylene, has been used as a strategy to broaden the distribution in crystallite size, lower the overall degree in crystallinity and increase compliance (L. Mandelkern, Crystallization of Polymers , McGraw-Hill Book Company, NY, 1964, p. 105–106). A similar but more difficult-to-implement approach to achieving such an effect on crystallinity as alluded to above has been used specifically in the production of linear segmented and block heterochain copolymers such as (1) non-absorbable polyether-esters of polybutylene terephthalate and polytetramethylene oxide [see S. W. Shalaby and H. E. Bair, Chapter 4 of Thermal Characterization of Polymeric Materials (E.A. Turi, Ed.) Academic Press, NY, 1981, p. 402; S. W. Shalaby et al., U.S. Pat. No. 4,543,952 (1985)]; (2) block/segmented absorbable copolymers of high melting crystallizable polyesters Such as polyglycolide with amorphous polyether-ester such as poly-1,5-dioxepane-2-one (see A. Kafrawy et al., U.S. Pat. No. 4,470,416 (1984)); and (3) block/segmented absorbable copolyesters of crystallizable and non-crystallizable components as cited in U.S. Pat. Nos. 5,554,170, 5,431,679, 5,403,347, 5,236,444, and 5,133,739. However, the use of a combination of controlled branching (polyaxial chain geometry) and chain segmentation or block formation of the individual branches to produce absorbable polymers with tailored properties cannot be found in the prior art. This and recognized needs for absorbable polymers having unique combinations of crystallinity and high compliance that can be melt-processed into high strength fibers and films with relatively brief absorption profiles as compared to their homopolymeric crystalline analogs provided an incentive to explore a novel approach to the design of macromolecular chains to fulfill such needs. Meanwhile, initiation of ring-opening polymerization with organic compounds having three or four functional groups have been used as a means to produce crosslinked elastomeric absorbable systems as in the examples and claims of U.S. Pat. No. 5,644,002. Contrary to this prior art and in concert with the recognized needs for novel crystallizable, melt-processable materials, the present invention deals with the synthesis and use of polyaxial initiators with three or more functional groups to produce crystallizable materials with melting temperatures above 100° C., which can be melt-processed into highly compliant absorbable films and fibers.
SUMMARY OF THE INVENTION
In one aspect the present invention is directed to an absorbable, crystalline, monocentric, polyaxial copolymer which includes a central atom which is carbon or nitrogen and at least three axes originating and extending outwardly from the central atom, each axis including an amorphous, flexible component adjacent to and originating from the central atom, the amorphous component being formed of repeat units derived from at least one cyclic monomer, either a carbonate or a lactone, and a rigid, crystallizable component extending outwardly from the amorphous, flexible component, the crystallizable component being formed of repeat units derived from at least one lactone, wherein the copolymer comprises a melting temperature greater than 120° C., a heat of fusion greater than 10 J/g, and an endothermic transition at 40–100° C., wherein the endothermic transition can be controlled by subsequent heat treatment, such as orientation or annealing, of the copolymer. In one embodiment, a composite cover or mantle for a stent which includes a polymeric matrix reinforced with monofilament cross-spirals may be provided wherein the matrix, the monofilaments or both may be made of the copolymer of the present invention.
The flexible polyaxial initiator can be derived from p-dioxanone, 1,5-dioxepan-2-one, or one of the following mixtures of polymers: (1) trimethylene carbonate and 1,5-dioxepan-2-one with or without a small amount of glycolide; (2) trimethylene carbonate and a cyclic dimer of 1,5-dioxepan-2-one with or without a small amount of glycolide; (3) caprolactone and p-dioxanone with or without a small amount of glycolide; (4) trimethylene carbonate and caprolactone with or without a small amount of d1-lactide; (5) caprolactone and d1-lactide with or without a small amount of glycolide; and (6) trimethylene carbonate and d1-lactide with or without a small amount of glycolide. Further, the crystallizable segment can be derived from glycolide or 1-lactide. Alternate precursors of the crystallizable segment can be a mixture that is predominantly glycolide or 1-lactide with a minor component of one or more of the following monomers: p-dioxanone, 1,5-dioxepan-2-one, trimethylene carbonate, and caprolactone.
In another embodiment the present invention is directed to a device for sealing a puncture in a blood vessel, which includes a first flexible sealing member, which is positionable inside the blood vessel immediately adjacent to the puncture; an elongated member which is a composite and has an axial direction, a cross-sectional diameter, a proximal end and a distal end, wherein the first sealing member is attached to the distal end of the elongated member, the elongated member is capable of positioning the first sealing member within the blood vessel and immediately adjacent to the puncture, the elongated member further includes a distal locking portion comprising an enlarged cross-sectional diameter at the distal portion which extends outwardly from the punctured blood vessel when the first sealing member is positioned within the blood vessel and immediately adjacent to the puncture; and a second flexible sealing member threadable onto the elongated member by an opening defined therein, the second sealing member comprising locking means for locking onto the distal locking portion of the elongated member, such that the second sealing means is locked onto the elongated member on the outside of the blood vessel immediately adjacent to the puncture thereby sealing the puncture. Preferably, the locking means of the second sealing member comprises the opening defined therein having a diameter less than the enlarged cross-sectional diameter of the distal locking portion of the elongated member such that the second flexible sealing member is capable of stretching the opening defined therein for frictional engagement with the distal locking portion of the elongated member. Alternatively, the locking means of the second sealing member is a further flexible member threadable onto the elongated member having an opening defined therein which has a diameter less than the enlarged cross-sectional diameter of the distal locking portion of the elongated member, the further flexible member being capable of stretching the opening defined therein for frictional engagement with the distal locking portion of the elongate member, wherein the further flexible member is locked immediately adjacent to the second sealing member and opposite to the puncture of the blood vessel.
Preferably, either the first sealing member, the second sealing member or both is a formed from an absorbable polymer. Most preferably, at least one of the first sealing member and the second sealing member comprise an absorbable, crystalline, monocentric, polyaxial copolymer which includes a central atom selected from the group consisting of carbon and nitrogen; and at least three axes originating and extending outwardly from the central atom, each axis including: an amorphous, flexible component adjacent to and originating from the central atom, the amorphous component consisting of repeat units derived from at least one cyclic monomer selected from the group consisting essentially of carbonates and lactones; and a rigid, crystallizable component extending outwardly from the amorphous, flexible component, the crystallizable component consisting of repeat units derived from at least one lactone.
Preferably, the elongated member comprises a composite of a highly flexible sheath and a less flexible solid, monofilament core, the less flexible core within the sheath comprising the enlarged cross-sectional diameter of the distal locking portion of the elongated member composite. It is preferred that the sheath is a braided suture and the less flexible filament is threaded through the interior portion of the suture. It is also preferred that the ends of the filament are tapered. In one embodiment the less flexible filament is sufficiently flexible to compress and frictionally engage the opening defined within the second sealing member.
According to still another aspect of the present invention the subject copolymer is converted to different forms of absorbable stents, a tubular mantle (or cover) for stents, sutures, sealing devices or parts of multicomponent sealing devices for closing (or plugging) a wound or a needle hole in a wall of a blood vessel.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other aspects of the present invention will be best appreciated with reference to the following detailed description of specific embodiments of the invention, given by way of example only, when read in conjunction with the accompanying drawing, wherein
FIG. 1 shows a sealing device for closing a wound in a wall of a vessel according to a first embodiment of a first specific application of the invention;
FIG. 2 shows a sectional view of a first sealing member;
FIG. 3 shows a sectional view of a second sealing member;
FIG. 4 shows a sealing device for closing a wound in a wall of a vessel according to a first embodiment of a first specific application of the invention;
FIG. 5 shows an elongated core;
FIG. 6 shows a sealing device for closing a wound in a wall of a vessel according to a second embodiment of a first specific application of the invention;
FIG. 7 shows a sealing device for closing a wound in a wall of a vessel according to a third embodiment of a first specific application of the invention;
FIG. 8 shows a sealing device for closing a wound in a wall of a vessel according to a fifth embodiment of a first specific application of the invention;
FIG. 9 shows a sealing device for closing a wound in a wall of a vessel according to a fifth embodiment of a first specific application of the invention;
FIG. 10 shows schematically a prior art stent applicable in the present invention;
FIG. 11 is a longitudinal view of a stent according to a preferred embodiment of the present invention;
FIG. 12 is a cross sectional view of the stent shown in FIG. 11 ; and
FIG. 13 is a longitudinal view of a stent according to another preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
This invention deals with absorbable, polyaxial, monocentric, crystallizable, polymeric molecules with non-crystallizable, flexible components of the chain at the core and rigid, crystallizable segments at the chain terminals. More specifically, the present invention is directed to the design of amorphous polymeric polyaxial initiators with branches originating from one polyfunctional organic compound so as to extend along more than two coordinates and their copolymerization with cyclic monomers to produce compliant, crystalline film- and fiber-forming absorbable materials. The absorbable copolymeric materials of this invention comprise at least 30 percent, and preferably 65 percent, by weight, of a crystallizable component which is made primarily of glycolide-derived or 1-lactide-derived sequences, and exhibit first and second order transitions below 222° C. and below 42° C., respectively, and undergo complete dissociation into water-soluble by-products in less than eighteen months and preferably less than twelve months, and more preferably less than six months, and much more preferably less than four months when incubated in a phosphate buffer at 37° C. and pH 7.4 or implanted in living tissues.
The amorphous polymeric, polyaxial initiators (PPIs) used in this invention to produce crystalline absorbable copolymeric materials can be made by reacting a cyclic monomer or a mixture of cyclic monomers such as trimethylene carbonate, caprolactone, and 1,5-dioxapane-2-one in the presence of an organometallic catalyst with one or more polyhydroxy, polyamino, or hydroxyamino compound having three or more reactive amines and/or hydroxyl groups. Typical examples of the latter compounds are glycerol and ethane-trimethylol, propane-trimethylol, pentaerythritol, triethanolamine, and N-2-aminoethy1-lactide 1,3-propanediamine.
The flexible polyaxial initiator can be derived from p-dioxanone, 1,5-dioxepan-2-one, or one of the following mixtures of polymers: (1) trimethylene carbonate and 1,5-dioxepan-2-one with or without a small amount of glycolide; (2) trimethylene carbonate and a cyclic dimer of 1,5-dioxepan-2-one with or without a small amount of glycolide; (3) caprolactone and p-dioxanone with or without a small amount of glycolide; (4) trimethylene carbonate and caprolactone with or without a small amount of d1-lactide; (5) caprolactone and d1-lactide (or meso-lactide) with or without a small amount of glycolide; and (6) trimethylene carbonate and d1-lactide (or meso-lactide) with or without a small amount of glycolide. Further, the crystallizable segment can be derived from glycolide or 1-lactide. Alternate precursors of the crystallizable segment can be a mixture of predominantly glycolide or 1-lactide with a minor component of one or more of the following monomers: p-dioxanone, 1,5-dioxepan-2-one, trimethylene carbonate, and caprolactone.
The crystalline copolymers of the present invention are so designed to (1) have the PPI devoid of any discernable level of crystallinity; (2) have the PPI component function as a flexible spacer of a terminally placed, rigid, crystallizable component derived primarily from glycolide so as to allow for facile molecular entanglement to create pseudo-crosslinks, which in turn, maximize the interfacing of the amorphous and crystalline fractions of the copolymer leading to high compliance without compromising tensile strength; (3) maximize the incorporation of the hydrolytically labile glycolate linkage in the copolymer without compromising the sought high compliance—this is achieved by directing the polyglycolide segments to grow on multiple active sites of the polymeric initiator and thus limiting the length of the crystallizable chain segments; (4) have a broad crystallization window featuring maximum nucleation sites and slow crystallite growth that in turn assists in securing a highly controlled post-processing and development of mechanical properties—this is achieved by allowing the crystallizable components to entangle effectively with non-crystallizable components leading to high affinity for nucleation, high pre-crystallization viscosity, slow chain motion, and low rate of crystallization; (5) force the polymer to form less perfect crystallites with broad size distribution and lower their melting temperature as compared to their homopolymeric crystalline analogs to aid melt-processing—this is achieved by limiting the length of the crystallizable segments of the copolymeric chain as discussed earlier; (6) allow for incorporating basic moieties in the PPI which can affect autocatalytic hydrolysis of the entire system which in turn accelerates the absorption rate; and (7) allow the polymer chain to associate so as to allow for endothermic thermal events to take place between 40 and 100° C. that can be associated with an increase in tensile toughness similar to that detected in PET relative to the so-called middle endothermic peak (MEP) (S. W. Shalaby, Chapter 3 of Thermal Characterization of Polymeric Materials , Academic press, NY, 1981, p. 330). The temperature at which these transitions take place is dependent on the degree of orientation of the polymers of this invention and the temperatures at which the polymers are annealed.
As an example, the crystalline copolymeric materials of the present invention may be prepared as follows, although as noted above, other monomers are also within the scope of the present invention. The amorphous polymeric polyaxial initiator is formed by a preliminary polymerization of a mixture of caprolactone and trimethylene carbonate in the presence of trimethylol-propane and a catalytic amount of stannous octoate, using standard ring-opening polymerization conditions which entail heating the stirred reactants in nitrogen atmosphere at a temperature exceeding 110° C. until substantial or complete conversion of the monomers is realized. This can be followed by adding a predetermined amount of glycolide. Following the dissolution of the glycolide in the reaction mixture, the temperature is raised above 150° C. but not to exceed 180° C. for more than 30 minutes to allow the glycolide to copolymerize with the polyaxial initiator without compromising the expected sequence distribution in PPI and the microtexture of the crystallizable terminal. When practically all the glycolide is allowed to react, the resulting copolymer is cooled to 25° C. After removing the polymer from the reaction kettle and grinding, trace amounts of unreacted monomer are removed by heating under reduced pressure. The ground polymer can then be extruded and pelletized prior to its conversion to fibers or films by conventional melt-processing methods. At the appropriate stage of polymerization and product purification, traditional analytical methods, such as gel-permeation chromatography (GPC), solution viscosity, differential scanning calorimetry (DSC), nuclear magnetic resonance (NMR), and infrared spectroscopy (IR) are used to monitor or determine (directly or indirectly) the extent of monomer conversion, molecular weight, thermal transitions (melting temperature, Tm, and glass transition temperature, Tg), chain microstructure, and chemical entity, respectively.
Another aspect of this invention deals with end-grafting a PPI with caprolactone or 1-lactide, and preferably in the presence of a minor amount of a second monomer, to produce absorbable crystalline polymers for use as bone sealants, barrier membranes, thin films, or sheets. The latter three can be made to have continuous cell microporous morphology.
Films made by compression molding of the copolymers described in the examples set forth below are evaluated for (1) tensile strength; (2) in vitro breaking strength retention and mass loss during incubation in a phosphate buffer at 37° C. and pH 7.4; (3) in vivo breaking strength retention using a rat model where strips of the films are implanted subcutaneously for 1 to 6 weeks and individual lengths are explanted periodically to determine percent of retained breaking strength; and (4) in vivo absorption (in terms of mass loss) using a rat model where a film strip, inserted in a sealed polyethylene terephthalate (PET) woven bag, is placed in the peritoneum for 6, 8, 10, 12 and 14 weeks. At the end of each period, the PET bag is removed and the residual mass of the strips is removed, rinsed with water, dried, and its weight is determined.
Specifically, an important aspect of this invention is the production of compliant absorbable films with modulated absorption and strength loss profiles to allow their use in a wide range of applications as vascular devices or components therefor. More specifically is the use of these devices in sealing punctured blood vessels.
In another aspect, this invention is directed to the use of the polymers described herein for the production of extruded or molded films for use in barrier systems to prevent post-surgical adhesion or compliant covers, sealants, or barriers for burns and ulcers as well as compromised/damaged tissue. The aforementioned articles may also contain one or more bioactive agent to augment or accelerate their functions. In another aspect, this invention is directed to melt-processed films for use to patch mechanically compromised blood vessels. In another aspect, this invention is directed to the use of the polymer described herein as a coating for intravascular devices such as catheters and stents. In another aspect, this invention is directed to the application of the polymers described herein in the production of extruded catheters for use as transient conduits and microcellular foams with continuous porous structure for use in tissue engineering and guiding the growth of blood vessels and nerve ends. Another aspect of this invention is directed to the use of the polymers described herein to produce injection molded articles for use as barriers, or plugs, to aid the function of certain biomedical devices used in soft and hard tissues and which can be employed in repairing, augmenting, substituting or redirecting/assisting the functions of several types of tissues including bone, cartilage, and lung as well as vascular tissues and components of the gastrointestinal and urinogenital systems. In another aspect, this invention is directed to the use of polymers described herein to produce compliant, melt-blown fabrics and monofilament sutures with modulated absorption and strength retention profiles.
In one aspect of this invention, the subject copolymers are converted to different forms of absorbable stents, such as those used (1) as an intraluminal device for sutureless gastrointestinal sutureless anastomosis; (2) in laparoscopic replacement of urinary tract segments; (3) as an intraluminal device for artery welding; (4) in the treatment of urethral lesions; (5) as a tracheal airway; (6) in the treatment of recurrent urethral strictures; (7) for vasectomy reversal; (8) in the treatment of tracheal stenoses in children; (9) for vasovasostomy; (10) for end-to-end ureterostomy; and (11) as biliary devices.
In another aspect of this invention, the subject copolymers are converted to a highly compliant, expandable tubular mantle, sleeve or cover that is placed tightly outside an expandable metallic or polymeric stent so that under concentric irreversible expansion at the desired site of a treated biological conduit, such as blood vessel or a urethra, both components will simultaneously expand and the mantle provides a barrier between the inner wall of the conduit and the outer wall of the stent. In another aspect of this invention, the subject copolymers are used as a stretchable matrix of a fiber-reinforced cover, sleeve, or mantle for a stent, wherein the fiber reinforcement is in the form of spirally coiled yarn (with and without crimping) woven, knitted, or braided construct. In another aspect of this invention, the stent mantle, or cover, is designed to serve a controlled release matrix of bioactive agents such as those used (1) for inhibiting neointima formation as exemplified by hirudin and the prostacyclic analogue, iloprost; (2) for inhibiting platelet aggregation and thrombosis; (3) for reducing intraluminal and particular intravascular inflammation as exemplified by dexamethasone and non-steroidal inflammatory drugs, such as naproxen; and (4) for suppressing the restenosis.
One aspect of this invention deals with the conversion of the subject copolymers into molded devices or components of devices used as a hemostatic puncture closure device after coronary angioplasty.
It is further within the scope of this invention to incorporate one or more medico-surgically useful substances into the copolymers and devices subject of this invention. Typical examples of these substances are those capable of (1) minimizing or preventing platelet adhesion to the surface of vascular grafts; (2) rendering anti-inflammatory functions; (3) blocking incidents leading to hyperplasia as in the case of synthetic vascular grafts; (4) aiding endothelialization of synthetic vascular grafts; (5) preventing smooth muscle cell migration to the lumen of synthetic vascular grafts; and (6) accelerating guided tissue ingrowth in fully or partially absorbable scaffolds used in vascular tissue engineering.
In order that those skilled in the art may be better able to practice the present invention, the following illustrations of the preparation of typical crystalline copolymers are provided.
EXAMPLE 1
Synthesis of 20/25 (Molar) Caprolactone/Trimethylene Carbonate Copolymer as a Triaxial Initiator and Reaction with 55 Relative Molar Parts of Glycolide
An initial charge consisted of 142.4 grams (1.249 moles) caprolactone, 159.4 grams (1.563 moles) trimethylene carbonate, 1.666 grams (1.24×10 −2 moles) trimethylol-propane, and 1.0 ml (2.03×10 −4 moles) of a 0.203M solution of stannous octoate catalyst in toluene after flame drying the reaction apparatus. The reaction apparatus was a 1 L stainless steel kettle with 3-neck glass lid equipped with an overhead mechanical stirring unit, vacuum adapter, and two 90° connectors for an argon inlet.
The apparatus and its contents were heated to 50° C. under vacuum with a high temperature oil bath. Upon complete melting of the contents after 30 minutes, the system was purged with argon, stirring initiated at 32 rpm, and the temperature set to 150° C. After 4 hours at 150° C., the viscosity of the polyaxial polymeric initiator (PPI) had increased and the temperature of the bath was reduced to 110° C. Upon reaching 110° C., 398.5 grams (3.435 moles) of glycolide were added to the system. When the glycolide had completely melted and mixed into the polyaxial polymeric initiator, the temperature was increased to 180° C. and stirring was stopped. The reaction was allowed to continue for 2 hours before cooling the system to 50° C. and maintaining the heat overnight. The polymer was isolated, ground, dried, extruded and redried as described below in Example 5.
The extrudate was characterized as follows: The inherent viscosity using hexafluoroisopropyl alcohol (HFIP) as a solvent was 0.97 dL/g. The melting temperature and heat of fusion, as determined by differential scanning calorimetry (using initial heating thermogram), were 215° C. and 40.8 J/g, respectively.
EXAMPLE 2
Synthesis of 25/30 (Molar) Caprolactone/Trimethylene Carbonate Copolymer as a Triaxial Initiator and Reaction with 45 Relative Molar Parts of Glycolide
An initial charge consisted of 122.8 grams (1.077 moles) caprolactone, 131.9 grams (1.292 moles) trimethylene carbonate, 1.928 grams (1.44×10 −2 moles) trimethylol-propane, and 1.0 ml (8.62×10 −5 moles) of a 0.086M solution of stannous octoate catalyst in toluene after flame drying the reaction apparatus. The reaction apparatus was a 1 L stainless steel kettle with 3-neck glass lid equipped with an overhead mechanical stirring unit, vacuum adapter, and two 90° connectors for an argon inlet.
The apparatus and its contents were then heated to 65° C. under vacuum with a high temperature oil bath. After 30 minutes, with the contents completely melted, the system was purged with argon, stirring initiated at 34 rpm, and the temperature set to 140° C. After 3 hours at 140° C., the temperature was raised to 150° C. for 1 hour and then reduced back to 140° C. At this point, 225.0 grams (1.940 moles) of glycolide were added to the system while rapidly stirring. When the glycolide had completely melted and mixed into the polyaxial polymeric initiator, the temperature was increased to 180° C. and stirring was stopped. The reaction was allowed to continue for 2 hours before cooling the system to room temperature overnight. The polymer was isolated, ground, dried, extruded, and redried as described in Example 5.
Characterization of the extrudate was conducted as follows: The inherent viscosity using HFIP as a solvent was 0.93 dL/g. The melting temperature and heat of fusion, as measured by differential scanning calorimetry (DSC using initial heating thermogram), were 196° C. and 32.1 J/g, respectively.
EXAMPLE 3
Synthesis of 20/25/3 (Molar) Caprolactone/Trimethylene Carbonate/Glycolide Copolymer as a Triaxial Initiator and Reaction with 52 Relative Molar Parts of Glycolide
An initial charge consisted of 101.6 grams (0.891 moles) caprolactone, 113.5 grams (1.113 moles) trimethylene carbonate, 15.5 grams of glycolide (0.134 moles), 1.996 grams (1.49×10 −2 moles) trimethylol-propane, and 1.0 ml (1.28×10 −4 moles) of a 0.128M solution of stannous octoate catalyst in toluene after flame drying the reaction apparatus. The reaction apparatus was a 1 L stainless steel kettle with 3-neck glass lid equipped, an overhead mechanical stirring unit, vacuum adapter, and two 90° connectors for an argon inlet.
The apparatus and its contents were then heated to 85° C. under vacuum with a high temperature oil bath. After 30 minutes, with the contents completely melted, the system was purged with argon, stirring initiated at 34 rpm, and the temperature set to 140° C. After 4 hours at 140° C., 268.8 grams (2.317 moles) of glycolide were added to the system while rapidly stirring. When the glycolide had completely melted and mixed into the polyaxial polymeric initiator, the temperature was increased to 180° C. and stirring was stopped. The reaction was allowed to continue for 2 hours before cooling the system to room temperature overnight. The polymer was isolated, ground, dried, extruded and redried as in Example 5.
The extrudate was characterized as follows: The inherent viscosity using HFIP as a solvent was 0.89 dL/g. The melting temperature and heat of fusion, as measured by differential scanning calorimetry (DSC using initial heating thermogram), were 212° C. and 34 J/g, respectively.
EXAMPLE 4
Synthesis of 20/25/3 (Molar) Caprolactone/Trimethylene-Carbonate/Glycolide Copolymer as a Triaxial Initiator and Reaction with 52 Relative Molar Parts of Glycolide
Glycolide (18.6 g, 0.1603 mole), TMC (136.7 g, 1.340 mole), caprolactone (122.0 g, 1.070 mole), trimethylolpropane (2.403 g, 0.01791 mole) and stannous octoate catalyst (0.2M in toluene, 764 μL, 0.1528 mmol) were added under dry nitrogen conditions to a 1.0 liter stainless steel reaction kettle equipped with a glass top and a mechanical stirrer. The reactants were melted at 85° C. and the system was evacuated with vacuum. The system was purged with dry nitrogen and the melt was heated to 160° C. with stirring at 30 rpm. Samples of the prepolymer melt were taken periodically and analyzed for monomer content using GPC. Once the monomer content of the melt was found to be negligible, glycolide (322.5 g, 2.780 mole) was added with rapid stirring. The stir rate was lowered to 30 rpm after the contents were well mixed. The melt was heated to 180° C. Stirring was stopped upon solidification of the polymer. The polymer was heated for 2 hours at 180° C. after solidification. The resulting polymer was cooled to room temperature, quenched in liquid nitrogen, isolated, and dried under vacuum. The polymer was isolated, ground, redried, and extruded as described in Example 5. The extrudate was characterized by NMR and IR for identity and DSC (using initial heating thermogram) for thermal transition (T m =208° C., ΔH=28.0 J/g) and solution viscosity in hexafluoroisopropyl alcohol (η=0.92 dL/g).
EXAMPLE 5
Size Reduction and Extrusion of Polymers of Examples 1 through 4
The polymer was quenched with liquid nitrogen and mechanically ground. The ground polymer was dried under vacuum at 25° C. for two hours, at 40° C. for two hours, and at 80° C. for four hours. The polymer was melt extruded at 225° C. to 235° C. using a ½ inch extruder equipped with a 0.094 in die. The resulting filaments were water cooled. The average filament diameter was 2.4 mm. The filament was dried at 40° C. and 80° C. under vacuum for eight and four hours, respectively.
EXAMPLE 6
Compression-Molding of Polymers from Examples 3 and 4 to a Sealing Device for a Punctured Blood Vessel and Its Packaging
The compression molding process entailed exposing the polymer to an elevated temperature between two mold halves. When temperature of the mold halves exceeded the polymer melting temperature, pressure was applied to the mold and the material was allowed to flow into a predefined cavity of the mold. The mold was then cooled to room temperature before it was opened and the newly shaped polymer was removed.
The full molding cycle can be described as: (1) Drying—typical: temperature 80° C. during 2 hours; (2) Pre-heating, temperature increase—typical: pressure 5,000N, temperature from room temperature up to 200° C.; (3) Forming, constant temperature under high pressure—typical: pressure 50,000N, temperature 200° C.; (4) Cooling, temperature decrease under high pressure—typical: pressure 50,000N, temperature from 200° C. down to 50° C.; (5) Mold opening; (6) Annealing—typical: temperature 80° C. during 2 hours; and (7) Packaging—typically the device was removed from the mold and packaged under vacuum under a protective gas environment.
EXAMPLE 7
Synthesis of 13.3/17.7/2 (Molar) Caprolactone/Trimethylene Carbonate/Glycolide Copolymer as a Triaxial Initiator and Reaction with Relative 67 Molar Parts of Glycolide
Glycolide (10.4 g, 0.090 mole), TMC (76.5 g, 0.750 mole), caprolactone (68.4 g, 0.600 mole), trimethylolpropane (1.995 g, 0.01487 mole) and stannous octoate catalyst (0.2M in toluene, 637 μL, 0.1274 mmole) were added under dry nitrogen conditions to a 1.0 liter stainless steel reaction kettle equipped with a glass top and a mechanical stirrer. The reactants were melted at 85° C. and the system was evacuated with vacuum. The system was purged with dry nitrogen and the melt was heated to 160° C. with stirring at 30 rpm. Samples of the prepolymer melt were taken periodically and analyzed for monomer content using GPC. Once the monomer content of the melt was found to be negligible, glycolide (344.5 g, 2.970 mole) was added with rapid stirring. The stir rate was lowered to 30 rpm after the contents were well mixed. The melt was heated to 180° C. Stirring was stopped upon solidification of the polymer. The polymer was heated for 2 hours at 180° C. after solidification. The resulting polymer was cooled to room temperature, quenched in liquid nitrogen, isolated, and dried under vacuum. The polymer was characterized by NMR and IR (for identity), DSC thermal transition (T m =215.7) and solution viscosity in hexafluoroisopropyl alcohol (η−0.95 dL/g).
EXAMPLE 8
Synthesis of 13.6/17.0/2.0 (Molar) Caprolactone/Trimethylene Carbonate/Glycolide Copolymer as a Basic Triaxial Initiator and Reaction with Relative 67.4 Molar Parts of Glycolide and Trimethylene Carbonate
Glycolide (3.1 g, 0.0267 mole), TMC (23.0 g, 0.2255 mole), caprolactone (20.5 g, 0.1798 mole), triethanolamine (0.6775 g, 4.55 mmole) and stannous octoate catalyst (0.2M in toluene, 519 μL, 0.1038 mmole) were added under dry nitrogen conditions to a 0.5 Liter stainless steel reaction kettle equipped with a glass top and a mechanical stirrer. The reactants were melted at 85° C. and the system was evacuated with vacuum. The system was purged with dry nitrogen and the melt was heated to 160° C. with stirring at 30 rpm. Samples of the prepolymer melt were taken periodically and analyzed for monomer content using GPC. Once the monomer content of the melt was found to be negligible, glycolide (103.4 g, 0.8914 mole) was added with rapid stirring. The stir rate was lowered to 30 rpm after the contents were well mixed. The melt was heated to 180° C. Stirring was stopped upon solidification of the polymer. The polymer was heated for 2 hours at 180° C. after solidification. The resulting polymer was cooled to room temperature, quenched in liquid nitrogen, isolated, and dried under vacuum. The polymer was characterized for identity and composition (IR and NMR, respectively) and thermal transition by DSC (T m 220° C.) and molecular weight by solution viscometry (η=0.80 in hexafluoroisopropyl alcohol).
EXAMPLE 9
Synthesis of 13.6/17.0/2.0 (Molar) Caprolactone/Trimethylene Carbonate/Glycolide Copolymer as a Basic Triaxial Initiator and Reaction with Relative 67.4 Molar Parts of Glycolide
The two-step polymerization was conducted as in Example 8 with the exception of using 0.6915 g triethanolamine and 693 μl of stannous octanoate solution. The final polymer was isolated and characterized as in Example 8 and it was shown to have a T m =221° C. and inherent viscosity (in HFIP)=0.82.
EXAMPLE 10
Synthesis of 13.3/17.7/2 (Molar) Caprolactone/Trimethylene Carbonate/Glycolide Copolymer as a Tetra-axial Initiator and Reaction with Relative 67 Molar Parts of Glycolide
Glycolide (3.1 g, 0.0267 mole), TMC (23.0 g, 0.2255 mole), caprolactone (20.5. g, 0.1796 mole), pentaerythritol (0.600 g., 0.0044 mole) and stannous octoate catalyst (0.2 M in toluene, 193 μl, 0.0386 mmol) were placed under dry nitrogen conditions to a 0.5 L stainless steel reaction kettle equipped with a glass top and a mechanical stirrer. The polymerization charge was dried at 25° C. and 40° C. under reduced pressure for 60 and 30 minutes, respectively. The reactants were then melted at 85° C. and the system was purged with dry nitrogen. The melt was heated to 160° C. with stirring at 30 rpm. Samples of the prepolymer melt were taken periodically and analyzed for monomer content using GPC (gel permeation chromatography). Once the monomer content of the polymer melt was found to be negligible, glycolide (103.4 g., 0.8914 mole) was added with rapid stirring that is more than 40 rpm. The stirring rate was then lowered to 30 rpm after the contents were well mixed. The reactants were heated to 180° C. Stirring was stopped upon solidification of the polymer. The polymer was heated for 2 hours at 180° C. after solidification. The resulting polymer was cooled to room temperature, quenched in liquid nitrogen, isolated, and dried at 25° C. and then 40° C. under reduced pressure.
The final polymer was isolated and characterized as in Example 8 and it was shown to have a T m =219° C. and inherent viscosity (in HFIP)=0.98.
EXAMPLE 11
Size Reduction and Extrusion of Polymer from Examples 7 through 10
The polymer was quenched with liquid nitrogen and mechanically ground. The ground polymer was dried under vacuum at 25° C. for two hours, at 40° C. for two hours, and at 80° C. for four hours. The polymer was melt extruded at 235° C. to 245° C. using a ½ inch extruder equipped with a 0.094 in die. The resulting monofilament was quenched in an ice-water bath before winding. The monofilament was dried at 40° C. and under vacuum for four hours before orientation.
EXAMPLE 12
Orientation of Melt-Spun Monofilaments
Polymers of Examples 7 through 10 that had been extruded as described in Example 11 were oriented by two-stage drawing into monofilament sutures. Prior to drawing Example 7, monofilaments were pre-tensioned and annealed. The drawing was conducted at 90–100° C. in the first stage and 100–130° C. in the second stage. The overall draw ratio varied between 3.73× and 4.6×. A number of monofilaments were relaxed at 70° C. for 15 minutes to reduce their free shrinkage. Properties of the oriented monofilaments are summarized in Table I.
TABLE I
Drawing Conditions and Fiber Properties of Polymers from Examples 7 through 9
Origin of
Pre-Draw
Post-Draw
Free
Straight
Modu-
Elonga-
Extruded
Fiber
Draw
Draw
Annealing
Relaxation
Shrinkage
Diameter
Strength
lus
tion
Polymer
Number
Ratio
Temp. (S1/S2)
(min/° C.)
(%)
(%)
(mil)
(Kpsi)
(Kpsi)
(%)
Example
7
7F-1
3.73X
95/130
35/65
—
4.4
13.4
75
444
22
7
7F-2
3.73X
95/130
35/65
2.3
1.8
15.1
53
182
36
7
7F-3
4.14X
95/120
30/65
—
4.2
10.2
66
434
19
7
7F-4
4.14X
95/120
30/65
3
1.5
11.0
61
257
31
8
8F-1
4.50X
100/120
—
—
3.1
10.2
71
195
26
9
9F-1
4.43X
100/130
—
—
2.1
10.6
72
230
27
10
10F-1
4.60X
95/120
—
—
2.4
12.6
57
158
25
EXAMPLE 13
Sterilization of Monofilament Sutures and Evaluation of their In Vitro Breaking Strength Retention
Monofilament sutures Numbers 8F-1 and 9F-1 described in Table I were radiochemically sterilized in hermetically sealed foil packages that have been pre-purged with dry nitrogen gas, using 5 and 7.5 KGy of gamma radiation. The radiochemical sterilization process entails the use of 200–400 mg of Delrin (poly-formaldehyde) film as package inserts for the controlled release, radiolytically, of formaldehyde gas as described earlier by Correa et al., [Sixth World Biomaterials Congress, Trans Soc. Biomat., II , 992 (2000)]. The sterile monofilament sutures were incubated in a phosphate buffer at 37° C. and pH=7.4 to determine their breaking strength retention profile as absorbable sutures. Using the breaking strength data of non-sterile sutures (Table I), the breaking strength retention data of sterile sutures were calculated. A summary of these data is given in Table II. These data indicate all sutures retained measurable strength at two weeks in the buffer solution.
TABLE II
Tensile Properties and In Vitro Breaking Strength Retention
(BSR) of Radiochemically Sterilized Monofilament Sutures
Suture Number
9F-1
8F-1
Sterilization Dose (KGy)
5
7.5
5
7.5
Post-irradiation Tensile Properties
Tensile Strength (Kpsi)
66
68
67
65
Modulus (Kpsi)
266
254
269
263
Elongation (Kpsi)
30
35
31
30
BSR, % at
Week 1
70
57
82
72
Week 2
24
22
18
17
EXAMPLE 14
Synthesis of 21/30/4 (Molar) Caprolactone/Trimethylene Carbonate as a Triaxial Initiator and Reaction with 40/5 Relative Molar Parts of 1-Lactide/Caprolactone
Glycolide (22.74 g, 0.2 mole), TMC (149.94 g, 1.47 mole), caprolactone (117.31 g, 1.03 mole), triethanolamine (1.34 g, 9 mmole), and stannous octoate (3.86×10 −4 mole as 0.2 M solution in toluene) were reacted in similar equipment and environment as those described in Example 7. The formation of the triaxial initiator was completed after heating at 180° C. for 160 minutes. The product was cooled to room temperature and a mixture of 1-lactide (282.24 g., 1.96 mole) and caprolactone (27.93 g, 0.25 mole) were added under nitrogen atmosphere. The reactants were prepared for the second step of polymerization as described in Example 7. And the final polymer formation was completed after heating between 195–200° C. for 15 minutes until complete dissolution of triaxial initiator, and then heating for 23 hours at 140° C. The polymer was isolated, ground, dried, and heated under reduced pressure to remove residual monomer. The polymer was characterized by NMR and IR (for identity), DSC for thermal transition (T m =148° C., ΔH=19 J/g), and inherent viscometry (I.V.) in chloroform (for molecular weight, I.V.=1.14 dL/g).
EXAMPLE 15
Synthesis of 156/20 (Molar) Caprolactone/Trimethylene Carbonate Copolymer as Triaxial Initiator and Reaction with Relative 65 Molar Parts Glycolide
Using a similar scheme to that used in Example 7, the triaxial initiator was prepared using caprolactone (45.5 g, 0.399 mole), TMC (54.3 g, 0.532 mole), trimethylolpropane (0.713 g, 5.32 mmole) and stannous octoate (5.32×10 −5 mole as a 0.2 M solution in toluene) and a polymerization temperature and time of 160° C./5 hours. As in Example 7, glycolide (200.6 g, 1.729 mole) was allowed to end-graft onto the triaxial initiator in presence of D & C Violet #2 (0.5 g) at 180° C./5 hours. The polymer was isolated, purified, and characterized as in Example 7. It had an inherent viscosity in HFIP=0.66 dL/g, T m =225° C., ΔH=66 J/g.
EXAMPLE 16
Processing of Example 15 Copolymer into Monofilaments and Evaluation of Their Properties
Following a similar processing scheme to those used for the copolymer of Example 7 (as described in Examples 11 and 12), the respective monofilaments of Example 15 were produced and exhibited the following properties:
T m −214° C., ΔH=64 J/g
The DSC thermogram showed a minor endothermic transition at about 65° C.
Fiber Diameter=0.28 mm
Straight tensile strength=76 Kpsi
Modulus=335 Kpsi
Elongation=42%
The monofilaments were examined for breaking strength retention (BSR) after incubation in a phosphate buffer at 37° C. and pH=7.4. The percent BSR at one and two weeks was 72 and 24, respectively.
EXAMPLE 17
Synthesis of 15/20 (Molar) Caprolactone/Trimethylene Carbonate Copolymer as Triaxial Initiator and Reaction with Relative 65 Molar Parts Glycolide
The triaxial initiator was prepared as in Example 15 with the exception of using (1) Triethanolamine as the monomeric initiator; (stannous octoate at ˜30% higher concentration; and (3) reaction time of 18 hours. End-grafting with glycolide was carried out as in Example 15. The purified polymer was shown to have inherent viscosity=0.94 dL/g, T m =220° C., and ΔH=81.1 J/g.
EXAMPLE 18
Processing of Example 17 Copolymer into Monofilaments and Evaluation of Their Properties
A monofilament suture was prepared from the copolymer of Example 17 and oriented following a similar scheme to that used in Example 16. The monofilaments exhibited the following properties:
T m −214° C., ΔH=53 J/g
A minor endothermic transition was observed in partially and fully oriented monofilament at about 60° C. and 90° C., respectively.
Fiber Diameter=0.29 mm
Straight tensile strength=78 Kpsi
Modulus=296 Kpsi
Elongation=58%
The monofilaments were examined for breaking strength retention at incubation in a phosphate buffer at 37° C. and pH=7.4. The percent BSR at one and two weeks was 78 and 51, respectively. In addition to the oriented monofilament described above, the copolymer of example 17 was extruded into microfilaments having a diameter of 60–120μ. These were used without additional orientation in composite assembling as described in Example 19. These microfilaments displayed an elongation that exceeded 300%.
EXAMPLE 19
General Method for Assembling Composite Stent Mantle
The undrawn microfilaments from Example 18 were wrapped in two opposite directions on a Teflon rod having a diameter of 2–4 mm to provide a two-component, cross-spiral construct. Each constituent spiral was comprised of 1 to 10 turns/cm along the axis of the Teflon rod. While on the Teflon rod, the cross-spiral construct was coated with a solution (10–20% in dichloromethane, DCM) of the copolymer of Example 14. The coating process entails multiple steps of dipping and air-drying and was pursued until the desirable coating thickness is achieved (25–50μ). Complete removal of the solvent was achieved by replacing the composite on the Teflon rod under reduced pressure at 25° C. for 6–12 hours until a constant weight is realized. The composite tube (typically 2–5 cm long) was removed from the Teflon cylinder by gentle sliding. This was then cut to the desired length before sliding over a metallic stent.
As indicated above a number of different applications for the copolymer exist. Below two specific applications, namely a device for sealing punctured blood vessels and a stent, will be described more thoroughly.
FIG. 1 shows a sealing device for closing a wound in a wall of a vessel according to a first embodiment of the invention. The sealing device comprises three separate parts, namely a first sealing member 2 an elongated member 4 and a second sealing member 6 . The first sealing member 2 is attached to a distal end of the elongate member 4 . In this first embodiment of the sealing device, the first sealing member comprises two through openings 8 , 10 ( FIG. 2 ) through which a multifilament suture wire 12 is thread so as to make a pair of suture wires constituting the elongated member 4 .
The second sealing member 6 is provided with an opening 14 ( FIG. 3 ), which is adapted to the elongate member 4 , i.e. the opening 14 is greater than the thickness of the proximal portion of the elongate member 4 . With a structure like this the second sealing member 6 is threadable onto and along the elongate element 4 ( FIG. 1 ). The most distal portion of the elongate member 4 has a constant thickness that is slightly greater than the opening 14 of the second sealing member 6 and constitutes the distal lock portion 16 . This will allow for frictional engagement between inside of the opening 14 of the second sealing member 6 and the distal lock portion 16 of the elongate member 4 which makes the sealing device infinitely variable lockable along said distal lock portion 16 ( FIG. 4 ).
The multifilament suture wire 12 is preferably made of a resorbable material such as glycolic/lactide polymer The first sealing member 2 and second sealing member 6 are made of the flexible resorbable copolymer, preferably the present inventive copolymer.
The choice of using a suture wire for the elongated element 4 is very important for the security of the sealing device. It is within the scope of the present invention, but less preferred, to use the same material, e.g. a polymer, in the elongated member 4 as in the second sealing member 6 . Since polymer gives a very glossy surface, it is hard to get high power frictional engagement between the elongated member 4 and the sealing member 6 . Using a suture wire 12 or braided suture for the elongate member 4 gives a safer sealing since the suture wire comprises a number of circulating fibres thus giving the wire a rough surface with a high frictional sealing power towards a glossy surface inside the opening 14 of the second sealing member 6 .
The suture wire also makes the sealing device safer in another way. The suture wire is made in one piece and has very high tensile strength. It constitutes a continuous wire from the inner seal through the outer seal and to a tampering grip of the insertion tool, being threaded in through the first opening 8 and out again through the second opening 10 and thus keeping the sealing device safe together. If a first sealing member and an elongated member are cast in one piece there is often problem with the casting process, giving the casted member air bubbles and inclusions and accordingly giving the sealing device poor structural strength. The challenge is to make the suture wire 12 thicker in the distal lock portion 16 .
In the first embodiment of the present invention, a hollow core of the suture wire sheath is filled with a less flexible filament core 18 ( FIG. 5 ), within the area of the distal lock portion 16 of the elongate member 4 , but also in the area which is to be threaded through the first sealing member 2 . (See again FIG. 1 ). The elongated core 18 is preferably made of an absorbable copolymer in accordance with the present invention. This gives the suture wire 12 a thickening in the distal lock portion 16 .
In a second embodiment of the present invention, shown in FIG. 6 , the suture wire 12 is left unfilled within the area ranging from the entry of the first opening 8 of the first sealing member 2 , through the first sealing member 2 , out on the on the other side and in again through the second opening 10 of the first sealing member 2 to the exit of said second opening 10 .
In a third embodiment of the present invention, shown in FIG. 7 , the thickening of the first suture, of the two sutures making a pair of sutures, extends beyond the distal lock portion 16 into the proximal portion of the elongated member 4 . This gives the suture wire 12 a more continuous increasing of the thickness which simplifies the threading of the second sealing member 6 from the proximal portion onto the distal lock portion 16 .
In a fourth embodiment of the present invention, instead of being filled, the suture 12 is thicker woven in the area of the distal lock portion.
In a fifth embodiment of the present invention, ( FIGS. 8 and 9 ) the second sealing member is divided into two parts, which first part 41 is a plate and is provided with an opening that is approximately the same or slightly grater than thickness of the distal lock portion 16 . This first part 41 is threadable onto and along the elongate member 4 ( FIG. 8 ), over the distal lock portion until it is in contact with the outside of the vessel wall. The first part plate 41 is preferably quite thin, which makes it flexible and easy to adapt to the Vessel wall. The second part 42 is provided with an opening that is slightly smaller than the thickness of the distal lock portion 16 . This second part 42 is threadable onto and along the elongate member 4 ( FIG. 8 ), over the distal lock portion until it is in contact with the first part 41 . The second part 42 allows for frictional engagement between the inside of the opening of the second part 42 and the distal portion 16 ( FIG. 9 ). The second part 42 is preferably thicker than the first part 41 , which will give it a large surface inside its opening for said frictional engagement. On the other hand, the diameter of the second part 42 is preferably smaller than that of the first part 41 .
In a sixth embodiment, the elongated portion 4 is not a suture wire, but another material, e.g. a resorbable polymer. The distal lock portion 16 is coated by a hollow, stocking-like suture wire so that a decent frictional engagement can be achieved between said coated distal lock portion and the inside of the opening of the second sealing member.
As mentioned above, the subject copolymers may be converted to a highly compliant, expandable tubular mantle, sleeve or cover that is placed tightly outside an expandable metallic or polymeric stent so that under concentric irreversible expansion at the desired site of a treated biological conduit, such as blood vessel or a urethra, both components will simultaneously expand and the mantle provides a barrier between the inner wall of the conduit and the outer wall of the stent. In another aspect of this invention, the subject copolymers are used as a stretchable matrix of a fiber-reinforced cover, sleeve, or mantle for a stent, wherein the fiber reinforcement is in the form of spirally coiled yarn (with or without crimping) woven, knitted, or braided construct. FIG. 10 shows schematically a radially expandable prior art spirally coiled metal stent which is applicable in the present invention.
FIG. 11 is a longitudinal view of a stent where the metal stent 100 is completely covered by the subject copolymer 101 according to a preferred embodiment of the present invention.
FIG. 12 is a cross sectional view of the stent shown in FIG. 11 .
FIG. 13 is a longitudinal view of a stent where the outer surface is covered by the subject copolymer 101 according to another preferred embodiment of the present invention. The size of a stent depends naturally of the intended use, i.e. the dimensions of the vessel where it should be applied. Typical coronary stent dimensions may have a pre deployment outer diameter of 1.6 mm and an expanded outer diameter of 3.0 mm to 4.5 mm. The length is preferably 15 mm or 28 mm.
Although the present invention has been described in connection with the preferred embodiments, it is to be understood that modifications and variations may be utilized without departing from the principles and scope of the invention, as those skilled in the art will readily understand. Accordingly, such modifications may be practised within the scope of the following claims. Moreover, Applicants hereby disclose all subranges of all ranges disclosed herein. These subranges are also useful in carrying out the present invention. | An absorbable crystalline, monocentric polyaxial copolymer comprising a central carbon or nitrogen atom and at least three axes, each of which includes an amorphous flexible component adjacent and originating from the central atom and a rigid, crystallizable component extending outwardly from the amorphous, flexible component is disclosed along with the use of such copolymer in medical devices which may contain a bioactive agent. The present invention also relates to a suture, stents, stent mantles and sealing devices made from the polyaxial copolymer. | 8 |
This application claims the benefit of U.S. Provisional Application No. 61/828,326, filed May 29, 2013.
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to drain and water containment safety pans placed under appliances that generate water output from defrosting and condensation and the like such as refrigerators.
2. Description of Prior Art
Prior art devices of this type have been heretofore directed to water overflow safety trays or pans that the appliance is placed. Such overflow safety trays typically have a drain line connected thereto extending to a drain assuring that no water damage will occur if the water is released from the appliance.
Examples of such safety drain pans can be seen in U.S. Pat. Nos. 1,034,340, 4,889,155 and 6,718,788. Additionally, design patents D337,154 and D388,566.
U.S. Pat. No. 1,034,340 discloses a drip pan under an ice box which is connected to a remote drain by a drain line extending there between.
U.S. Pat. No. 4,889,155 discloses a water collection mat for dishwashers having a flexible base with an upstanding perimeter rim and an inner surface incline towards a center opening therein connected to a flexible drain tube.
U.S. Pat. No. 6,718,788 claims a method for producing a drain pan in which an appliance can be placed.
Design Patent D337,154 discloses a design for a drain tray having an inclined interior to collect water to a central drain outlet.
Design Patent D388,566 shows a water catcher for an appliance having a water tray which is elevated on multiple adjustable legs.
SUMMARY OF THE INVENTION
A water collection and containment pan for appliances, specifically refrigerators that elevates the appliance within a water retention pan having upstanding sidewalls with an inclined interior base surface. Elevated elongated appliance receiving platforms extend from the interior surface of the pan providing support for an appliance positioned thereon in an elevated position. Auxiliary access loading ramps are provided to allow for rolling the appliance up and onto the platforms within the containment pan.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the collection pan of the invention with access ramps being positioned for use.
FIG. 2 is a front elevational view of the retainment support pan.
FIG. 3 is a section on lines 3 - 3 of FIG. 1 .
FIG. 4 is a rear elevational view of the retainment support pan.
FIG. 5 is a top plan view of one of the access ramps.
FIG. 6 is a partial sectional view on lines 6 - 6 of FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
A water containment pan 10 can be seen in FIG. 1 of the drawings having a pan portion 11 and multiple ramps 12 and 13 removably attached thereto as will be described in greater detail hereinafter.
The pan portion 11 has oppositely disposed front and rear walls 14 and 15 with interconnecting spaced parallel sidewalls 16 and 17 . The wall pairs 14 and 15 and 16 and 17 are integral with a continuous interior surface 18 which has a dual incline pitch orientation extending from the front wall 14 downwardly to the rear wall 15 and correspondingly from the respective oppositely disposed sidewalls 16 and 17 inwardly towards a central area defined by a broken pitch line PL shown for representation purposes only.
An outlet drain 19 is formed within the interior surface 18 at a cross translateral point of the hereinbefore described dual pitch interior surface.
The drain 19 may be static having a gravity feed channel 20 extending outwardly therefrom through the rear wall 15 or active by having inclusion of an attached powered transfer pump P illustrated in dotted lines for an alternate illustration purpose only in FIG. 1 of the drawings.
A pair of spaced parallel elongated elevated platforms 21 and 22 extend integrally from the dual pitch interior surface 18 extending from adjacent the front wall 14 and in spaced relation to the respective rear wall 15 .
Referring now to FIGS. 1 and 2 of the drawings, the front wall 14 has a pair of spaced elongated notches 23 and 24 therein which will provide for respective access ramps 12 and 13 selective engagement registration and stabilization thereto for loading and unloading the wheeled appliance thereon as will be described in greater detail hereinafter.
The platforms 21 and 22 orientation within the pan portion 11 and corresponding dual side to side and front to back internal interior surface pitch can clearly be seen in FIGS. 2 and 3 of the drawings assuring that any liquid leakage that is generated from the appliance such as will occur during normal operation inclusive of defrosting or cooling as would occur in a refrigerator will safely be caught and retained there within.
The appliance receiving platforms 21 and 22 have respective flat level upper surfaces 21 A and 22 B which are the same height as that of the respective perimeter walls 14 - 17 and are of a transverse width and parallel spacing to accommodate a variety of different appliance support wheeled configurations.
Referring now to FIGS. 1, 3, 5 and 6 of the drawings the access ramps 12 and 13 can be seen having an inclined tapered upper surface 25 , an oppositely disposed flat ground engagement bottom 26 with respective vertical sides 27 and end 28 . The end 28 has a wall engagement flange 29 extending in offset relation thereto forming a wall notch engagement channel 30 therein so as to be registerably engaged within and over the respective front wall notches 23 and 24 , as best seen in FIG. 6 of the drawings.
In use, the appliance (refrigerator) indicated by wheel W is moved temporarily and the pan portion 11 is positioned in its place. A drain line DL shown in broken lines may be attached thereto, as noted. Additionally, an optional moisture sensor MS shown in broken lines can be placed within the pan portion to indicate the presence of moisture, if needed, in specific application purposes.
Each of the access ramps 12 and 13 are fitted over the corresponding aligned notches 23 and 24 temporarily securing them to the pan portion 11 forming a level abutting surface with the elevated platforms 21 and 22 respective flat upper surface 21 A and 22 A. This orientation of engagement of the respective ramps 12 and 13 over the front wall 14 , notches 23 and 24 assures a smooth and barrier free pathway for the wheeled appliance (represented by the wheel W in broken lines) to be rolled up the respective ramp transition onto the upper surfaces of the platforms so as to be positioned.
Once positioned on the platforms 21 and 22 , the ramps 12 and 13 are removed and stored for future use.
The appliance (refrigerator) indicated by wheel W is now safely positioned within the pan portion 11 providing a safe secure water containment pan 10 of the invention. The pan portion 11 and the respective identical access ramps 12 and 13 may be molded from synthetic resin or its equivalent and are to be of a structure sufficient in strength to support and maintain the elevated appliance in its position on the respective platforms.
It will thus be seen that a new and novel water collection pan for appliances has been illustrated and described and it will be apparent to those skilled in the art that various changes and modifications may be made thereto without departing from the spirit of the invention. | A liquid containment device for use with refrigerators to prevent overflow and damage to flooring. The containment device allows for appliance elevation within and integral support and water collection pan. The detachable loading ramps provide for smoothly rolling the appliance up onto the integrated independent elevated level support surfaces within the water retainment pan. | 5 |
BACKGROUND
The present invention relates generally to the construction of a roofing shingle. In particular, the present invention relates to the construction of an asphalt roofing shingle utilizing a unique combination of exposure dimension and arrangement of color striations thereon to create a greater visual impact than existing asphalt shingles.
Asphalt shingles (sometimes also often referred to as composite shingles) are one of the most commonly used roofing materials. Asphalt shingles typically comprise an organic felt or fiberglass mat base on which is applied an asphalt coating. The organic felt or fiberglass mat base gives the asphalt shingle the strength to withstand manufacturing, handling, installation and servicing, and the asphalt coating provides resistance to weathering and stability under temperature extremes. An outer layer of mineral granules is also commonly applied to the asphalt coating to form a weather surface which shields the asphalt coating from the sun's rays, adds color to the final product, and provides fire resistance.
Asphalt shingles are typically manufactured as strip shingles, laminated shingles, interlocking shingles, and large individual shingles in a variety of weights and colors. Even though asphalt shingles offer significant cost, service life, and fire resistance advantages over wood shingles, wood shingles are often preferred due to their pleasing aesthetic features, such as their greater thickness as compared to asphalt shingles, which results in a more pleasing, layered look for a roof.
Various asphalt shingles have been developed to provide an appearance of thickness comparable to wood shingles. Examples of such asphalt shingles are shown in U.S. Pat. No. 5,232,530 entitled “Method of Making a Thick Shingle”; U.S. Pat. No. 3,921,358 entitled “Composite Shingle”; U.S. Pat. No. 4,717,614 entitled “Asphalt Shingle”; and U.S. Pat. Des. No. D309,027 entitled “Tab Portion of a Shingle.” Each of these patents is incorporated by reference herein in its entirety.
In addition to these patents, significant improvements in the art of roofing shingles have been disclosed and patented in U.S. Pat. Nos. 5,369,929; 5,611,186; and 5,666,776; each entitled “Laminated Roofing Shingle”, issued to Weaver et al. and assigned to the Elk Corporation of Dallas. These patents disclose laminated roofing shingles having a color gradient or gradation thereon to create the illusion of thickness or depth on a relatively flat surface. These patents are also incorporated by reference herein in their entireties. The present invention substantially improves on the roofing shingles described in the above-identified patents.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a roofing shingle that includes a unique combination of exposure dimension and arrangement of color striations thereon to provide a greater visual impact than existing asphalt shingles. In accordance with one aspect of the present invention, there is provided a laminated roofing shingle having a first shingle sheet and a second shingle sheet. The first shingle sheet has a headlap section and a buttlap section, the buttlap section being about 7 inches or greater in height and including a plurality of tabs which are spaced apart to define one or more openings between the tabs. Each of the tabs has a relatively uniform color throughout the tab. The relatively uniform color throughout the tab may very in contrast between each of the tabs. The second shingle sheet is attached to the underside of the first shingle sheet and has portions exposed through the openings between the tabs. The second shingle sheet has at least first, second, third, and fourth horizontal striations thereon across at least partial portions of the second sheet which are exposed through the openings between the tabs. The first striation has a substantially uniform dark color throughout a first quadrilateral area. The second striation includes a second elongated quadrilateral area below the first striation. The second striation has a substantially uniform color throughout the second quadrilateral area. The third striation includes a third elongated quadrilateral area below the second striation. The third striation has a substantially uniform color throughout the third quadrilateral area, which is lighter than the color of the second striation. The fourth striation includes a fourth elongated quadrilateral area below the third striation. The fourth striation has a substantially uniform color throughout the fourth quadrilateral area, which is lighter than the color of the third striation. At least the second, third, and fourth striations provide a color gradation on at least partial portions of the second sheet which are exposed through the openings between the tabs. The color of the first striation may be selected to be consistent with (i.e., to continue) the color gradation of the second through fourth striations.
Other aspects of the present invention include methods for manufacturing the above-described laminated shingle.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings in which:
FIG. 1 is a perspective view of a laminated shingle incorporating one embodiment of the present invention;
FIG. 2 is a top plan view of the shingle of FIG. 1;
FIG. 3 is a front plan view of the shingle of FIG. 1;
FIG. 4 is a left side view of the shingle of FIG. 1;
FIG. 5 is a perspective view of a partial roofing section covered with shingles incorporating one embodiment of the present invention;
FIG. 6 is an isometric, schematic drawing of a sheet of roofing material incorporating one embodiment of the present invention from which components for the shingle of FIG. 1 may be obtained;
FIG. 7 is an exploded isometric view showing shingle components taken from the sheet of roofing material in FIG. 6 which may be used to form the shingle of FIG. 1;
FIG. 8A is an exploded isometric view showing shingle components taken from a sheet of roofing material according to another embodiment of the present invention; and
FIG. 8B is an enlarged drawing of a portion of a backer strip of FIG. 8A with transition stripes disposed between adjacent horizontal striations.
FIG. 9 is a top plan view of a laminated shingle wherein the tabs have different color contrasts from one another.
DETAILED DESCRIPTION OF THE INVENTION
A laminated shingle 20 according to an exemplary embodiment of the present invention is shown in FIGS. 1 to 4 . The laminated shingle 20 preferably comprises a first shingle sheet 30 attached to a second shingle sheet 50 . First shingle sheet 30 has a generally rectangular configuration defining a headlap section 32 of the laminated shingle 20 , with a plurality of tabs 36 extending therefrom to define a buttlap section 34 of the laminated shingle 20 . Tabs 36 may also be referred to as “dragon teeth.” A plurality of openings 38 are formed between adjacent tabs 36 . The second shingle sheet 50 also has a generally rectangular configuration and is disposed beneath tabs 36 with portions of the second shingle sheet 50 exposed through the plurality of openings 38 .
Various techniques such as glueing or self-sealing adhesive strips (not shown) may be used to attach the second shingle sheet 50 to the underside of the first shingle sheet 30 . The resulting laminated shingle 20 has a generally rectangular configuration defined in part by longitudinal edges 22 and 24 with lateral edges 26 and 28 disposed therebetween. Longitudinal edge 22 is defined by an end of headlap section 32 and constitutes the upper edge of the laminated shingle 20 . Longitudinal edge 24 is defined by an end of buttlap section 34 and constitutes the lower (or leading) edge of laminated shingle 20 . A plurality of self sealing adhesive strips 40 are preferably disposed on the exterior of first shingle sheet 30 between headlap section 32 and buttlap section 34 .
First shingle sheet 30 may sometimes be referred to as a “tab sheet” or a “dragon tooth sheet,” and second shingle sheet 50 may sometimes be referred to as a “backer strip” or “shim.” In addition, openings 38 formed between adjacent tabs 36 with portions of backer strip 50 disposed thereunder may sometimes be referred to as “valleys.” Depending upon the desired application and appearance of each laminated shingle 20 , tabs 36 may have equal or different widths and may have a square, rectangular, trapezoidal, or any other desired geometric configuration. In the same respect, openings 38 may have equal or different widths and may have a square, rectangular, trapezoidal or any other desired geometric configuration. As will be explained later in more detail, laminated shingles 20 may be formed from a sheet 80 of roofing material shown in FIG. 6 with tabs 36 and opening 38 formed as a “reverse image” of each other.
For one embodiment of the present invention, laminated shingle 20 may be formed from a fiberglass mat (not shown) with an asphalt coating on both sides of the mat. If desired, the present invention may also be used with shingles formed from organic felt or other types of base material. The present invention is not limited to use with shingles having a fiberglass mat.
The exposed outer surface or weather surface 42 for shingle 20 is defined in part by tabs 36 and the portions of backer strip 50 which are exposed through openings 38 between adjacent tabs 36 . Weather surface 42 of laminated shingle 20 may be coated with various types of mineral granules to protect the asphalt coating, to add color to laminated shingle 20 and to provide fire resistance. For some applications, ceramic coated mineral granules may be used to form the outer layer comprising weather surface 42 . Also, a wide range of mineral colors from white and black to various shades of red, green, brown and any combination thereof may be used to provide the desired color for shingle 20 . The underside of shingle 20 may be coated with various inert minerals with sufficient consistency to seal the asphalt coating.
According to the present invention, the buttlap section 34 (the exposed section of the shingle when it is laid up on a roof) is made about 7 inches or greater and four or more horizontal striations are provided on the surface of backer strip 50 which is exposed through openings 38 . The horizontal striation nearest the headlap section of the shingle is made a uniformly dark color. Other horizontal striations are each made of a uniform color which together provide a color gradient or gradation according to the teachings of U.S. Pat. Nos. 5,369,929; 5,611,186; and 5,666,776, which are incorporated herein by reference in their entireties. The color of the striation nearest the headlap section may be selected to be consistent with (i.e., to continue) the color gradation of the other horizontal striations.
Using the foregoing unique combination of buttlap section (exposure) dimension and arrangement of color striations, the laminated shingle according to the present invention provides a significantly greater visual appearance than existing laminated shingles. While the improvement in visual appearance is applicable to all types of roofs, it is especially significant on low-sloped roofs (i.e., those roofs having less than six feet of rise for every twelve feet of run).
While many different shingle dimensions may be utilized with the present invention, the following exemplary dimensions and number of shingles per square are suitable for easy handling and packaging of the shingles:
1. 38 inch length, 7.9 inch exposure height, 17.8 inch overall height, and 48 shingles/square;
2. 36 inch length, 8 inch exposure height, 18 inch overall height, and 50 shingles/square;
3. 36 inch length, 8.3 inch exposure height, 18.6 inch overall height, and 48 shingles/square; and
4. 36 inch length, 9 inch exposure height, 20 inch overall height, and 44 shingles/square.
Returning to FIGS. 1 through 4, the exemplary embodiment shown includes a backer strip 50 with four horizontal striations 52 , 54 , 56 , and 58 . Striation 58 , the striation adjacent the headlap section of the shingle, is a uniformly dark-colored striation. The horizontal striations 52 , 54 , and 56 are colored striations that provide a color gradient or gradation from a light color near the leading edge 24 to a dark color near the upper portion of each opening 38 . The color of the horizontal striation 58 may be selected to be consistent with (i.e., to continue) the color gradient or gradation of the other striations (so that striations 52 through 58 altogether provide a color gradient or gradation). Preferably, the height of each striation is approximately equal. In addition, for aesthetic reasons it is preferred that the height of each striation be in the range of one to two inches.
The number of horizontal striations and the width of each striation on backer strip, 50 may be varied depending upon the desired aesthetic appearance of the resulting laminated shingle 20 . It is preferred, however, for a shingle to have an exposure height of 7 to 9 inches and four to six horizontal striations thereon.
Each striation may have a different color to establish the desired amount of contrast. For the purposes of this patent application, a different color may include a different tone. In addition, contrast for purposes of this patent application is defined as the degree of difference in the tone or shading between areas of lightest and darkest color. For some applications, a gradual change in contrast associated with a large number of striations may provide the appearance of depth or thickness associated with wood or other natural products. Also, the amount or degree of contrast in the color gradient exposed in each opening 38 may be varied depending upon the desired aesthetic appearance. An important feature of the present invention is the ability to vary the color gradient and the amount of contrast to provide the desired illusion or appearance of thickness on the finished roof.
As shown in FIG. 5, a plurality of laminated shingles 20 may be installed on a roof or other structure (not shown) to provide protection from the environment and to provide an aesthetically pleasing appearance. The normal installation procedure for laminated shingles 20 includes placing each shingle 20 on a roof in an overlapping configuration. Typically, buttlap section 34 of one shingle 20 will be disposed on the headlap section of another shingle 20 . Self-sealing adhesive strips 40 are used to secure the overlapping shingles 20 with each other. Also, a limited lateral offset is preferably provided between horizontally adjacent rows of shingles 20 to provide an overall aesthetically pleasing appearance for the resulting roof.
FIGS. 6 and 7 show one procedure for fabricating a laminated shingle 20 from a sheet 80 of roofing material. Various procedures and methods may be used to manufacture sheet 80 from which shingles incorporating the present invention may be fabricated. Examples of such procedures are contained in U.S. Pat. No. 1,722,702entitled “Roofing Shingle”; U.S. Pat. No. 3,624,975 entitled “Strip Shingle of Improved Aesthetic Character”; U.S. Pat. No. 4,399,186 entitled “Foam Asphalt Weathering Sheet for Rural Roofing Siding or Shingles”; and U.S. Pat. No. 4,405,680 entitled “Roofing Shingle.” Each of these patents is incorporated by reference herein in its entirety.
Sheet 80 is preferably formed from a fiberglass mat placed on a jumbo roll (not shown) having a width corresponding to the desired sheet 80 . Laminated shingles 20 are typically fabricated in a continuous process starting with the jumbo roll of fiberglass mat. As previously noted, laminated shingle 20 may also be fabricated using organic felt or other types of base material.
Sheet 80 shown in FIG. 6 preferably comprises a fiberglass mat with an asphalt coating which both coats the fibers and fills the void spaces between the fibers. A powdered mineral stabilizer (not shown) may be included as part of the asphalt coating process. A smooth surface of various inert minerals of sufficient consistency may be placed on the bottom surface of sheet 80 to seal the asphalt coating.
Top surface 82 is preferably coated with a layer of mineral granules such as ceramic coated stone granules to provide the desired uniform color portions and the color gradient portions associated with weather surface 42 of shingle 20 . Typically, the mineral granules are applied to the sheet 80 while the asphalt coating is still hot and forms a tacky adhesive.
FIG. 6 shows a schematic representation of a roller 86 and mineral granule hopper 90 which may be used to provide the desired granular surface coating to sheet 80 . The hopper 80 , which may be any hopper which is well known in the art, includes a plurality of partitions 91 which divide the hopper 90 into three sets of compartments: a set of compartments 92 , 94 , 96 and 98 at each end of the hopper and a central compartment 99 between the ends. The central compartment 99 of hopper 90 contains a uniform mixture of the mineral granules which will produce the desired color on dragon teeth or tabs 36 and the other portions of first shingle sheet 30 which will be exposed to the environment. This transfer of mineral granules is sometimes referred to as a “color drop.” The rotation of roller 86 and the movement of sheet 80 are coordinated to place the desired color drop on each shingle 20 .
For the embodiment of the present invention shown in FIGS. 6 and 7, each first shingle sheet 30 will have the same uniform mixture of mineral granules on both the headlap section and the buttlap section. For the embodiment shown in FIGS. 1 to 4 , headlap section 32 may have the same layer of mineral granules as buttlap section 34 or headlap section 32 may have a neutral or non-colored layer of mineral granules. The surface layer on headlap section 32 may be varied as desired for each application.
Different colored mineral granules corresponding to the desired color of horizontal striations 52 , 54 , 56 , and 58 are preferably placed in the appropriate compartments 92 , 94 , 96 , and 98 , respectively. As sheet 80 passes under roller 86 , mineral granules from the appropriate compartment in hopper 90 will fall onto roller 86 and will be transferred from roller 86 to top surface 82 of sheet 80 . The volume or pounds per square foot of mineral granules placed on surface 82 is preferably the same throughout the full width of sheet 80 . However, by dividing the hopper 90 into compartments, the color of various portions of sheet 80 may be varied including providing horizontal striations 52 , 54 , 56 , and 58 for backer strip 50 .
It is important to note that conventional procedures for fabricating shingles having an exterior surface formed by mineral granules include the use of granule blenders and color mixers, along with other sophisticated equipment to ensure a constant uniform color at each location on the exposed portions of the shingles. Extensive procedures are used to ensure that each color drop on a sheet of roofing material is uniform. The color drop between shingles may be varied to provide different shades or tones in color. However, within each color drop, concerted efforts have traditionally been made to insure uniformity of the color on the resulting shingle associated with each color drop.
Once the color drop process is complete, the sheet 80 is allowed to cool. After the sheet 80 is cooled, it is then cut. As shown by dotted lines 84 , 86 , and 88 in FIG. 6, sheet 80 may be cut into four horizontal lengths or lanes 60 , 62 , 64 , and 66 . The width of lanes 62 and 64 corresponds with the desired width for first shingle sheet 30 . The width of lanes 60 and 66 corresponds with the desired width for second shingle sheet 50 .
The cut along dotted line 86 corresponds with the desired pattern for dragon teeth 36 and associated openings 38 . For some applications, more than four lanes may be cut from a sheet of roofing material similar to sheet 80 . The number of lanes is dependent upon the width of the respective sheet of roofing material and the desired width of the resulting shingles.
Sheet 80 may also be cut laterally to correspond with the desired length for the resulting first shingle sheet 30 and second shingle sheet 50 . As shown in FIG. 7, each lateral cut of sheet 80 results in two backer strips 50 and two first shingle sheets 30 which may be assembled with each other to form two laminated shingles 20 . The resulting laminated shingles 20 may be packaged in a square for future installation on a roof as is well known in the art.
The cutting of sheet 80 and the assembly of laminated shingles 20 may be performed in a number of ways. For example, the laminated shingles 20 may be produced through an off-line lamination process in which the sheet 80 is cut both longitudinally and laterally and then the tab sheets and backer sheets which are produced are matched and attached together. Alternatively, and more preferably, the laminated shingles 20 may be produced in a continuous in-line lamination process in which the sheet 80 is cut longitudinally by a rotary die cutter, producing horizontal lengths (such as lanes 60 , 62 , 64 , and 66 ) which consist of continuous tab sheet strips and backer sheet strips. The tab sheet strips and backer sheet strips are joined and adhered together to produce laminated shingle strips through means well known in the art. The laminated shingle strips may then be passed through a cutting cylinder, which cuts the strips into individual shingles. After discrete shingles are formed, they can be processed with commonly used apparatus for handling shingles, such as a shingle stacker to form stacks of shingles and a bundle packer to form shingle bundles.
It is important to note that a color gradient of the present invention may be placed on shingles using various procedures and various types of materials. The present invention is not limited to shingles formed by the process shown in FIGS. 6 and 7.
FIG. 8A is an exploded isometric view showing shingle components taken from a sheet of roofing material according to another embodiment of the present invention. In the embodiment of FIG. 8A, as better shown in FIG. 8B which is an enlarged drawing of a portion of a backer strip of FIG. 8A, transition stripes 152 and 154 are disposed between adjacent pairs 52 / 54 and 54 / 56 of the horizontal striations 52 , 54 and 56 . Each transition stripe has a color value that is a mixture of the colors associated with the two horizontal striations adjacent to the transition stripe. The transition stripes may be used when the difference in contrast between adjacent horizontal striations is sufficiently great that a shingle would present a confused or disjointed appearance without the transition stripes. The transition stripes may be applied as described in U.S. Pat. No. 5,611,186, which is incorporated by reference herein in its entirety.
FIG. 9 illustrates a laminated shingle according to the present invention wherein the backer strip 50 has four horizontal striations 52 , 54 , 56 and 58 , and wherein each of the tabs 36 has a relatively uniform color throughout each tab and different color contrasts between each tab.
Although the present invention has been described with reference to certain preferred embodiments, various modifications, alterations, and substitutions will be apparent to those skilled in the art without departing from the spirit and scope of the invention, as defined by the appended claims. | There is provided a laminated roofing shingle having a first shingle sheet and a second shingle sheet. The first shingle sheet has a headlap section and a buttlap section, the buttlap section being about 7 inches or greater in height and including a plurality of tabs which are spaced apart to define one or more openings between the tabs. Each of the tabs has a relatively uniform color throughout the tab. The second shingle sheet is attached to the underside of the first shingle sheet and has portions exposed through the openings between the tabs. The second shingle sheet has at least first, second, third, and fourth horizontal striations thereon across at least partial portions of the second sheet which are exposed through the openings between the tabs. The first striation includes a first elongated quadrilateral area with a substantially uniform dark color throughout the first quadrilateral area. The second striation includes a second elongated quadrilateral area below the first striation. The second striation has a substantially uniform color throughout the second quadrilateral area. The third striation includes a third elongated quadrilateral area below the second striation. The third striation has a substantially uniform color throughout the third quadrilateral area, which is lighter than the color of the second striation. The fourth striation includes a fourth elongated quadrilateral area below the third striation. The fourth striation has a substantially uniform color throughout the fourth quadrilateral area, which is lighter than the color of the third striation. There are also provided methods for manufacturing the above-described laminated shingle. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention concerns a forming panel including a parts receiver for holding separate, discrete parts which may be used in connection with the forming panel.
[0003] 2. Description of the Prior Art
[0004] Forming panels used in erecting concrete walls for structures are often provided in standard sizes and shapes, and thus must be connected in order to establish a pair of opposed forming walls into which concrete may be poured for hardening into the final structural shape. Thus, adjacent forming panels are coupled together by pins, wedges and other fasteners, and opposing walls are connected by tie bars and the like. The purpose of such forms is that they may be removed and reused after the concrete is hardened. However, keeping track of the large number of pins, wedges, nuts and other connectors has been a problem. One other problem associated with such small parts is that they are often not readily available to the workman who must assemble the forms. Thus, parts may be lost or displaced, located in a remote area on the jobsite, or otherwise separated from the forming panel. Certain parts are relatively specialized and thus somewhat expensive to replace, and are repeatedly used with the same forming panel. Moreover, several workman must often wait while the parts are obtained by another workman, resulting in the loss of productive time of not merely one but several workers. Thus, the expensive of replacement parts and the time lost in locating and retrieving such small parts is an economic loss as well as an aggravation to the construction crew.
[0005] While the forming panels include a plurality of coupling sites which are normally adapted to receive some or all of the parts for use in, for example, attaching the forming panel to a complementally configured forming member, it is unsatisfactory to carry the separate parts in these locations during transit and storage. Typically, these “in use” positions are exposed, and placing the parts in these coupling sites subjects the parts, and more importantly the forms themselves which are often of a softer material, to substantial use and wear as the parts are impacted. Moreover, holding the parts in such “in use” positions interferes with handling and positioning the forms for coupling as well as storage. In addition, such “in use” positions in the coupling sites subjects the parts themselves to impact and loosening at the site, whereby parts may be readily separated and lost.
[0006] One attempt to ameliorate this problem has been to attach small parts by wires to the forming panel. This helps to keep certain parts constant associated with a single form. However, the wire connecting the parts to the form may become entangled with other equipment resulting in a potential safety hazard. In addition, when two or more such small parts are used at a single location, the positioning of the wires may be cumbersome. Also, not all parts will be coupled to a form, or certain special applications may require different small parts to couple the forms together.
[0007] There has thus developed a need for improved methods of coupling small parts to concrete forming panels, and in particular aluminum forming panels of a lightweight type of construction.
SUMMARY OF THE INVENTION
[0008] These problems have largely been solved by the method and apparatus for retaining separable coupling parts for a concrete forming panel in accordance with the present invention. That is to say, the method and apparatus hereof solves the problem of holding separate and discrete parts on a forming panel at a location spaced from their eventual position for use. By having a parts receiver as a part of the form itself, the parts are releasably held but remain available for use. Moreover, by having the parts receiver spaced from the coupling sites, the parts may be held by the parts receiver during handling and alignment of adjacent forms, so that the parts do not interfere with such alignment but may be quickly transferred to the coupling sites when desired.
[0009] Broadly speaking, the forming panel of the present invention includes a face sheet for receiving concrete thereagainst, a frame for supporting the face sheet, and a parts receiver for temporarily holding one or a plurality of separate and discrete parts. By “separate”, it is meant that the parts are not held by a wire or other permanent attachment to the forming panel, but rather are completely separable therefrom so that parts may be readily transferred between different forming panels as desired for specific applications. The parts receiver may be provided with openings therein whereby the parts may be frictionally engaged by the parts receiver. In addition, one or more of the openings may be provided with a gripper of an elasotmeric material which increases the frictional engagement between the parts receiver and the part. Because the parts may be configured differently, different shapes of openings may be provided for holding parts of different shapes. For example, some openings may be substantially rectangular or elongated, suitable for holding complementally shaped parts such as wedges, while other openings may be substantially circular for holding, for example, round-shank pins therein. The parts receiver may be provided with a magnetic coupler which is especially beneficial for holding parts of iron or steel when the forming panel frame and face are primarily constructed of aluminum. Thus, the provision of a magnetic coupler helps to hold selected parts, without causing any substantial interference between one form and another. Further, the parts receiver may be provided with a self-sticking material such as grip and loop fabric material, one of the grip and loop fabric being provided on the part while the other of the grip and loop fabric material is provided on the forming panel. Parts may thereby be quickly attached and removed for use. The parts receiver may also be configured and positioned in such a way as to provide stiffening and reinforcement to the frame and or face sheet of the forming panel.
[0010] The method of the present invention includes providing a concrete forming panel and at least one part adapted for use therewith, the part being discrete and separate from the forming panel. The forming panel so provided includes a plurality of coupling sites adapted for coupling said panel to a complementally configured forming member which may be positioned adjacent thereto, the forming panel including a parts receiver positioned on said forming panel remote from said coupling sites. The parts are then releasably attached to parts receiver and may thereafter be subsequently moved into the coupling sites during coupling of the forming panel to the adjacent forming member. As a result, no separate box or container need be maintained for the parts during transport and storage, but the parts carried by the parts receivers of different forming panels may be readily interchanged or moved as needed.
[0011] These and other advantages will be readily apparent to those skilled in the art with reference to the drawings and description which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 is a rear perspective view of a forming panel having a face sheet, a frame, and a plurality of parts receivers for receiving discrete parts;
[0013] [0013]FIG. 2 is a fragmentary enlarged rear perspective view of the forming panel hereof showing a parts receiver having a plurality of circular openings extending between two parts receivers having a plurality of elongated openings and two parts positioned for receipt by one of the parts receivers;
[0014] [0014]FIG. 3 is an enlarged horizontal cross-sectional view taken along line 3 - 3 of FIG. 2 showing a pin received in a gripper placed in an opening of a parts receiver;
[0015] [0015]FIG. 4 is an enlarged horizontal cross-sectional view taken along line 4 - 4 of FIG. 2 showing a wedge received in a gripper placed in an opening of a parts receiver;
[0016] [0016]FIG. 5 is an enlarged horizontal cross-sectional view taken along line 5 - 5 of FIG. 1 showing a parts receiver having a plurality of holes and spanning between two other parts receivers in reinforcing relationship thereto;
[0017] [0017]FIG. 6 is an enlarged horizontal cross-sectional view taken along line 6 - 6 of FIG. 1 showing a parts retainer having a grip and loop fabric material for temporarily and releasably holding a part thereto;
[0018] [0018]FIG. 7 is an enlarged horizontal cross-sectional view taken along line 7 - 7 of FIG. 1 showing a parts retainer having a magnet section for temporarily and releasably holding a part thereto; and
[0019] [0019]FIG. 8 is a fragmentary enlarged rear perspective view of an alternate embodiment of the forming panel hereof showing a parts receiver having a wing to which a flexible strip is attached for gripping a part.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Referring now to the drawing, a forming panel 10 for receiving flowable concrete thereagainst and providing a form for hardening the concrete to a desired shape is generally shown in FIG. 1 and includes a face sheet 12 and a frame 14 . The face sheet and frame are provided preferably primarily of aluminum, to include alloys thereof such as ASTM 6061-T6. The face sheet 12 is relatively thin, for example about 0.090 to 0.125 for lightweight applications but may be made thicker for heavier duty applications, and may be substantially flat or textured to provide a brickface or other texture to the concrete hardening thereagainst. The face sheet 12 includes a perimeter 15 , a front side 16 and a back side 18 , and is welded to the frame 14 . The frame 14 has at least one rail of a thickness typically varying between 0.125″ and ⅜″ for lightweight applications, with thicker aluminum stock provided for larger sizes and heavier duty applications if desired. The frame 14 may be round, oval, polygonal or any other shape as desired, but it is most common to provide a frame 14 having a generally rectangular shape with a pair of parallel, spaced-apart end rails 20 and 22 and a pair of parallel, spaced-apart side rails 24 and 26 which are welded together to provide the support and shape desired for the face sheet 12 as shown in FIG. 1. Stiffeners 28 may be provided as a part of the frame 14 and located on the back side of the face sheet 12 . In addition, the present invention includes at least one parts receiver 30 . Some of the rails, such as side rails 24 and 26 , have coupling sites 32 . As shown in FIG. 1, the coupling sites 32 typically include a hole 34 and a relieved area 36 . The holes 34 may receive a part 37 , such as a pin 38 therein, which can be held by a wedge 40 to couple the forming panel to an adjacent forming structure, such as another panel, corner member, or the like. The relieved areas may have tie-bars placed therealong to connect the forming panels 10 to opposite forming structures.
[0021] The parts receiver 30 of the present invention may be provided in different configurations. One example of such a parts receiver 30 is a cross-member 42 extending between the side rails 24 and 26 includes a plurality of elongated openings 44 in a first bar 46 extending generally perpendicular to the face sheet 12 and further supported and reinforced by a second bar 48 oriented generally perpendicular to the face sheet 12 . In addition, a plurality of circular openings 50 are provided in the first bar 36 of the cross-member 32 . Either or both of the openings 44 and 50 may be provided with grippers 52 inserted therein which are formed of an elastomeric material such as natural or synthetic rubber and which enhance the frictional engagement between the parts receiver and the part held therein. It may be appreciated that among the parts which may be readily held by the elongated openings 44 are the wedges 40 and that, for example, either the pins 38 or the wedges 40 may be held in the circular openings 50 . Furthermore, it may be appreciated that the cross-member 42 serves not only as a parts receiver but also acts as a stiffener for the frame 12 .
[0022] Another type of parts receiver 30 useful in the present invention is a brace 54 as shown in FIGS. 1 - 5 . The brace 54 as shown has a first wall 56 extending generally perpendicular to the face sheet 12 which includes openings 50 therein, and a second wall 60 oriented generally parallel to the face sheet 12 . The openings 50 are shown as circular, but may be elongated or of other shapes to receive desired parts in complemental interfitting relationship. As shown in FIGS. 1 - 5 , some or all of the openings 50 may be provided with grippers 52 , which frictionally engage the parts. The brace 54 may be positioned between and welded to cross-members 42 as shown in FIG. 2 to provide both structural reinforcement to the frame 14 , stiffness to the face sheet 12 , and a retaining member for the parts. It can also be positioned between adjacent stiffeners 28 as shown in FIGS. 1 and 5. In these configurations, the second wall 60 serves to both reinforce the first wall 56 and to protect the parts received therein against unintended impact which may cause them to loosen and fall. In another configuration as shown in FIG. 1, the brace 54 can be placed with the second wall 60 against the back side of the face sheet 12 for ease of access to parts placed therein.
[0023] [0023]FIG. 6 shows a parts receiver 30 used in connection with the forming panel 10 which includes a strip 62 of one of hook and loop type material and another strip 64 of the other of the hook and loop type material attached to a part 37 such as a wedge 40 . Such strips 62 may be attached to either the first bar 46 or the second bar 48 preferably by adhesive, or alternatively by a mechanical fastener. One example of a hook and loop type material useful for the strips is sold by McMaster-Carr of Chicago, Ill. as mushroom grip and loop fabric, the mushroom grip material being of woven polypropylene with a polyester base as part number 94975K62, and the loop fabric provided as a knit nylon base with nylon napped loops as part number 94975K72. It may be appreciated that other types of hook and loop material may also be used for the strips, and that the hook or mushroom material may be applied to either the part or the parts receiver and the loop material would then be used with the other of the part and parts receiver.
[0024] [0024]FIG. 7 shows a parts receiver 30 used in connection with the forming panel 10 which includes a strip 66 of magnetic material. The strip 66 may be of magnetized metal such as iron, nickel or cobalt or alloys thereof, or ceramic magnets, or alternatively flexible magnetic material, and adhesive 58 , welding or the like may be used to attach the strip 66 of magnetic material to the parts receiver 30 . The parts 37 are typically of steel which permits easy magnetic releasable coupling of the part, such as wedge 40 , to the strip 66 on the parts receiver 30 . In addition, the grippers 52 may be of a magnetic material to further enhance retention of the parts 37 placed into an opening. Furthermore, the entire parts receiver 30 may be provided entirely of a magnetic material if desired.
[0025] [0025]FIG. 8 shows an alternate embodiment of the forming panel 10 with a parts receiver 30 wherein a flange 68 is provided on the first bar 56 which holds, by friction, a mechanical fastener, adhesive bonding or the like, a flexible gripper 70 to hold the parts 37 . The flexible gripper 70 is shown as a strip 72 of steel bonded to the flange 68 , but it may be appreciated that natural or synthetic rubber, aluminum or the like may be bonded to the parts receiver 30 and used for the strip 72 . The part 37 , such as wedge 40 , may be tucked into the opening 74 behind the strip 72 which is opposed to the first bar 36 , and thus held between the strip 72 and the first bar 36 .
[0026] The forming panel 10 with the parts receiver 30 is especially convenient in use. The parts 37 may be temporarily stored in a complementally configured location on the parts receiver 30 , and as shown in FIGS. 3 and 4, differently shaped parts may be stored on the parts receiver 30 in different locations. For example, when a pin 38 or wedge 40 is to be stored, either may be placed in a circular opening 50 . Alternatively, wedges 40 may be releasably held by the elongated openings 48 and the pins 38 may be held by the circular openings 50 . More than one shape of opening may be provided, such that, for example, a cross-member 42 may include both elongated openings 48 and circular openings 50 . The forming panel 10 may include only one type of parts receiver, or several as illustrated in FIG. 1. The parts receivers 30 are all positioned relatively remotely from the coupling sites so as not to interfere with storage and assembly of the forming panels 10 into a composite forming wall of several forming panels and associated forming structures. However, they are located on the forming panel so as to be readily accessible for use, such that when two such forming panels 10 are to be coupled together, it is easy to retrieve a pin 38 , place it into the holes in the adjacent forming panels, and insert the wedge 40 into the slot in the pin to couple the forms together. After use, the parts 37 may be returned to the parts receiver until needed for the next job. The provision of the grippers is useful for improving the frictional engagement between the parts receiver 30 and the parts 37 , thus inhibiting loosening of the parts 37 placed therein but still permitting them to be readily separated from use. Because the parts 37 are completely separate, a variety of differently configured parts may be held by a single forming panel 10 , and may be moved to different forming panels 10 as the need arises.
[0027] It is to be appreciated that the shapes of the openings and parts shown and described are illustrative only, and that a variety of different parts may be used with the forming panel.
[0028] Although preferred forms of the invention have been described above, it is to be recognized that such disclosure is by way of illustration only, and should not be utilized in a limiting sense in interpreting the scope of the present invention. Obvious modifications to the exemplary embodiments, as hereinabove set forth, could be readily made by those skilled in the art without departing from the spirit of the present invention.
[0029] The inventors hereby state their intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of their invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention as set out in the following claims. | A method and apparatus for retaining separable parts for a concrete forming panel includes the provision of a retaining member on the forming panel located separately from any one of a plurality of coupling sites. Separate and discrete parts may be held on the retaining member until the parts are ready for use. The retaining member may include a reinforcing bar having at least one and preferably a plurality of openings therein for frictionally holding the part therein. The opening may be provided with a gripper to enhance the frictional engagement and improve the parts holding ability of the retaining member. The retaining member may include a magnetic coupler which is especially useful with aluminum forms for holding steel parts in position. Further, the retaining member may include a self-sticking material with cooperating components on the part and the form whereby the parts may be readily attached and removed from predetermined areas on the forming panel. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to a system for the registration of radiation images of the type, having a radiation pick-up device and a control device that controls the operation thereof.
2. Description of the Prior Art
Systems of the above type for the registration of radiation images are utilized, for example in medical technology, for the registration of X-ray images. They can be employed in ordinary X-ray systems; however, employment in computed tomography is also possible.
The central element of such a system is the radiation pick-up device. Components referred to as a-Si-panels that have a scintillator layer, mainly of Csl, are for use in such a known device. The incident x-ray quanta are converted into visible light therein, and the light is processed by a following, amorphous semiconductor layer wherein a matrix of photodiodes is fashioned. This matrix is followed by dedicated read-out electronics. Dependent on the quantity of light arising from the conversion, charge, i.e. electrons, is generated in the photodiodes, which is read out via the dedicated read-out electronics. A problem associated with such radiation pick-up devices is the presence of non-variable light coupling between the scintillator and the photodiode matrix. This causes there to be hardly any possibilities for variation of the conversion efficiency (incident x-ray quanta to output voltage of the panel). This means that no variation of the conversion efficiency or of the gain can be achieved given different operating modes or different pick-up modes that operate with x-radiation having different doses. In medical technology, for example, modes for producing fluoroscopic or transillumination exposures, and digital radiography or digital subtraction angiography exposures, are often implemented in alternation.
The first-cited operating mode operates with a low x-ray dose with simultaneous pick-up of many images; the latter operating modes operate with x-rays of a high dose per individual image that is registered. Since no variation of the conversion efficiency is possible given known a-Si panels, these panels must be selected such that no over-modulation occurs given pick-up of images having a high radiation dose. This, however, causes an increase in electronic noise for fluoroscopic or transillumination exposures, particularly compared to known x-ray image intensifier video systems.
Alternatively to such a-Si panels, radiation pick-up devices are known that employ a layer referred to as a HARP layer (HARP—high gain avalanche rushing amorphous photoconductor). Such a HARP layer is composed of a charge layer that generates electrical charges dependent on the incident x-rays and an electrode layer allocated thereto that is chargeable with high-voltage for triggering an electron-multiplying avalanche effect in the charge layer via, causing a potential to arise in the high-voltage-condition. The read-out ensues using an electron beam that scans the HARP layer. Such a radiation pick-up device is known, for example, from German OS 44 10 269. In this radiation pick-up device, a high-voltage is connected between the electrode layer and the emitter cathode that generates the electron beam. This high-voltage causes high electrical fields to arise in the charge layer, which is preferably composed of amorphous silicon. The electrical fields ultimately produce an avalanche effect in the amorphous semiconductor charge layer. This multiplies the electrical charges exponentially for increasing the electrical potentials. Strong electrical fields are required in order to generate this avalanche effect, but such fields are able to be achieved in a relatively simple way by making the charge layer extremely thin. A considerable signal gain can in fact be achieved as a result; however, this known system is likewise a rigid system that does not allow any variation in gain.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a system of the type initially described that allows the gain to be adapted to the image exposure mode which is to be implemented in a simple way.
This object is inventively achieved in a system is provided for the registration of radiation images, having a radiation pick-up device and a control device controlling the operation thereof, wherein the radiation pick-up device has: a charge layer that generates electrical charges dependent on the incident radiation and an allocated electrode layer chargeable with high-voltage for triggering an electron-multiplying avalanche effect in the charge layer by producing a potential across the charge layer, a read-out device for reading out the generated charges in the charge layer by means of an electron beam, and wherein the potential across the charge layer can be varied for varying the gain of the charge layer caused by the avalanche effect.
The invention is based on radiation pick-up device as disclosed, for example, by German OS 44 10 269. For solving the aforementioned problem, the invention proceeds from the perception that a variable gain for the signals that are generated on the basis of the incident x-radiation can be achieved by varying the potential across the charge layer. By varying the voltage via the charge or HARP layer, the local gain due to the avalanche effect can be varied. The avalanche effect, i.e., its intensity, is dependent on how large the potential is between the free surface of the charge layer and the coupled electrode layer. The avalanche effect is more pronounced the higher the potential is and vice versa.
This allows that the inventive system to adapt the gain of the radiation pick-up device to the currently selected image exposure mode in a simple way. When, for example, it is necessary to register transillumination images with a low x-ray dose and radiography images with a high radiation dose, then the gain can be switched between the two different operating modes by a corresponding variation of the layer potential. Given image registrations with low radiation dose, a high gain is selected; a lower gain suffices given exposures with a low radiation dose.
The layer potential can be varied in a simple way by varying the high-voltage that is applied to the electrode layer, controlled by the aforementioned control device. The voltage can be varied either before or during the registration of a radiation image, by setting the free surface of the charge layer to a pre-selected potential. Additionally, the phenomenon that the potential across the charge layer is somewhat reduced dependent on the of induced charge carriers can be used to advantage, so that a gain reduction arises by itself during the exposure, even though it is slight. Since the curve of this gain reduction is known by virtue incident quantity of charge carriers, a linear amplitude characteristic can be determined, producing the advantage that there is hardly any over-variations; further, any variation range can be optimally scanned in view of the signal-to-noise ratio.
The amplitude of the high-voltage that is applied preferably should be continuously variable dependent on the dose of the incident radiation in order to thus be able to optimally adapt the gain to the operating mode employed.
The electrode layer can be arranged on a film-like carrier, particularly on a glass film, such as by printing, and can be composed of a of essentially parallel layer strips spaced from one another. A closed electrode layer surface, however, is also conceivable.
The read-out device can be a flat emitter device, so that an extremely low overall structure of the radiation pick-up device is achieved. The surface emitter device can have linear electron emitter cathodes having allocated horizontal and/or vertical deflection electrodes. Alternatively, the surface emitter device can have micro-structured electron emitter cathodes arranged in a matrix or an array, for example in the form of nano tubes or small emitter micro-tips.
It is expedient for the radiation pick-up device to be integrated in a flat vacuum housing wherein stabilization elements, particularly in the form of structural webs, are provided, to intercept the significant high forces that act between the large-area sides.
It is also expedient to provide at least one reset light source for the exposure of the charge layer, which should be capable of being operated in pulsed fashion via the control device. Using this reset light source and given simultaneous activation of one or more or of all electron emitters, it is possible to stabilize the free surface of the charge layer to a lower potential compared to the potential that was previously present. As a result, it is possible in a simple way to lower the sensitivity of the radiation pick-up device before the registration of radiation images having a high dose that were preceded by registrations having a low dose, wherein, thus, registration was carried out with a high gain.
Overall, the inventive system offers several advantages. First, the employment of a-Si panels provided with photodiodes having allocated switches can be foregone, since the inventive system and radiation pick-up device operate with an electron beam that scans line-by-line. This has the advantage that parasitic capacitances are minimized due to the elimination of the switch capacitances with a simultaneous increase of the fill factor and of the maximum charge that can be scanned (since the scanning electron beam allows an enhanced voltage boost of the pixels). The avoidance of the photodiodes, further, is advantageous because a significantly more beneficial inertia behavior is established, particularly when switching between the various operating modes. The afterglow behavior of known a-Si panels is essentially defined and dominated by the inertia behavior of the a-Si photodiodes, which are no longer present in the inventive system.
The employment, in particular, of micro-structured flat emitter cathodes also leads to lower acquisition costs and devices having a longer service life. The greater range of dynamics established due to the possibility of varying the gain also allows employment in multi-line computed tomography detectors as well as in x-ray photon-counting detectors.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of an inventive radiation image pick-up system having a radiation pick-up device shown in an exploded view.
FIG. 2 is an enlarged illustration of the region 11 from FIG. 1 .
FIG. 3 is a schematic illustration of a micro-structured electron emitter cathode.
FIG. 4 is a plan view of the back of a substrate used in the inventive radiation image pick-up system, showing an embodiment wherein the electrode layer is formed by a number of stripes on the substrate.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an inventive system 1 composed of a radiation pick-up device 2 and a control device 3 that controls the operation thereof. The radiation pick-up device 2 is arranged in a housing 4 (which is not shown in detail). Since the sides of the housing 4 are relatively large in area, they can be provided with stabilization elements 4 a , to assist in withstanding the high forces acting on the walls of the housing 4 . The device 2 has a substrate 5 at the beam entry side identified with the arrow, for example in the form of a glass carrier, on which a scintillator layer 6 is applied, for example, in the form of Csl needles. This is followed by a conductive electrode layer 7 of, for example, ITO (indium tin oxide) or S n O 2 . This electrode layer 7 should be as thin as possible (in the range of a few 100 Å) in order to avoid stray effects. A charge layer 8 , preferably of amorphous silicon, is applied on this electrode layer 7 . X-ray quanta incident thereon initially penetrate through the substrate 5 and subsequently penetrate into the scintillator 6 wherein conversion into visible light occurs. This light subsequently penetrates the extremely thin electrode layer and is incident on the charge layer 8 . Dependent on the intensity of the penetrating light, charges are generated in the charge layer 8 .
These charges are read out by an electron beam with a following read-out device. This read-out device has a cooperating cathode 9 followed by a of linear cathodes 10 which can, for example, be coated tungsten wires. These linear cathodes 10 serve as electron beam sources. Further, vertically converging electrodes 11 , 12 are provided, as are vertically deflecting electrodes 13 . Further, an electron beam control electrode 14 as well as a horizontally converging electrode 15 and a horizontally deflecting electrode 16 are provided. The read-out device also has an electrode 17 that accelerates the electron beam, and a retarding electrode 18 .
In the illustrated example, the linear cathodes 10 extend horizontally and enable the generation of an electron beam having a linear horizontal expanse. Of course, more than the four electrodes 10 that are shown can be provided, dependent on the size of the panel. The cooperating electrodes 9 serve the purpose of generating a potential gradient with the vertically converging electrodes 11 in order to prevent the generation of electron beams from cathodes 10 other than the cathode driven for the emission of the electron beam.
Each vertically converging electrode 11 and 12 is plate-shaped and has a of oblong slots 19 , each slot lying opposite a linear cathode 10 . Each of the electron beams emitted by the cathodes 10 passes through a slot 19 , causing the beam to converge vertically.
The vertically deflecting electrodes 13 are allocated to the respective slots 19 and are composed of upper and lower conductor 20 between which an insulator 21 is provided. When a voltage is applied between two conductors 20 lying opposite one another in two different electrodes 13 , then an electron beam that passes therethrough is deflected.
The electron beam control electrode 14 is composed of a number of individual electrodes that each have an oblong slot 22 . An electron beam can pass only through the slot of a correspondingly driven electron beam control electrode. An electron beam that passes through is employed for reading out the signals of a number of horizontally arranged pixels, for example ten pixels, i.e. distributions of electrical potential on the charge layer 8 . After the ten pixels adjacent to this currently driven electrode are read out, then the electron beam control electrode skips ahead to the next driven electrode.
The horizontally converging electrode 15 is likewise plate-shaped and has a number of individual slots 23 that are respectively positioned opposite the slots 22 . This electrode 15 causes the electron beam to be contracted horizontally to form a thin ray corresponding to the size of a pixel or to a distribution of potential.
The horizontally deflecting electrode 16 also has the shape of a conductive plate that is composed of individual plate segments. When a voltage is applied between two neighboring plate segments, then the electron beam can be horizontally deflected, and the allocated pixels or distributions of potential, for example ten pixels, are horizontally scanned.
The acceleration electrodes 17 also are plate-shaped here and serve the purpose of accelerating the electron beam. The retarding electrode 18 has the shape of a grid conductor with numerous grid openings and serves the purpose of retarding the electron beam immediately before the charge layer 8 and of guiding the electron beam such that it strikes the charge layer at the correct angle.
As shown, a high-voltage V is applied to the electrode layer 7 , the amplitude thereof being controlled via the control device 3 . As a result, a high-voltage is also present across the charge layer 8 . This induces an avalanche effect in the charge layer 8 , dependent on the amplitude of the high-voltage that is applied as well as on the number of electrons that are generated in the quanta-to-photon. By variation of the high-voltage V, the gain via the charge layer 8 can be set, so that switching can be carried out in a simple way between different operating modes that need different gains. This can ensue very quickly, particularly by using reset light 24 serving the purpose of exposing the charge layer 8 . This reset light 24 can be operated, for example, in a pulsed manner by the control device 3 and causes the potential at the free surface of the charge layer 8 to be stabilized. The reset light 24 is mainly utilized for stabilizing the potential and thus for setting a desired potential when the following image exposure was previously preceded by an image exposure having low radiation dose, and thus a high gain.
FIG. 2 shows the enlarged excerpt II from FIG. 1 in the form of a schematic diagram, showing the substrate 15 , for example in the form of a glass plate, onto which the scintillator 6 is applied. An intermediate carrier 25 is in turn applied on the scintillator 6 , for example in the form of the glass plate. An intermediate carrier 25 , for example in the form of a glass film, is in turn applied thereon, the electrode layer 7 , preferably being printed on the intermediate carrier 25 , for in the form of the ITO electrode. The electrode layer 7 can be composed of a number of parallel, preferably vertically arranged, electrode stripes 7 a (see FIG. 4 ). Finally, the charge layer 8 is applied onto the electrode layer 7 . As shown, the high-voltage V is applied to the electrode layer 7 .
FIG. 3 is a schematic diagram of a second embodiment of an inventive system 26 . The structure at the beam entry side (substrate, scintillator, electrode layer, charge layer) is the same as in the previously described embodiment, however, a different readout device is employed in the embodiment of FIG. 3 . In this read-out device, a micro-structured electron emitter cathode 27 is provided as a flat emitter device, this being shown in the form of a schematic diagram. Any micro-structured emitter cathode that allows a targeted, punctiform emission of the electrons can be utilized, for example in the form of nano-tubes or micro-tips. Here, as well, the emitted electron beam is shaped by corresponding electrodes (not shown) and strikes the charge layer for the readout, a potential due to the high-voltage V at the electrode layer also being present across the charge layer.
Although modifications and changes may be suggested by those skilled in the art, it is the intention of the inventor to embody within the patent warranted hereon all changes and modifications as reasonably and properly come within the scope of his contribution to the art. | A system for the registration of radiation images has a radiation pick-up device and a control device controlling the operation thereof. The radiation pick-up device has a charge layer that generates electrical charges dependent on the incident radiation and an allocated electrode layer that is chargeable with high-voltage for triggering an electron-multiplying avalanche effect in the charge layer by virtue of a potential produced across the charge layer by the high-voltage. A read-out device reads out the generated charges in the charge layer by means of an electron beam. The potential via the charge layer can be modulated for varying the gain of the charge layer caused by the avalanche effect. | 6 |
FIELD OF THE INVENTION
[0001] This invention relates to compounds, formulations, drinks, foodstuffs, methods and therapeutic uses involving, containing, comprising, including and/or for preparing certain isoflavone compounds and analogues thereof. In particular, the invention relates to 6-hydroxy substituted isoflavones, derivatives thereof and medicaments involving same.
BACKGROUND OF THE INVENTION
[0002] Naturally-occurring plant isoflavones are known to possess a wide range of fundamental biological effects on human cells including anti-oxidation and the up-regulation and down-regulation of a wide variety of enzymes and signal transduction mechanisms. Mitotic arrest and cytotoxicity of human cancer cells, increased capillary permeability, increased cellular adhesion, increased response of vascular smooth muscle cells to vaso-relaxants, and agonism of estrogen receptors, are just a few examples of the responses of animal cells to the biological effects of naturally-occurring isoflavonoids.
[0003] A range of therapeutic benefits as a result of these biological outcomes have been identified including the treatment and prevention of pre-menopausal symptoms such as pre-menstrual syndrome, endometriosis, uterine fibroids, hyperlipidaemia, cardiovascular disease, menopausal symptoms such as osteoporosis and senile dementia, alcoholism, benign prostatic hypertrophy, and cancers such as prostate, breast and large bowel carcinomas [see WO 93/23069; WO 96/10341; U.S. Pat. No. 5,424,331; JP 62-106017; JP 62-106016; U.S. Pat. No. 5,516,528; JP 62-106016A2; JP 62-106017A2; JP 61-246124; WO 98/50026; WO 99/43335; WO 00/49009; WO 00/644,438; WO 99/48496].
[0004] While over 700 different naturally occurring isoflavones are described, only a few are confirmed as having potential therapeutic benefits in animals including humans. These include daidzein, genistein, formononetin, biochanin and glycitein. These and all naturally occurring isoflavones are found in nature as the monomeric form either in a free state, or, more likely, bound to a carbohydrate moiety (glycoside). The isoflavone has to be separated from this moiety before it becomes biologically active.
[0005] A number of compounds with a structure related to naturally occurring plant isoflavones are also described as having biological properties with potential therapeutic benefit to animals including humans. These include compounds that are naturally occurring metabolites of plant isoflavones produced by bacterial fermentation by gut flora and embrace compounds such as equol and 0-desmethylangolensin [WO 93/23069; WO 98/08503; WO 01/17986; WO 00/66576]. Also included in this group is the synthetic isoflavonoid ipriflavone, which is developed for the treatment of postmenopausal osteoporosis [WO 91/14429] and a wide range of synthetic isoflavonoid analogues [WO 98/08503].
[0006] Despite the considerable research and accumulated knowledge in relation to isoflavonoid compounds and derivatives thereof, the full ambit of therapeutically useful isoflavonoid compounds and their activities is yet to be realised. Moreover, there is a continual need for new, improved or at least alternative active agents for the treatment, prophylaxis, amelioration, defence against and/or prevention of various diseases and disorders.
[0007] A requirement accordingly exists for new generation compounds that exhibit important pharmacological effects for use as prophylactics and in therapy.
SUMMARY OF THE INVENTION
[0008] According to an aspect of this invention there is provided isoflavone compounds and analogues thereof of the general formula (I):
in which
R 1 and R 2 are independently hydrogen, hydroxy, OR 9 , OC(O)R 10 , OS(O)R 10 , CHO, C(O)R 10 , COOH, CO 2 R 10 , CONR 3 R 4 , alkyl, haloalkyl, aryl, arylalkyl, thio, alkylthio, amino, alkylamino, dialkylamino, nitro or halo, and Z O is hydroxy, or R 2 is as previously defined, and R 1 and Z O taken together with the carbon atoms to which they are attached form a five-membered ring selected from
R 1 is as previously defined, and R 2 and Z O taken together with the carbon atoms to which they are attached form a five-membered ring selected from
and
W is R 1 , A is hydrogen, hydroxy, NR 3 R 4 or thio, and B is selected from
W is R 1 , and A and B taken together with the carbon atoms to which they are attached form a six-membered ring selected from
W, A and B taken together with the groups to which they are associated comprise
W and A taken together with the groups to which they are associated comprise
and B is
wherein
R 3 is hydrogen, alkyl, aryl, arylalkyl, an amino acid, C(O)R 11 where R 11 is hydrogen alkyl, aryl, arylalkyl or an amino acid, or CO 2 R 12 where R 12 is hydrogen, alkyl, haloalkyl, aryl or arylalkyl, R 4 is hydrogen, alkyl or aryl, or R 3 and R 4 taken together with the nitrogen to which they are attached comprise pyrrolidinyl or piperidinyl, R 5 is hydrogen, C(O)R 11 where R 11 is as previously defined, or CO 2 R 12 where R 12 is as previously defined, R 6 is hydrogen, hydroxy, alkyl, aryl, amino, thio, NR 3 R 4 , COR 11 where R 11 is as previously defined, CO 2 R 12 where R 12 is as previously defined or CONR 3 R 4 , R 7 is hydrogen, C(O)R 11 where R 11 is as previously defined, alkyl, haloalkyl, aryl, arylalkyl or Si(R 13 ) 3 where each R 13 is independently hydrogen, alkyl or aryl, R 8 is hydrogen, hydroxy, alkoxy or alkyl, R 9 is alkyl, haloalkyl, aryl, arylalkyl, C(O)R 11 where R 11 is as previously defined, or Si(R 13 ) 3 where R 13 is as previously defined, R 10 is hydrogen, alkyl, haloalkyl, amino, aryl, arylalkyl, an amino acid, alkylamino or dialkylamino,
the drawing “ ” represents either a single bond or a double bond,
T is independently hydrogen, alkyl or aryl, X is O, NR 4 or S, and Y is
wherein
R 14 , R 15 and R 16 are independently hydrogen, hydroxy, OR 9 , OC(O)R 10 , OS(O)R 10 , CHO, C(O)R 10 , COOH, CO 2 R 10 , CONR 3 R 4 , alkyl, haloalkyl, aryl, arylalkyl, thio, alkylthio, amino, alkylamino, dialkylamino, nitro or halo, or any two of R 14 , R 15 and R 16 are fused together to form a cyclic alkyl, aromatic or heteroaromatic structure,
with the proviso that
when B is
Y is phenyl, 4-hydroxyphenyl, 4-methoxyphenyl, 3-hydroxyphenyl, 3-methoxyphenyl, 3-hydroxy-4-methoxyphenyl, 4-hydroxy-3-methoxyphenyl, 3,4-dihydroxyphenyl or 3,4-dimethoxyphenyl, and W and R 2 are hydrogen,
then
R 1 is not hydrogen, hydroxy or methoxy, or R 1 and Z O together with the carbon atoms to which they are attached are not cyclic boronates, carbonates, acetyls or ketals, and when A and B taken together with the carbon atoms to which they are attached form a six-membered ring selected from
X is O, Y is phenyl, 4-hydroxyphenyl, 4-methoxyphenyl, 3-hydroxyphenyl, 3-methoxyphenyl, 3-hydroxy-4-methoxyphenyl, 4-hydroxy-3-methoxyphenyl, 3,4-dihydroxyphenyl or 3,4-dimethoxyphenyl, and W and R 2 are hydrogen,
then
R 1 is not hydrogen, hydroxy or methoxy, or R 1 and Z O together with the carbon atoms to which they are attached are not a cyclic boronate, carbonate, acetyl or ketal,
or a pharmaceutically acceptable salt or prodrug thereof.
[0049] It has surprisingly been found by the inventors that the isoflavonoid derivatives of the general formula (I) have particular utility and effectiveness in the treatment, prophylaxis, amelioration defence against, and/or prevention of one of more of the following diseases and disorders (for convenience hereinafter referred to as the “therapeutic indications”):
(a) all forms of cancer (pre-malignant, benign and malignant) in all tissues of the body including breast cancer; uterine cancer; ovarian cancer; testicular cancer; large bowel cancer; endometrial cancer; prostatic cancer; uterine cancer. In this regard, the compounds may be used as the sole form of anti-cancer therapy or in combination with other forms of anti-cancer therapy including but not limited to radiotherapy and chemotherapy; (b) diseases and disorders associated with inflammatory reactions of an abnormal or prolonged nature in any of the body's tissues including but not limited to rheumatoid arthritis, tendonitis, inflammatory bowel disease, ulcerative colitis, Crohn's Disease, sclerosing cholangitis; (c) papulonodular skin lesions including but not limited to sarcoidosis, angiosarcoma, Kaposi's sarcome, Fabry's Disease (d) papulosquamous skin lesions including but not limited to psoriasis, Bowen's Disease, and Reiter's Disease; (e) actinic damage characterized by degenerative changes in the skin including but not limited to solar keratosis, photosensitivity diseases, and wrinkling; (f) diseases and disorders associated with abnormal angiogenesis affecting any tissue within the body including but not limited to hemangiomas and telangiectasia; (g) proliferative disorders of bone marrow including but not limited to megaloblastic disease, myelodysplastic syndromes, polycythemia vera, thrombocytosis and myelofibrosis; (h) autoimmune disease characterized by abnormal immunological responses including but not limited to multiple sclerosis, Type 1 diabetes, systemic lupus erythematosis, and biliary cirrhosis; (i) neurodegenerative diseases and disorders characterised by degenerative changes in the structure of the neurological system including but not limited to Parkinson's Disease, Alzheimer's Disease, muscular dystrophy, Lou-Gehrig Disease, motorneurone disease; (j) diseases and disorders associated with degenerative changes within the walls of blood vessels including but not limited to atherosclerosis, stenosis, restenosis, atheroma, coronary artery disease, stroke, myocardial infarction, hypertensive vascular disease, malignant hypertension, thromboangiitis obliterans, fibromuscular dysplasia; (k) diseases and disorders associated with abnormal immunological responses including but limited to dermatomyositis and scleroderma; (l) diseases and disorders associated with degenerative changes within the eye including but not limited to cataracts, macular degeneration, retinal atrophy.
[0062] In particular the isoflavonoid derivatives also surprisingly have been found to have a potent effect on the production and function of reproductive hormones such as estrogens and androgens. As a result of this, these compounds may be used in the treatment and prevention of one or more of the following disorders and diseases:
(a) conditions in women associated with abnormal estrogen/androgen balance including but not limited to cyclical mastalgia, acne, dysmenorrhoea, uterine fibroids, endometriosis, ovarian cysts, premenstrual syndrome, acute menopause symptoms, osteoporosis, senile dementia, infertility; and (b) conditions in men associated with abnormal estrogen/androgen balance including but not limited to benign prostatic hypertrophy, infertility, gynecomastia, alopecia hereditaria and various other forms of baldness.
[0065] Thus, according to a second aspect of the present invention there is provided a method for the treatment, prophylaxis or amelioration of a disease or disorder which method includes the step of administering a therapeutically effective amount of one or more compounds of formula (I) to a subject.
[0066] According to a third aspect of the present invention there is provided the use of one or more compounds of formula (I) in the manufacture of a medicament for the treatment of disease or disorder.
[0067] According to a forth aspect of the present invention there is provided the use of one or more compounds selected from formula (I) for the treatment, amelioration, defence against, prophylaxis and/or prevention of abnormal estrogen/androgen balance or a condition resulting from said abnormal balance in men or women.
[0068] According to a fifth aspect of the present invention there is provided the use of one or more compounds selected from formula (I) in the manufacture of a medicament for the treatment, amelioration, defence against, prophylaxis and/or prevention of abnormal estrogen/androgen balance or a condition resulting from said abnormal balance in men or women.
[0069] According to a sixth aspect of the present invention there is provided an agent for the treatment, prophylaxis or amelioration of a disease or disorder which agent comprises one or more compounds of formula (I).
[0070] According to a seventh aspect of the present invention there is provided a pharmaceutical composition which comprises one or more compounds of formula (I) in association with one or more pharmaceutical carriers, excipients, auxiliaries and/or diluents.
[0071] According to an eighth aspect of the present invention there is provided a drink or food-stuff, which contains one or more compounds of formula (I).
[0072] According to a ninth aspect of the present invention there is provided a microbial culture or a food-stuff containing one or more microbial strains which microorganisms produce one or more compounds of formula (I).
[0073] According to an tenth aspect of the present invention there is provided one or more microorganisms which produce one or more compounds of formula (I). Preferably the microorganism is a purified culture, which may be admixed and/or administered with one or more other cultures which product compounds of formula (I).
[0074] These and other aspects of the invention will become evident from the description and claims which follow.
[0075] Throughout this specification and the claims which follow, unless the text requires otherwise, the word “comprise”, and variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
DETAILED DESCRIPTION OF THE INVENTION
[0076] The term “isoflavone” as used herein is to be taken broadly to include ring-fused benzopyran molecules having a pendent phenyl group from the pyran ring based on a 1,2-diphenylpropane system and to ring-opened benzopyran molecules where the pyran oxygen may also be a heteratom selected from nitrogen and sulfur. Thus, the classes of compounds generally referred to as isoflavones, isoflavenes, isoflavans, isoflavanones, isoflavanols and the like are generically referred to herein as isoflavones, isoflavone derivatives or isoflavonoid molecules, compounds or derivatives.
[0077] The term “alkyl” is taken to include straight chain, branched chain and cyclic (in the case of 5 carbons or greater) saturated alkyl groups of 1 to 10 carbon atoms, preferably from 1 to 6 carbon atoms, such as methyl, ethyl, propyl, isopropyl, butyl, isobutyl, secbutyl, tertiary butyl, pentyl, cyclopentyl, and the like. The alkyl group is more preferably methyl, ethyl, propyl or isopropyl. The alkyl group may optionally be substituted by one or more of fluorine, chlorine, bromine, iodine, carboxyl, C 1 -C 4 -alkoxycarbonyl, C 1 -C 4 -alkylamino-carbonyl, di-(C 1 -C 4 -alkyl)-amino-carbonyl, hydroxyl, C 1 -C 4 -alkoxy, formyloxy, C 1 -C 4 -alkyl-carbonyloxy, C 1 -C 4 -alkylthio, C 3 -C 6 -cycloalkyl or phenyl.
[0078] The term “alkenyl” is taken to include straight chain, branched chain and cyclic (in the case of 5 carbons or greater) hydrocarbons of 2 to 10 carbon atoms, preferably 2 to 6 carbon atoms, with at lease one double bond such as ethenyl, 1-propenyl, 2-propenyl, 1-butenyl, 2-butenyl, 2-methyl-1-peopenyl, 2-methyl-2-propenyl, and the like. The alkenyl group is more preferably ethenyl, 1-propenyl or 2-propenyl. The alkenyl groups may optionally be substituted by one or more of fluorine, chlorine, bromine, iodine, carboxyl, C 1 -C 4 -alkoxycarbonyl, C 1 -C 4 -alkylamino-carbonyl, di-(C 1 -C 4 -alkyl)-amino-carbonyl, hydroxyl, C 1 -C 4 -alkoxy, formyloxy, C 1 -C 4 -alkyl-carbonyloxy, C 1 -C 4 -alkylthio, C 3 -C 6 -cycloalkyl or phenyl.
[0079] The term “alkynyl” is taken to include both straight chain and branched chain hydrocarbons of 2 to 10 carbon atoms, preferably 2 to 6 carbon atoms, with at least one triple bond such as ethynyl, 1-propynyl, 2-propynyl, 1-butynyl, 2-butynyl, and the like. The alkynyl group is more preferably ethynyl, 1-propynyl or 2-propynyl. The alkynyl group may optionally be substituted by one or more of fluorine, chlorine, bromine, iodine, carboxyl, C 1 -C 4 -alkoxycarbonyl, C 1 -C 4 -alkylamino-carbonyl, di-(C 1 -C 4 -alkyl)-amino-carbonyl, hydroxyl, C 1 -C 4 -alkoxy, formyloxy, C 1 -C 4 -alkyl-carbonyloxy, C 1 -C 4 -alkylthio, C 3 -C 6 -cycloalkyl or phenyl.
[0080] The term “aryl” is taken to include phenyl, biphenyl and naphthyl and may be optionally substituted by one or more C 1 -C 4 -alkyl, hydroxy, C 1 -C 4 -alkoxy, carbonyl, C 1 -C 4 -alkoxycarbonyl, C 1 -C 4 -alkylcarbonyloxy or halo.
[0081] The term “heteroaryl” is taken to include five-membered and six-membered rings which include at least one oxygen, sulfur or nitrogen in the ring, which rings may be optionally fused to other aryl or heteroaryl rings including but not limited to furyl, pyridyl, pyrimidyl, thienyl, imidazolyl, tetrazolyl, pyrazinyl, benzofuranyl, benzothiophenyl, quinolyl, isopuinolyl, purinyl, morpholinyl, oxazolyl, thiazolyl, pyrrolyl, xanthinyl, purine, thymine, cytosine, uracil, and isoxazolyl. The heteroaromatic group can be optionally substituted by one or more of fluorine, chlorine, bromine, iodine, carboxyl, C 1 -C 4 -alkoxycarbonyl, C 1 -C 4 -alkylamino-carbonyl, di-(C 1 -C 4 -alkyl)-amino-carbonyl, hydroxyl, C 1 -C 4 -alkoxy, formyloxy, C 1 -C 4 -alkyl-carbonyloxy, C 1 -C 4 -alkylthio, C 3 -C 6 -cycloalkyl or phenyl. The heteroaromatic can be partially or totally hydrogenated as desired.
[0082] The term “halo” is taken to include fluoro, chloro, bromo and iodo, preferably fluoro and chloro, more preferably fluoro. Reference to for example “haloalkyl” will include monohalogenated, dihalogenated and up to perhalogenated alkyl groups. Preferred haloalkyl groups are trifluoromethyl and pentafluoroethyl.
[0083] The term “pharmaceutically acceptable salt” refers to an organic or inorganic moiety that carries a charge and that can be administered in association with a pharmaceutical agent, for example, as a counter-cation or counter-anion in a salt. Pharmaceutically acceptable cations are known to those of skilled in the art, and include but are not limited to sodium, potassium, calcium, zinc and quaternary amine. Pharmaceutically acceptable anions are known to those of skill in the art, and include but are not limited to chloride, acetate, citrate, bicarbonate and carbonate.
[0084] The term “pharmaceutically acceptable derivative” or “prodrug” refers to a derivative of the active compound that upon administration to the recipient is capable of providing directly or indirectly, the parent compound or metabolite, or that exhibits activity itself.
[0085] As used herein, the terms “treatment”, “prophylaxis” or “prevention”, “amelioration” and the like are to be considered in their broadest context. In particular, the term “treatment” does not necessarily imply that an animal is treated until total recovery. Accordingly, “treatment” includes amelioration of the symptoms or severity of a particular condition or preventing or otherwise reducing the risk of developing a particular condition.
[0086] The invention in particular relates to compounds of the general formulae (II)-(VIII):
in which
R 1 , R 2 , R 5 , R 6 , R 14 , R 15 , W and Z O are as defined above
more preferably
R 1 , R 2 , R 14 , R 15 , and W are independently hydrogen, hydroxy, OR 9 , OC(O)R 10 , C(O)R 10 , COOH, CO 2 R 10 , alkyl, haloalkyl, arylalkyl, aryl, thio, alkylthio, amino, alkylamino, dialkylamino, nitro or halo, Z O is hydroxy, R 5 is hydrogen, C(O)R 11 where R 11 is hydrogen, alkyl, aryl, or an amino acid, or CO 2 R 12 where R 12 is hydrogen, alkyl or aryl, R 6 is hydrogen, hydroxy, alkyl, aryl, COR 11 where R 11 is as previously defined, or CO 2 R 12 where R 12 is as previously defined, R 9 is alkyl, haloalkyl, arylalkyl, or C(O)R 11 where R 11 is as previously defined, and R 10 is hydrogen, alkyl, amino, aryl, an amino acid, alkylamino or dialkylamino,
more preferably
R 1 and R 14 are independently hydroxy, OR 9 , OC(O)R 10 or halo, R 2 , R 15 , and W are independently hydrogen, hydroxy, OR 9 , OC(O)R 10 , C(O)R 10 , COOH, CO 2 R 10 , alkyl, haloalkyl, or halo, Z O is hydroxy, R 5 is hydrogen, C(O)R 11 where R 11 is hydrogen or alkyl, or CO 2 R 12 where R 12 is hydrogen or alkyl, R 6 is hydrogen or hydroxy, R 9 is alkyl, arylalkyl or C(O)R 11 where R 11 is as previously defined, and R 10 is hydrogen or alkyl,
and more preferably
R 1 and R 14 are independently hydroxy, methoxy, benzyloxy, acetyloxy or chloro, R 2 , R 15 , and W are independently hydrogen, hydroxy, methoxy, benzyloxy, acetyloxy, methyl, trifluoromethyl or chloro, Z O is hydroxy, R 5 is hydrogen or CO 2 R 12 where R 12 is hydrogen or methyl, and R 6 is hydrogen.
[0110] Particularly preferred compounds of the present invention are selected from:
[0111] The preferred compounds of the present invention also include all derivatives with physiologically cleavable leaving groups that can be cleaved in vivo from the isoflavone or derivative molecule to which it is attached. The leaving groups include acyl, phosphate, sulfate, sulfonate, and preferably are mono-, di- and per-acyl oxy-substituted compounds, where one or more of the pendant hydroxy groups are protected by an acyl group, preferably an acetyl group. Typically acyloxy substituted isoflavones and derivatives thereof are readily cleavable to the corresponding hydroxy substituted compounds. In addition, the protection of functional groups on the isoflavone compounds and derivatives of the present invention can be carried out by well established methods in the art, for example as described in Protective Groups in Organic Syntheses , T. W. Greene, John Wiley & Sons, New York, 1981.
[0112] Chemical and functional equivalents of a particular isoflavone should be understood as molecules exhibiting any one of more of the functional activities of the isoflavone and may be derived from any source such as being chemically synthesised or identified via screening processes such as natural product screening.
[0113] Compounds of the present invention have particular application in the treatment of diseases associated with or resulting from estrogenic effects, androgenic effects, vasodilatory and spasmodic effects, inflammatory effects and oxidative effects.
[0114] The amount of one or more compounds of formula I which is required in a therapeutic treatment according to the invention will depend upon a number of factors, which include the specific application, the nature of the particular compound used, the condition being treated, the mode of administration and the condition of the patient. Compounds of formula I may be administered in a manner and amount as is conventionally practised. See, for example, Goodman and Gilman, The Pharmacological Basis of Therapeutics, 1299 (7th Edition, 1985). The specific dosage utilised will depend upon the condition being treated, the state of the subject, the route of administration and other well known factors as indicated above. In general, a daily dose per patient may be in the range of 0.1 mg to 2 g; typically from 0.5 mg to 1 g; preferably from 50 mg to 200 mg.
[0115] The production of pharmaceutical compositions for the treatment of the therapeutic indications herein described are typically prepared by admixture of the compounds of the invention (for convenience hereafter referred to as the “active compounds”) with one or more pharmaceutically or veterinarially acceptable carriers and/or excipients as are well known in the art.
[0116] The carrier must, of course, be acceptable in the sense of being compatible with any other ingredients in the formulation and must not be deleterious to the subject. The carrier or excipient may be a solid or a liquid, or both, and is preferably formulated with the compound as a unit-dose, for example, a tablet, which may contain from 0.5% to 59% by weight of the active compound, or up to 100% by weight of the active compound. One or more active compounds may be incorporated in the formulations of the invention, which may be prepared by any of the well known techniques of pharmacy consisting essentially of admixing the components, optionally including one or more accessory ingredients.
[0117] The formulations of the invention include those suitable for oral, rectal, optical, buccal (for example, sublingual), parenteral (for example, subcutaneous, intramuscular, intradermal, or intravenous) and transdermal administration, although the most suitable route in any given case will depend on the nature and severity of the condition being treated and on the nature of the particular active compound which is being used.
[0118] Formulation suitable for oral administration may be presented in discrete units, such as capsules, sachets, lozenges, or tablets, each containing a predetermined amount of the active compound; as a powder or granules; as a solution or a suspension in an aqueous or non-aqueous liquid; or as an oil-in-water or water-in-oil emulsion. Such formulations may be prepared by any suitable method of pharmacy which includes the step of bringing into association the active compound and a suitable carrier (which may contain one or more accessory ingredients as noted above). In general, the formulations of the invention are prepared by uniformly and intimately admixing the active compound with a liquid or finely divided solid carrier, or both, and then, if necessary, shaping the resulting mixture such as to form a unit dosage. For example, a tablet may be prepared by compressing or moulding a powder or granules containing the active compound, optionally with one or more accessory ingredients. Compressed tablets may be prepared by compressing, in a suitable machine, the compound of the free-flowing, such as a powder or granules optionally mixed with a binder, lubricant, inert diluent, and/or surface active/dispersing agent(s). Moulded tablets may be made by moulding, in a suitable machine, the powdered compound moistened with an inert liquid binder.
[0119] Formulations suitable for buccal (sublingual) administration include lozenges comprising the active compound in a flavoured base, usually sucrose and acacia or tragacanth; and pastilles comprising the compound in an inert base such as gelatin and glycerin or sucrose and acacia.
[0120] Compositions of the present invention suitable for parenteral administration conveniently comprise sterile aqueous preparations of the active compounds, which preparations are preferably isotonic with the blood of the intended recipient. These preparations are preferably administered intravenously, although administration may also be effected by means of subcutaneous, intramuscular, or intradermal injection. Such preparations may conveniently be prepared by admixing the compound with water or a glycine buffer and rendering the resulting solution sterile and isotonic with the blood. Injectable formulations according to the invention generally contain from 0.1% to 60% w/v of active compound and are administered at a rate of 0.1 ml/minute/kg.
[0121] Formulations suitable for rectal administration are preferably presented as unit dose suppositories. These may be prepared by admixing the active compound with one or more conventional solid carriers, for example, cocoa butter, and then shaping the resulting mixture.
[0122] Formulations or compositions suitable for topical administration to the skin preferably take the form of an ointment, cream, lotion, paste, gel, spray, aerosol, or oil. Carriers which may be used include Vaseline, lanoline, polyethylene glycols, alcohols, and combination of two or more thereof. The active compound is generally present at a concentration of from 0.1% to 0.5% w/w, for example, from 0.5% to 2% w/w. Examples of such compositions include cosmetic skin creams.
[0123] Formulations suitable for transdermal administration may be presented as discrete patches adapted to remain in intimate contact with the epidermis of the recipient for a prolonged period of time. Such patches suitably contain the active compound as an optionally buffered aqueous solution of, for example, 0.1 M to 0.2 M concentration with respect to the said active compound.
[0124] Formulations suitable for transdermal administration may also be delivered by iontophoresis (see, for example, Pharmaceutical Research 3 (6), 318 (1986)) and typically take the form of an optionally buffered aqueous solution of the active compound. Suitable formulations comprise citrate or bis/tris buffer (pH 6) or ethanol/water and contain from 0.1 M to 0.2 M active ingredient.
[0125] The active compounds may be provided in the form of food stuffs, such as being added to, admixed into, coated, combined or otherwise added to a food stuff. The term food stuff is used in its widest possible sense and includes liquid formulations such as drinks including dairy products and other foods, such as health bars, desserts, etc. Food formulations containing compounds of the invention can be readily prepared according to standard practices.
[0126] Compounds of the present invention have potent antioxidant activity and thus find wide application in pharmaceutical and veterinary uses, in cosmetics such as skin creams to prevent skin ageing, in sun screens, in foods, health drinks, shampoos, and the like.
[0127] It has surprisingly been found that compounds of the formula I interact synergisticly with vitamin E to protect lipids, proteins and other biological molecules from oxidation.
[0128] Accordingly a further aspect of this invention provides a composition comprising one or more compounds of formula I, vitamin E, and optionally a pharmaceutically, veterinarily or cosmetically acceptable carriers and/or excipients.
[0129] Therapeutic methods, uses and compositions may be for administration to humans or animals, such as companion and domestic animals (such as dogs and cats), birds (such as chickens, turkeys, ducks), livestock animals (such as cattle, sheep, pigs and goats) and the like.
[0130] Compounds of formula I may be prepared by standard methods known to those skilled in the art. Suitable methods may be found in, for example, International Patent Applications WO 98/08503 and WO 00/49009 which are incorporated herein in their entirety by reference. Methods which may be employed by those skilled in the art of chemical synthesis for constructing the general ring structures depicted in formulae I and II are depicted in schemes 1-8 below. Chemical functional group protection, deprotection, synthons and other techniques known to those skilled in the art may be used where appropriate in the synthesis of the compounds of the present invention. In the formulae depicted in the schemes below the moities R 1 , R 2 , R 6 , R 8 , R 14 , R 15 , R 16 , W and X are as defined above. The hydroxy moiety Z O may also be protected, deprotected or derived from a synthon as appropriate during the synthesis or administration of the compounds of the present invention. Reduction of the isoflavone derivatives may be effected by procedures well known to those skilled in the art including sodium borohydride reduction, and hydration over metal catalysts such as Pd/C, Pd/CaCO 3 and Platinum(IV)oxide (Adam's catalyst) in protic or aprotic solvents. The end products and isomeric ratios can be varied depending on the catalyst/solvent system chosen. The schemes depicted below are not to be considered limiting on the scope of the invention described herein.
[0131] The invention will now be further described by the following non-limiting examples.
EXAMPLE 1
[heading-0132] General Syntheses of Substituted Isoflavones
[0133] 8-Chloro-4′,6,7-trihydroxyisoflavone (1) was synthesised by the general method of condensing 3-chloro-1,2,4-benzenetriol with 4-hydroxyphenylacetic acid to afford 2-chloro-2,4,5,4′-tetrahydroxydeoxybenzoin according to Scheme 8. Cyclisation of the intermediate deoxybenzoin was achieved by treatment with dimethylformamide and methanesulfonyl chloride in the presence of boron triflouride etherate to afford compound (1).
[0134] In a similar manner numerous other substituted isoflavones and derivatives thereof of general formula (I) and formulae (II)-(VIII) and compounds (2)-(30) can also be synthesised by varying the substitution pattern and/or protecting groups on the phenol derivatives or phenylacetic acid groups. For example starting with 6-methyl-1,2,4-benzenetriol affords 4′,6,7-trihydroxy-5-methylisoflavone (27); whilst use of 3-hydroxy phenyl acetic acid in the general synthetic method affords 3′-hydroxy isoflavone derivatives, such as compound (20).
[0135] It will be appreciated by those skilled in the art that protecting groups may be utilised in the synthetic methods described as appropriate. For example, vicinal hydroxy groups can be protected as cyclic ketals, acetyls, boronates and carbonates according to standard methods known in the art (see for example March, Advanced Organic Chemistry, 3rd Ed., 1985, John Wiley & Sons). Additionally or alternatively well known protection and deprotection methods of functional group chemistry or synthons may be employed (see Green, ibid. or March, ibid., or references cited therein).
[0136] As an example, the starting phenol from Scheme 8 may be first protected as an n-butyl boronate:
and then deprotected as required during the synthesis of the compounds of formula (I).
EXAMPLE 2
[0138] The binding affinity of various compounds of the invention for both subtypes of the estrogen receptor is determined using the “Estrogen Receptor Alpha or Beta Competitor Assay Core HTS Kit” supplied by Panvera Corporation (Product No. P2614/2615). Many of the exemplified and named compounds show good competitive binding to the estrogen receptors ER alpha and ER beta.
[0139] The results show that the compounds of the present invention have particular application in the treatment, prophylaxis or amelioration of diseases associated with or resulting from estrogenic effects, androgenic effects, vasodilatory and spasmodic effects, inflammatory effects and oxidative effects.
[0140] The invention has been described herein, with reference to certain preferred embodiments, in order to enable the reader to practice the invention without undue experimentation. However, a person having ordinary skill in the art will readily recognise that many of the components and parameters may be varied or modified to a certain extent without departing from the scope of the invention. Furthermore, titles, headings, or the like are provided to enhance the reader's comprehension of this document, and should not be read as limiting the scope of the present invention.
[0141] The entire disclosures of all applications, patents and publications, cited herein, if any, are hereby incorporated by reference.
[0142] Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. It is to be understood that the invention includes all such variations and modifications. The invention also includes all of the steps, features, compositions and compounds referred to or indicated in this specification individually or collectively, and any and all combinations of any two or more of said steps or features.
[0143] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that that prior art forms part of the common general knowledge in the field of endeavour. | Isoflavone compounds of the formula (I) or (II) Where R can be R 7? or OR 7? or O and the formula (III) is either a single or double bond extends to Y then Y is an optionally substituted benzyl. W, R 1?, Z o? R 2? and R 7? are as defined in the specification. The compounds are useful for the treatment of certain diseases and disorders, including cancer and inflammation. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to semiconductor transistors and more particularly to semiconductor transistors having high-K gate dielectric layers and metal gate electrodes.
BACKGROUND OF THE INVENTION
[0002] A typical semiconductor transistor having high-K gate dielectric layer and metal gate electrode usually has poor gate dielectric quality at bottom corners of the gate electrode. Therefore, there is a need for a structure (and a method for forming the same) in which the gate dielectric quality at bottom corners of the gate electrode has a higher quality than that of the prior art.
SUMMARY OF THE INVENTION
[0003] The present invention provides a semiconductor structure, comprising a semiconductor substrate which includes a channel region; a first source/drain region on the semiconductor substrate; a second source/drain region on the semiconductor substrate, wherein the channel region is disposed between the first and second source/drain regions; a final gate dielectric region, wherein the final gate dielectric region comprises a first dielectric material, wherein the final gate dielectric region is in direct physical contact with the channel region via an interfacing surface, and wherein the interfacing surface defines a reference direction perpendicular to the interfacing surface and pointing from the final gate dielectric region toward the channel region; a final gate electrode region, wherein the final gate dielectric region is disposed between and in direct physical contact with the channel region and the final gate electrode region, and wherein the final gate electrode region comprises an electrically conductive material; and a first gate dielectric corner region, wherein the first gate dielectric corner region comprises a second dielectric material that is different from the first dielectric material, wherein the first gate dielectric corner region is disposed between and in direct physical contact with the first source/drain region and the final gate dielectric region, wherein the first gate dielectric corner region is not in direct physical contact with the final gate electrode region, and wherein the first gate dielectric corner region overlaps the final gate electrode region in the reference direction.
[0004] The present invention provides a structure (and a method for forming the same) in which the gate dielectric quality at bottom corners of the gate electrode has a higher quality than that of the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIGS. 1A-1M show cross-section views used to illustrate a fabrication process of a semiconductor structure, in accordance with embodiments of the present invention.
[0006] FIGS. 2A-2L show cross-section views used to illustrate a fabrication process of another semiconductor structure, in accordance with embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0007] FIGS. 1A-1M show cross-section views used to illustrate a fabrication process of a semiconductor structure 100 , in accordance with embodiments of the present invention. More specifically, with reference to FIG. 1A , the fabrication process of the semiconductor structure 100 can start with a silicon substrate 110 .
[0008] Next, in one embodiment, a temporary gate dielectric layer 112 is formed on top of the silicon substrate 110 . The temporary gate dielectric layer 112 can comprise silicon dioxide. If silicon dioxide is used, the temporary gate dielectric layer 112 can be formed by thermally oxidizing the top surface 118 of the silicon substrate 110 resulting in the temporary gate dielectric layer 112 .
[0009] Next, in one embodiment, a temporary gate electrode layer 120 is formed on top of the temporary gate dielectric layer 112 . The temporary gate electrode layer 120 can comprise poly-silicon. The temporary gate electrode layer 120 can be formed by CVD (Chemical Vapor Deposition) of poly-silicon on top of the temporary gate dielectric layer 112 resulting in the temporary gate electrode layer 120 .
[0010] Next, in one embodiment, a cap layer 125 is formed on top of the temporary gate electrode layer 120 . The cap layer 125 can comprise silicon dioxide. The cap layer 125 can be formed by CVD of silicon dioxide on top of the temporary gate electrode layer 120 resulting in the cap layer 125 .
[0011] Next, in one embodiment, the cap layer 125 and the temporary gate electrode layer 120 are patterned resulting in the cap region 125 and the temporary gate electrode region 120 of FIG. 1B . More specifically, the cap layer 125 and the temporary gate electrode layer 120 can be patterned by anisotropically and selectively etching in a direction defined by an arrow 115 (hereafter can be referred to as the direction 115 ) resulting the cap region 125 and the temporary gate electrode region 120 of FIG. 1B . The direction 115 is perpendicular to the top surface 118 of the silicon substrate 110 and points from the temporary gate dielectric layer 112 toward the silicon substrate 110 .
[0012] Next, with reference to FIG. 1B , in one embodiment, a thermal oxidization of the exposed surfaces of the structure 100 of FIG. 1B is performed resulting in dielectric regions 130 a and 130 b of FIG. 1C on side walls of the temporary gate electrode region 120 . Also as a result of this thermal oxidization step, most of the portions of the temporary gate dielectric layer 112 of FIG. 1B increase in thickness in the direction 115 resulting in the temporary gate dielectric layer 112 ′. More specifically, the closer to the surrounding ambient a portion of the temporary gate dielectric layer 112 of FIG. 1B is, the thicker in the direction 115 this portion is. For instance, with reference to FIG. 1C , for the portions of the temporary gate dielectric layer 112 ′ sandwiched between the temporary gate electrode region 120 and the silicon substrate 110 , the closer to the center point C a portion is, the thinner in the direction 115 this portion is.
[0013] The temporary gate dielectric layer 112 ′ comprises bird's beaks 112 a and 112 b at bottom corners of the temporary gate electrode region 120 . The dielectric regions 130 a and 130 b and the temporary gate dielectric layer 112 ′ can comprise silicon dioxide.
[0014] Next, with reference to FIG. 1D , in one embodiment, extension regions 114 a and 114 b are formed in the silicon substrate 110 . The extension regions 114 a and 114 b can be formed using a conventional ion implantation process.
[0015] Next, with reference to FIG. 1E , in one embodiment, a spacer layer 140 is formed on top of the structure 100 of FIG. 1D . The spacer layer 140 can comprise silicon nitride. The spacer layer 140 can be formed by CVD of silicon nitride on top of the structure 100 of FIG. 1D resulting in the spacer layer 140 .
[0016] Next, in one embodiment, the spacer layer 140 and the temporary gate dielectric layer 112 ′ are anisotropically etched in the direction 115 until the top surface 118 of the silicon substrate 110 is exposed to the surrounding ambient resulting in the structure 100 of FIG. 1F . After the etching of the spacer layer 140 and the temporary gate dielectric layer 112 is performed, with reference to FIG. 1F , what remain of the spacer layer 140 are spacer regions 140 a and 140 b , whereas what remains of the temporary gate dielectric layer 112 is the temporary gate dielectric region 112 ″ which includes the bird's beaks 112 a and 112 b.
[0017] Next, with reference to FIG. 1F , in one embodiment, source/drain regions 116 a and 116 b are formed in the silicon substrate 110 . The source/drain regions 116 a and 116 b can be formed using a conventional ion implantation process.
[0018] Next, with reference to FIG. 1G , in one embodiment, silicide regions 150 a and 150 b are formed on the source/drain regions 116 a and 116 b , respectively. More specifically, the silicide regions 150 a and 150 b can be formed by (i) depositing a metal layer (not shown) on top of the structure 100 of FIG. 1F , then (ii) heating the structure 100 resulting in the metal chemically reacting with silicon of the source/drain regions 116 a and 116 b , and then (iii) removing unreacted metal resulting in the silicide regions 150 a and 150 b . If the metal used is nickel, then the silicide regions 150 a and 150 b comprise nickel silicide.
[0019] Next, with reference to FIG. 1H , in one embodiment, a silicon nitride layer 160 and a BPSG (boro-phospho-silicate glass) layer 170 are formed in turn on top of the structure 100 of FIG. 1G . More specifically, the silicon nitride layer 160 and the BPSG layer 170 can be formed by (i) depositing silicon nitride on top of the structure 100 of FIG. 1G resulting in the silicon nitride layer 160 and then (ii) depositing BPSG on top of the silicon nitride layer 160 resulting in the BPSG layer 170 .
[0020] Next, in one embodiment, a CMP (Chemical Mechanical Polishing) process is performed on top of the structure 100 of FIG. 1H until the top surface 122 of the temporary gate electrode region 120 is exposed to the surrounding ambient resulting in the structure 100 of FIG. 1I . After the CMP process is performed, what remain of the BPSG layer 170 are BPSG regions 170 a and 170 b , and what remain of the silicon nitride layer 160 are silicon nitride regions 160 a and 160 b.
[0021] Next, with reference to FIG. 1I , in one embodiment, the temporary gate electrode region 120 is removed resulting in a trench 124 of FIG. 1J . The temporary gate electrode region 120 can be removed using a wet etching process.
[0022] Next, with reference to FIG. 1J , silicon dioxide on side walls and bottom walls of the trench 124 is removed (by using a wet etching process, for example) resulting in the top surface 118 of the silicon substrate 110 being exposed to the surrounding ambient, as shown in FIG. 1K . After the removal, what remain of the temporary gate dielectric region 112 ″ are the bird's beaks 112 a and 112 b.
[0023] Next, with reference to FIG. 1L , in one embodiment, a final gate dielectric layer 180 and a final gate electrode layer 190 are formed in turn on top of the structure 100 of FIG. 1K . The final gate dielectric layer 180 can comprise a high-K dielectric material, wherein K is dielectric constant and K is greater than 4. For example, the final gate dielectric layer 180 comprises hafnium silicon oxynitride (HfSiON). The final gate electrode layer 190 can comprise a metal such as tantalum nitride (TaN). The final gate dielectric layer 180 and the final gate electrode layer 190 can be formed by (i) CVD or ALD (Atomic Layer Deposition) of the hafnium silicon oxynitride on top of the structure 100 of FIG. 1K resulting in the final gate dielectric layer 180 and then (ii) CVD or ALD of tantalum nitride on top of the final gate dielectric layer 180 such that the trench 124 is completely filed with tantalum nitride resulting in the final gate electrode layer 190 .
[0024] Next, in one embodiment, a CMP process is performed on top of the structure 100 of FIG. 1L until the top surface 170 ′ of the BPSG regions 170 a and 170 b is exposed to the surrounding ambient resulting in the structure 100 of FIG. 1M . After the CMP process is performed, what remain of the final gate dielectric layer 180 and the final gate electrode layer 190 are the final gate dielectric region 180 and the final gate electrode region 190 , respectively. In one embodiment, each of the bird's beaks 112 a and 112 b overlaps the final gate electrode region 190 in the direction 115 . A first region is said to overlap a second region in a reference direction if and only if there exits at least one point inside the first region such that a straight line going through that point and being parallel to the reference direction would intersect the second region.
[0025] Next, in one embodiment, interconnect layers (not shown) are formed on top of the structure 100 to provide electrical access to the source/drain regions 116 a and 116 b and the final gate electrode region 190 .
[0026] With reference to FIG. 1M , the structure 100 shows a transistor having the final gate electrode region 190 , the final gate dielectric region 180 , the source/drain regions 116 a and 116 b and the channel 119 . The presence of the bird's beaks 112 a and 112 b at corners of the final gate electrode region 190 increases the distances between the final gate electrode region 190 and the source/drain regions 116 a and 116 b and thereby helps reduce leakage currents between the final gate electrode region 190 and the source/drain regions 116 a and 116 b during the operation of the transistor.
[0027] FIGS. 2A-2L show cross-section views used to illustrate a fabrication process of a semiconductor structure 200 , in accordance with embodiments of the present invention. More specifically, with reference to FIG. 2A , the fabrication process of the semiconductor structure 200 can start with the structure 200 of FIG. 2A . The structure 200 is similar to the structure 100 of FIG. 1B . The formation of the structure 200 is similar to the formation of FIG. 1B .
[0028] Next, in one embodiment, the structure 200 is annealed in ammonia (NH 3 ) or ammonia plasma resulting in silicon dioxide of the cap region 225 and exposed portions of the temporary gate dielectric layer 112 being converted to SiON, as shown in FIG. 2B . More specifically, with reference to FIG. 2B , dielectric regions 230 a and 230 b of the temporary gate dielectric layer 112 now comprise SiON, whereas the temporary gate dielectric region 212 still comprises silicon dioxide. The cap region 225 now comprises SiON. In one embodiment, the annealing of the structure 200 is performed such that the dielectric regions 230 a and 230 b undercut the temporary gate electrode region 120 . As a result, both the dielectric regions 230 a and 230 b overlap the temporary gate electrode region 120 in the direction 115 .
[0029] Next, with reference to FIG. 2C , in one embodiment, extension regions 114 a and 114 b are formed in the silicon substrate 110 . The extension regions 114 a and 114 b can be formed using a conventional ion implantation process.
[0030] Next, with reference to FIG. 2D , in one embodiment, a spacer layer 240 is formed on top of the structure 200 of FIG. 2C . The spacer layer 240 can comprise silicon nitride. The spacer layer 240 can be formed by CVD of silicon nitride on top of the structure 200 of FIG. 2C resulting in the spacer layer 240 .
[0031] Next, in one embodiment, the spacer layer 240 and the dielectric regions 230 a and 230 b are anisotropically etched in the direction 115 until the top surface 118 of the silicon substrate 110 is exposed to the surrounding ambient resulting in the structure 100 of FIG. 2E . After the etching of the spacer layer 240 and the dielectric regions 230 a and 230 b is performed, with reference to FIG. 2E , what remain of the spacer layer 240 are spacer regions 240 a and 240 b , whereas what remain of the dielectric regions 230 a and 230 b are gate dielectric corner regions 230 a and 230 b.
[0032] Next, with reference to FIG. 2F , in one embodiment, source/drain regions 116 a and 116 b are formed in the silicon substrate 110 . The source/drain regions 116 a and 116 b can be formed using a conventional ion implantation process.
[0033] Next, in one embodiment, silicide regions 250 a and 250 b are formed on the source/drain regions 116 a and 116 b , respectively. More specifically, the silicide regions 250 a and 250 b can be formed in a manner similar to the manner in which the silicide regions 150 a and 150 b are formed on the source/drain regions 116 a and 116 b of the structure 100 of FIG. 1G .
[0034] Next, with reference to FIG. 2G , in one embodiment, a silicon nitride layer 260 and a BPSG layer 270 are formed in turn on top of the structure 200 of FIG. 2F . More specifically, the silicon nitride layer 260 and the BPSG layer 270 can be formed by (i) depositing silicon nitride on top of the structure 200 of FIG. 2F resulting in the silicon nitride layer 260 and then (ii) depositing BPSG on top of the silicon nitride layer 260 resulting in the BPSG layer 270 .
[0035] Next, in one embodiment, a CMP process is performed on top of the structure 200 of FIG. 2G until the top surface 122 of the temporary gate electrode region 120 is exposed to the surrounding ambient resulting in the structure 200 of FIG. 2H . After the CMP process is performed, what remain of the BPSG layer 270 are BPSG regions 270 a and 270 b , and what remain of the silicon nitride layer 260 are silicon nitride regions 260 a and 260 b.
[0036] Next, with reference to FIG. 2H , in one embodiment, the temporary gate electrode region 120 is removed resulting in a trench 224 of FIG. 2I . The temporary gate electrode region 120 can be removed using a wet etching process.
[0037] Next, with reference to FIG. 2I , in one embodiment, the temporary gate dielectric region 212 is removed resulting in the top surface 118 of the silicon substrate 110 being exposed to the surrounding ambient, as shown in FIG. 2J . The temporary gate dielectric region 212 can be removed by a conventional wet etching process.
[0038] Next, with reference to FIG. 2K , in one embodiment, a final gate dielectric layer 280 and a final gate electrode layer 290 are formed in turn on top of the structure 200 of FIG. 2J . The final gate dielectric layer 280 can comprise a high-K dielectric material. For example, the final gate dielectric layer 280 comprises hafnium silicon oxynitride (HfSiON). The final gate electrode layer 290 can comprise a metal such as tantalum nitride (TaN). The final gate dielectric layer 280 and the final gate electrode layer 290 can be formed by (i) CVD or ALD (Atomic Layer Deposition) of the hafnium silicon oxynitride on top of the structure 200 of FIG. 2K resulting in the final gate dielectric layer 280 and then (ii) CVD or ALD of tantalum nitride on top of the final gate dielectric layer 280 such that the trench 224 is completely filed with tantalum nitride resulting in the final gate electrode layer 290 .
[0039] Next, in one embodiment, a CMP process is performed on top of the structure 200 of FIG. 2K until the top surface 270 ′ of the BPSG regions 270 a and 270 b is exposed to the surrounding ambient resulting in the structure 200 of FIG. 2L . After the CMP process is performed, what remain of the final gate dielectric layer 280 and the final gate electrode layer 290 are the final gate dielectric region 280 and the final gate electrode region 290 , respectively. In one embodiment, each of the gate dielectric corner regions 230 a and 230 b overlaps the final gate electrode region 290 in the direction 115 .
[0040] Next, in one embodiment, interconnect layers (not shown) are formed on top of the structure 200 to provide electrical access to the source/drain regions 116 a and 116 b and the final gate electrode region 290 .
[0041] With reference to FIG. 2L , the structure 200 shows a transistor having the final gate electrode region 290 , the final gate dielectric region 280 , the source/drain regions 116 a and 116 b and the channel 119 . The presence of the gate dielectric corner regions 230 a and 230 b at corners of the final gate electrode region 290 increases the distances between the final gate electrode region 290 and the source/drain regions 116 a and 116 b and thereby helps reduce leakage currents between the final gate electrode region 290 and the source/drain regions 116 a and 116 b during the operation of the transistor.
[0042] While particular embodiments of the present invention have been described herein for purposes of illustration, many modifications and changes will become apparent to those skilled in the art. Accordingly, the appended claims are intended to encompass all such modifications and changes as fall within the true spirit and scope of this invention. | A semiconductor structure and a method for forming the same. The semiconductor structure includes (i) a semiconductor substrate which includes a channel region, (ii) first and second source/drain regions on the semiconductor substrate, (iii) a final gate dielectric region, (iv) a final gate electrode region, and (v) a first gate dielectric corner region. The final gate dielectric region (i) includes a first dielectric material, and (ii) is disposed between and in direct physical contact with the channel region and the final gate electrode region. The first gate dielectric corner region (i) includes a second dielectric material that is different from the first dielectric material, (ii) is disposed between and in direct physical contact with the first source/drain region and the final gate dielectric region, (iii) is not in direct physical contact with the final gate electrode region, and (iv) overlaps the final gate electrode region in a reference direction. | 7 |
RELATED APPLICATIONS
This application claims priority from U.S. provisional patent application entitled “IQ imbalance equalization system and method” Ser. No. 61/086,937 filed Aug. 7, 2008.
TECHNICAL FIELD
The disclosed method and apparatus relates to communication systems, and more particularly, some embodiments relate to IQ imbalance equalization for communications systems.
DESCRIPTION OF THE RELATED ART
Designers of integrated circuits (ICs) face several challenges today. One of these challenges is to increase the capabilities of an IC while decreasing the cost, power consumption and size of the IC. Designers of ICs used in wired and wireless communication devices are no exception. One particular challenge that communications IC designers face involves the imbalance that typically occurs between the in-phase (I) and quadrature-phase (Q) components of a radio frequency (RF) signal when the received RF signal is down-converted to baseband. Such IQ imbalances can limit the achievable operating signal-to-noise ratio (SNR) at the receiver. Limitations in the SNR adversely impact the density of the modulation constellations that can be used and thus the rate at which data can be communicated through the communication system. Although so-called “zero-IF”, or “direct-conversion” receivers are preferable for low-cost and power-sensitive applications, they tend to be more sensitive to IQ imbalance. When IQ imbalances are present, spectral components from the associated ‘negative’ frequency bin can cause interference with the desired signal. However, even in receivers in which a final conversion from the intermediate frequency (IF) to baseband is performed, the heterodyne process employed by the receiver may impose an IQ imbalance.
Another phenomenon that can impact performance is multipath interference. In wireless systems, reflections from buildings, topographic features and other channel anomalies can cause a signal to take two or more different paths between a given transmitter and receiver. Throughout this disclosure, the term channel means the transmission media between a transmitter and a receiver, whether that media is a wire in a wireline system or the space through which a signal is propagated in a wireless system. In wireline systems, imperfect terminations at connections can create reflections of the signals. Whether in wireless or wireline systems, the dominant main signal and any reflected signals can combine in the channel resulting in distortion. In the frequency domain, a reflection produces ripples in the response of the channel, creating amplitude and phase variations across the frequencies of interest. To overcome the effects of the frequency domain ripple, an equalizer is commonly used in the receiver. The use of such equalizers is intended to restore a flat frequency response over the frequencies of interest.
In some systems, such as quadrature-amplitude-modulation (QAM) systems, a signal with a bandwidth that is substantially wider than the coherence bandwidth (i.e., the bandwidth over which the frequency response is essentially flat) can encounter distortion. Accordingly, some systems, for example, OFDM systems, break-up this bandwidth and transmit the data in a plurality of narrowband subcarriers. For example, a data symbol can comprise a plurality of subcarrier symbols. Each subcarrier symbol is transmitted on a different subcarrier having a bandwidth that is substantially narrower than the coherence bandwidth. This reduces the distortion levels, but introduces other challenges, such as variations in the signal losses and phase delays from subcarrier to subcarrier. Accordingly, channel equalization coefficients are computed for each subcarrier to “equalize” the channel.
In OFDM networking environments, equalization can be implemented by sending a known channel estimation symbol over the channel. For example, a known channel estimation symbol is sent in an OFDM data packet. The symbol is examined at the receiver to determine amount of distortion to which the signal has been subjected (i.e., distortions in the relative amplitude and phase of the signal that occur due to the characteristics and nature of the channel). Compensation for such amplitude and phase distortion to the symbol is applied to equalize the channel. In one case, the “ideal” channel estimation symbol (i.e., the channel estimation symbol that would have been received if no variation in amplitude or phase occurred) is divided by the received channel estimation symbol. The result of this operation is an average channel equalization coefficient. The channel equalization coefficient can then be used to correct channel-induced amplitude and phase variations in received data symbols.
OFDM systems transmit data within the payload of a packet. The packet also includes a preamble. The information in the preamble and payload are transmitted using OFDM symbols. Both the OFDM symbols that make up the payload (i.e., data symbols) and the OFDM symbols that make up the preamble (i.e., preamble symbols) are spread over a plurality of subcarriers. In some systems, each of the OFDM symbols is made up of 256 subcarriers. Each subcarrier is modulated with QAM modulation, for example. Accordingly, each OFDM symbol comprises 256 subcarrier symbols (however, in some OFDM systems, only 224 of the 256 subcarriers are used to transmit information). The simplest form of QAM modulation is binary phase shift key (BPSK) modulation.
FIG. 1 illustrates the relationship between a radio frequency carrier and the associated subcarrier bins of an OFDM system, such as the OFMD systems that conform to the MoCA (Multimedia over Coaxial Alliance) industry standard for communicating multimedia content over coaxial cables. As shown in FIG. 1 , each of the 256 subcarriers is designated with a reference number (or bin number). For the purpose of this description, the bin numbers start with 0 at the carrier center frequency. The bin numbers increment by one for each subcarrier having a higher frequency than the center frequency. The subcarriers are spaced in increments of 50 MHz divided by 256. The first of the 256 carriers having a higher frequency than the center frequency is designated as bin number 1. The bin numbers increase up to 127 for subcarriers of higher frequency than the center frequency. Likewise, for subcarriers with frequencies lower than the center frequency, the bin numbers start at −1 and decrease (get more negative) in increments of one. The frequency of the subcarrier associated with each bin decreases in increments of 50 MHz divided by 256 with the bin number of the subcarrier with the lowest frequency being −128. For the purpose of this description, bin number −k and bin number k are considered “image bins”. Accordingly, bin number −1 and bin number 1 are considered to be image bins, bin number −2 and bin number 2 are considered to be image bins, etc. Said another way, bin number 2 is the image of bin number −2. Likewise, bin number − 2 is the image of bin number 2.
In OFDM systems, using OFDM channel estimation symbols to perform channel equalization suffers from the effects of interference between subcarrier symbols, primarily from interference between image bins. Because of interference between image bins, subcarrier symbols associated with some bins are properly corrected, while the error in subcarrier symbols associated with other bins is increased.
FIG. 2 a - e illustrate channel estimation subcarrier symbols used for conventional channel equalization. In this example, the channel equalization subcarrier symbols are modulated onto the subcarriers using BPSK modulation. Each channel estimation subcarrier symbol is sent at one of the subcarrier frequencies. For the purpose of this explanation, the variable “k” is used to represent the bin number Those subcarriers that have a frequency that is higher than the carrier center frequency have positive bin numbers (“k”), as shown in FIG. 1 . Those subcarriers that have a frequency that is lower than the carrier center frequency have a negative bin number (“−k”).
In FIG. 2 a , the channel estimation subcarrier symbol has a value of +1, represented by a positive in-phase amplitude and a zero quadrature-phase amplitude, as shown by the dot 101 being placed to the right of the origin 102 and along the x axis of the graph 1. This symbol is sent in bin −k. The same channel estimation subcarrier symbol value +1 is also sent at bin k (shown by the dot 103 in FIG. 2 b ).
FIG. 2 c illustrates the distortion 104 to the value of a channel estimation subcarrier symbol that has an undistorted value 106 of +1 and is modulated in bin k, while a channel estimation subcarrier symbol having a value of 1 is modulated in the image bin −k. As illustrated in FIG. 2 c , the channel estimation subcarrier symbol 104 is offset (or distorted) from the desired or “ideal” symbol 106 . The offset is equal to the distance between points 104 and 106 . This offset is due to the effect of an IQ imbalance which causes some of the information from the −k th bin to “bleed over” into the k th bin. FIG. 2 d illustrates the distortion 110 that occurs to the undistorted symbol 108 in the k th bin when the image bin −k is modulated with a symbol having a value of −1. This results in the distortion 110 from the undistorted modulation symbol 108 . Accordingly, the channel estimation subcarrier symbol for the k th bin, at the transmitter output, is:
y k,ce =x k,ce +β k x* −k,ce (eq. 1)
where x k,ce is the undistorted channel estimation symbol of the k th bin, x −k,ce is the undistorted channel estimation symbol of the −k th bin, and δ k is a complex coefficient (less than 1) that is multiplied by x −k,ce to indicate to the amount of image distortion resulting from an IQ imbalance. This equation illustrates that a fraction of the original −k th bin symbol adds to the original k th bin symbol to form the actual transmitted channel estimation symbol for the k th bin. The fact that β k is complex means that it includes both the amplitude distortion and phase distortion (i.e., a rotation to the signal) caused by the IQ imbalance. It should be noted that the distortion is added as the complex conjugate of the value in the −k th bin.
In addition to any distortion that is caused by the IQ imbalance, over the course of transmission, the channel estimation subcarrier symbol is scaled and rotated by the channel. The scaling and rotation is represented by a complex channel coefficient, c k . This scaled and rotated channel estimation subcarrier symbol r k,ce is then received by the receiver and has the value:
r k,ce =c k y k,ce =c k x k,ce +c k β k x* −k,ce (eq. 2)
The equalizer system measures the received channel estimation subcarrier symbol, and saves this measurement. Once the equalizer makes the measurement, a correction factor is determined based upon the measurement made by the equalizer. Subsequently received data symbols are equalized by applying the correction factor to the received symbols. However, in measuring the received channel estimation subcarrier symbol, the equalization process cannot distinguish the effect of IQ imbalance c k β k x* −k,ce from the effect of the channel c k , and so the measurement includes correction for the IQ imbalance as well as the effect of the channel. This would be a good thing if the effect of the IQ imbalance were constant, since it would eliminate the IQ imbalance. However, the IQ imbalance changes depending upon the value that is modulated into the image bin, as can be seen in equation (1) and equation (2) and FIGS. 2 c and 2 d.
One channel estimation process estimates c k by dividing the received symbol by the known channel estimation symbol:
c ^ k = r k , ce x k , ce = c k x k , ce + c k β k x - k , ce * x k , ce = c k ( 1 + β k x - k , ce * x k , ce ) ( eq . 3 )
For BPSK channel estimation symbols, x q,ce ε{−1+j0,+1+j0}∀q. Therefore
x
-
k
,
ce
*
x
k
,
ce
∈
{
+
1
,
-
1
}
.
Accordingly, for each subsequently received subcarrier symbol that is equalized, as long as the same value is modulated on the image as was modulated on the image when the equalization measurement was made, the correction will be accurate and will appropriately remove the effects of both the channel distortion and the distortion caused by the IQ imbalance.
However, FIG. 2 c and FIG. 2 d illustrate that the distortion that occurs when the image subcarrier symbol has a value of −1 is the inverse of the distortion that occurs when the image subcarrier is modulated with a symbol having a value of 1. This is easy to see, since both the real and imaginary parts of β k are multiplied by 1 when the image bin carries a 1 and by −1 when the image bin carries a −1. The distortion occurs to the subcarrier symbol prior to transmission due to the IQ imbalance. Accordingly, applying the same equalization measurement made for FIG. 2 d to the symbol of FIG. 2 c would result in an increase in the error, as is shown in FIG. 2 e in which point 104 is moved to point 112 by the equalizer. It should be noted that FIG. 2 e assumes no rotation or scaling due to the channel, but only distortion due to the IQ imbalance.
Accordingly, assuming an equal distribution of data in the image bin, 50% of the time the IQ imbalance causes no or negligible error, and 50% of the time there is an error vector magnitude of approximately 2β k . In addition to the error caused by the IQ imbalance in the transmitter which is proportional to the coefficient β k , residual IQ imbalance in the receiver causes similar errors proportional to a coefficient, β k rx , associated with receiver hardware. However, typically there is a small frequency offset between the transmitter and receiver reference oscillators. This frequency offset causes receiver IQ imbalance to generate interference from bins near the image bin and not just from the image bin itself, as is the case with transmitter IQ imbalance. Accordingly, receiver IQ imbalance creates crosstalk with bins near the image bin.
SUMMARY OF DISCLOSED METHOD AND APPARATUS
Various embodiments of the disclosed method and apparatus for channel equalization are presented. Some of these embodiments are directed toward systems and methods for performing channel equalization in an OFDM system.
According to one embodiment, a method of negating the effects of IQ imbalance includes: (1) transmitting a channel estimation string across a channel, the channel estimation string comprising a plurality of known channel estimation symbols; (2) logically inverting predetermined symbols within the known channel estimation string; (3) transmitting a second channel estimation string across the channel, the second channel estimation string including the logically inverted predetermined symbols; and (4) estimating the IQ image noise based on received first and second channel estimation symbols. In one embodiment, the operation of estimating comprises determining a channel equalization coefficient from both the transmitted first and second channel estimation strings.
The IQ image noise can be determined for a plurality of subcarriers that make up the communication channel. For a given subcarrier an estimation of the IQ image noise can include: (1) determining a first equalization coefficient for a channel estimation symbol for that subcarrier in the first channel estimation string; (2) determining a second equalization coefficient for a channel estimation symbol for that subcarrier in the second channel estimation string; and (3) generating an average channel equalization coefficient by computing an average of the first and second equalization coefficients. Accordingly, the IQ image noise can be removed from the equalizer for each of the plurality of subcarriers. It should be noted that since the effects of the IQ imbalance are removed from the equalizer, these effects will remain in the received signal after equalization. Accordingly, the equalizer will only remove the effects of the channel.
In some embodiments, the second channel estimation string comprises the known channel estimation symbols and the logically inverted channel estimation symbols. The second channel estimation string can be transmitted before or after the first channel estimation string. In other embodiments, the symbols of the second channel estimation string are transmitted in a predetermined subcarrier, and the step of logically inverting includes logically inverting only the channel estimation symbols that are designated for a predetermined set of subcarriers. The predetermined set of subcarriers can comprise image subcarrier bins.
In one embodiment, the second channel estimation string comprises the same data as the first channel estimation string and the data of the second channel estimation string is logically inverted at a receiver. The channel estimation symbols can be, for example, BPSK symbols, and inverting a symbol can include changing a symbol from +1+j 0 to −1+j 0 , or from −1+j 0 to +1+j 0 (Note that in BPSK modulation, the quadrature phase component “j” is always zero prior to any added phase distortion).
In yet another embodiment, a communication transmitter includes: (1) a memory in which channel estimation strings comprising channel estimation symbols are stored; (2) a channel estimation inverter coupled to an output of the memory to receive channel estimation symbols from the memory; (3) a controller coupled to the channel estimation inverter which causes the inverter to invert a portion of the channel estimation symbols; and (4) a radio that transmits channel estimation strings. In one embodiment, the controller inverts half of the channel estimation symbols in a channel estimation string.
In some embodiments, the transmitter is configured to transmit a first channel estimation string across a channel. A second channel estimation string is then sent across the channel. The second channel estimation strings includes a predetermined set of inverted symbols relative to the first channel estimation string. The controller can be configured to invert the portion of the channel estimation symbols in one of the channel estimation strings. Additionally, the second channel estimation string can include the known channel estimation symbols and the inverted channel estimation symbols.
In yet another embodiment, each channel estimation symbol of a channel estimation string is transmitted in a predetermined subcarrier, and only the channel estimation symbols that are designated for a predetermined set of subcarriers are inverted. The predetermined set of subcarriers can be, for example, the image subcarrier bins.
In still another embodiment, a receiver includes: (1) a memory in which a channel estimation string comprising channel estimation symbols is stored; (2) a channel estimation inverter coupled to the memory; (3) a radio that receives channel estimation strings; and (4) a controller coupled to the channel estimation inverter that causes a portion of the received channel estimation symbols to be inverted. The controller can invert half of the channel estimation symbols in a channel estimation string. The controller can also invert the portion of the channel estimation symbols in a first received transmission of a channel estimation string.
Other features and aspects of the disclosed method and apparatus will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the features in accordance with embodiments of the disclosed method and apparatus. The summary is not intended to limit the scope of the invention, which is defined solely by the claims attached hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
The disclosed method and apparatus, in accordance with one or more various embodiments, is described with reference to the following figures. The drawings are provided for purposes of illustration only and merely depict examples of some embodiments of the disclosed method and apparatus. These drawings are provided to facilitate the reader's understanding of the disclosed method and apparatus. They should not be considered to limit the breadth, scope, or applicability of the claimed invention. It should be noted that for clarity and ease of illustration these drawings are not necessarily made to scale.
FIG. 1 illustrates the relationship between a radio frequency carrier and the associated subcarrier bins of an OFDM system, such as the system used with the MOCA (Multimedia Over Coaxial Alliance) industry standard for communicating multimedia content over coaxial cables.
FIG. 2 a - e illustrate examples of channel estimation symbols.
FIG. 3 is a diagram illustrating an example where the error is corrected accurately 50% of the time and the magnitude of the error is approximately doubled the other 50% of the time.
FIG. 4 is a diagram illustrating an example process for channel estimation in accordance with one embodiment of the disclosed method and apparatus.
FIGS. 5 a and 5 b illustrate channel equalization symbols resulting from the equalization system described with respect to FIG. 4 .
FIG. 6 is a block diagram illustrating an example architecture for channel equalization in accordance with one embodiment of the disclosed method and apparatus.
The figures are not intended to be exhaustive or to limit the claimed invention to the precise form disclosed. It should be understood that the disclosed method and apparatus can be practiced with modification and alteration, and that the invention should be limited only by the claims and the equivalents thereof.
DETAILED DESCRIPTION
The disclosed method and apparatus performs channel equalization in a communication system. More particularly, embodiments of the disclosed method and apparatus perform channel equalization in an OFDM system. The disclosed method and apparatus is described in terms of transmitter IQ imbalance effects, but analogous effects and advantages apply equally well to receiver-generated IQ imbalance errors or residual errors.
In one embodiment of the disclosed method and apparatus, difficulties associated with conventional equalization systems are avoided by sending two channel estimation strings, or two sets of channel estimation symbols, and calculating a channel equalization coefficient based on the two sets of channel estimation symbols. More particularly, in one embodiment, a first set of channel estimation symbols is sent across the channel. The symbols are distributed among the subcarrier bins for the channel. Then, a second set of channel information symbols is transmitted, but the second set of symbols is different from the first set of symbols. Particularly, in one embodiment, the second set of channel estimation symbols is the same as the first channel estimation symbols except that half of the subcarrier symbols of the second set of channel estimation symbols are inverted.
Averaging between the effects of the first and second set of subcarrier symbols is performed to remove the effects of IQ imbalance from the received channel estimation subcarrier symbols. The average is used to determine an average channel equalization coefficient that does not include a correction factor for the transmitter IQ imbalance. Accordingly, the error vector magnitude for received symbols that have been equalized using the average channel equalization coefficient is always approximately β k x −k,ce rather than being 2β k x −k,ce half the time and approximately zero the other half of the time. Because the impact of the error is nonlinear, the doubling of the error, half of the time, causes worse performance when compared with half of the error, all of the time.
The selection of which subcarrier symbols should be inverted can be made in various ways. For example, in one embodiment, the symbols on each of the negative subcarriers (i.e., the −k th bins) are inverted. In another embodiment, the symbols of each of the positive subcarriers are inverted. In yet another embodiment, the subcarrier symbols are inverted in an interlaced pattern. In other words, the symbols on alternate positive and negative subcarriers are inverted.
FIG. 4 is a diagram illustrating an example process for channel estimation in accordance with one embodiment of the disclosed method and apparatus. In STEP 121 , a first set of channel estimation symbols is sent across the communication channel.
In STEP 125 , a second set of channel estimation subcarrier symbols is sent across the communication channel. In one embodiment, certain symbols in the second set of channel estimation subcarrier symbols are inverted. For example, either the symbols on the negative subcarriers or the symbols on the positive subcarriers are inverted prior to transmission. In some embodiments, including embodiments in which OFDM is used, the channel estimation subcarrier symbols are BPSK symbols. Accordingly, in such embodiments, a symbol is inverted by multiplying that symbol by −1. For example, +1+j 0 is inverted to be −1−j 0 . BPSK is commonly used in OFDM applications. For a system that uses BPSK j 0 =0. That is, the imaginary part of the symbol (+j) is always zero in BPSK modulation.
In STEP 129 , the results of the equalization steps are averaged to obtain an average channel equalization coefficient for which the effects of the IQ imbalance are removed. Then, in operation, the new average channel equalization coefficient can be applied to data sent across the channel. Inverting half of the channel estimation symbols when measuring the channel and generating the average channel equalization coefficient removes any contribution from IQ imbalance from the average channel equalization coefficient. Therefore, an error will be present on the recovered equalized data subcarrier symbols as a result of the transmitter's IQ imbalance. However, by removing the effects of the IQ imbalance by generating the average channel equalization coefficient, the error is approximately one-half of the worst-case error that occurs in conventional equalization systems described above.
As noted above, in conventional equalization systems perfect (or near perfect) equalization occurs in approximately one half of the received symbols. However, the error is doubled in the other half of the symbols. Because the impact of the error is nonlinear, this doubling of the error can be detrimental to the performance of the system. In contrast, in embodiments of the disclosed method and apparatus, half of this worst-case error appears in each symbol. Accordingly, due to the non-linear nature of the system, it is typically preferable to have half of the error all of the time rather than the worst-case error half of the time on the equalized data.
FIGS. 5 a and 5 b illustrate channel equalization symbols that result from the equalization system described in FIG. 4 . Referring now to FIG. 5 a , the point 501 illustrates the ideal value of data bin k before equalization. In this case, the k th bin was modulated with the symbol +1. The point 503 in FIG. 5 a illustrates the value of the data bin k with distortion caused by the IQ imbalance and after equalization. Note that the equalization does nothing to correct for the IQ imbalance, but will correct for any channel effects (i.e., scaling and rotation caused by the channel). The average channel equalization coefficient used to equalize the data in bin k is the average of a first measurement made when the −k th bin contains +1 and a second measurement made when the −k th bin contains −1. As can be seen, applying this average channel equalization coefficient results in an error after equalization. The error is caused by the IQ imbalance which remains in the received symbol, since the IQ imbalance has been removed from the average channel equalization coefficient by averaging the two measurements. Similarly, FIG. 5 b shows the scenario for data bin k modulated with a symbol having a value of +1, after equalization, where the −k th bin is modulated with a symbol having a value of −1. The average channel equalization coefficient used to equalize the data in bin k is the average of a first measurement made when the −k th bin contains +1 and a second measurement made when the −k th bin contains −1.
In contrast. FIG. 2 e shows the situation where this error is doubled. FIG. 2 e shows the scenario for the received constellation in the k th bin after equalization having a value of +1. The equalization was performed with the −k th bin having a symbol with a value of −1 at the time the +1 was being transmitted in the k th bin. However, the channel equalization coefficient was determined from a channel estimation symbol in which the value of the symbol for the −k th bin was +1.
As will be appreciated by one of ordinary skill in the art after reading the above examples, a number of different architectures can be used to implement this and other embodiments of the disclosed method and apparatus. FIG. 6 is a block diagram illustrating one such example architecture for channel equalization in accordance with the disclosed method and apparatus. The architecture of FIG. 6 can be used to invert a plurality of channel estimation symbols for the equalization process. The transmit architecture 202 includes a channel estimation sequence memory 212 , a channel estimation inverter 214 , a multiplexer or switch 216 , a constellation mapper 218 , a serial-to-parallel converter 220 , an inverse fast Fourier transform block 222 and a parallel-to-serial converter 224 . The receiver architecture 204 includes a serial-to-parallel converter 244 , a fast Fourier transform block 246 , a parallel-to-serial converter 248 , a multiplexer or switch 250 , a mixer 252 , a channel estimation inverter 254 , and a channel equalization coefficient memory 256 .
In the transmitter, a channel estimation string comprising a series of channel estimation symbols, is stored in the channel sequence memory 212 . In one embodiment, the same sequence can be stored in the memory 212 and reused for equalization. This is particularly true when a plurality of the subcarrier symbols of the first channel estimation string or sequence are inverted.
Modulation data is received by the system, selected by the multiplexer 216 and sent to the constellation mapper 218 . Constellation mapper 218 maps the received modulation data into a plurality of constellation symbols that are complex numbers, unless BPSK modulation is being used. The constellations are forwarded to the serial-to-parallel converter 220 , which places each of the data bits into its respective subcarrier. The inverse fast Fourier transform block 222 converts these into time domain symbols for transmission across the channel. The sequence is similar for transmitting channel estimation and equalization symbols, however instead of utilizing modulation data (or actual data), the channel estimation sequence that was stored in the memory 212 is used. In terms of the example described above with respect to FIG. 4 , in STEP 121 , the channel estimation sequence is retrieved from the memory 212 and sent through the inverter 214 (which is depicted in FIG. 6 as an exclusive-OR gate). It should be understood by those skilled in the art that the inverter 214 may be a hardware inverter, such as the exclusive-OR gate shown in FIG. 6 , a software inverter wherein the inversion is performed by a processor running software code, or some combination of hardware and software. Hardware inverters can be fashioned in many ways, such as by an amplifier, transistor, switch, logic gate, etc.
The inverted signal is selected by the multiplexer 216 and switched into the mapper 218 . The channel estimation sequence is mapped to the constellation and the serial-to-parallel converter 220 places the constellations into their respective subcarrier channels. The inverse Fourier transform places the symbols in the time domain for transmission across the channel.
As stated above with respect to STEP 125 of FIG. 4 , the channel estimation process is repeated, but with selected symbols in the channel estimation sequence inverted. Accordingly, in this step, the channel estimation sequence is retrieved from the memory 212 and sent through the exclusive-OR gate 214 . However, in this step, a controller (not shown) can set a control bit in line 262 to selectively invert subcarrier symbols of the channel estimation sequence. Accordingly, the stream of inverted and non-inverted channel estimation symbols is selected by the multiplexer 216 and sent to the mapper 218 for constellation mapping. Again, the serial-to-parallel converter 220 places the symbols into their respective channels, and the inverse Fourier transform block 222 creates time domain symbols for transmission across the channel.
At the receive side, the symbols sent across the channel are received and broken into their constituent subcarriers by the serial-to-parallel converter 244 . The fast Fourier transform block 246 places these into the frequency domain and sends them to the parallel-to-serial converter 248 where they can be placed into a sequence of symbols. The demultiplexer 250 couples data symbols to the mixer 252 . Alternatively, if channel estimation symbols are received, the channel estimation symbols are sent to a processor (not shown) where they are used to characterize the channel. The value of each received symbol is divided by the value of the “ideal” symbol that was supposed to have been received (which is stored in memory at the receiver). The results are the channel equalization coefficients, which are stored in the channel equalization coefficient memory 256 . A channel estimation inverter 254 can be used to invert the stored channel estimation sequence to remove the inversion in the received symbols. After removing the inversion, the symbols can be compared with the “ideal” symbols. The stored channel equalization coefficients can then be averaged and the average channel equalization coefficient can be used to equalize received data.
While various embodiments of the disclosed method and apparatus have been described above, it should be understood that they have been presented by way of example only, and should not limit the claimed invention. Likewise, the various diagrams may depict an example architectural or other configuration for the disclosed method and apparatus. This is done to aid in understanding the features and functionality that can be included in the disclosed method and apparatus. The claimed invention is not restricted to the illustrated example architectures or configurations, rather the desired features can be implemented using a variety of alternative architectures and configurations. Indeed, it will be apparent to one of skill in the art how alternative functional, logical or physical partitioning and configurations can be implemented to implement the desired features of the disclosed method and apparatus. Also, a multitude of different constituent module names other than those depicted herein can be applied to the various partitions. Additionally, with regard to flow diagrams, operational descriptions and method claims, the order in which the steps are presented herein shall not mandate that various embodiments be implemented to perform the recited functionality in the same order unless the context dictates otherwise.
Although the disclosed method and apparatus is described above in terms of various exemplary embodiments and implementations, it should be understood that the various features, aspects and functionality described in one or more of the individual embodiments are not limited in their applicability to the particular embodiment with which they are described. Thus, the breadth and scope of the claimed invention should not be limited by any of the above-described exemplary) embodiments.
Terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing: the term “including” should be read as meaning “including, without limitation” or the like; the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof; the terms “a” or “an” should be read as meaning “at least one,” “one or more” or the like; and adjectives such as “conventional,” “traditional,” “normal,” “standard,” “known” and terms of similar meaning should not be construed as limiting the item described to a given time period or to an item available as of a given time, but instead should be read to encompass conventional, traditional, normal, or standard technologies that may be available or known now or at any time in the future. Likewise, where this document refers to technologies that would be apparent or known to one of ordinary skill in the art, such technologies encompass those apparent or known to the skilled artisan now or at any time in the future.
A group of items linked with the conjunction “and” should not be read as requiring that each and every one of those items be present in the grouping, but rather should be read as “and/or” unless expressly stated otherwise. Similarly, a group of items linked with the conjunction “or” should not be read as requiring mutual exclusivity among that group, but rather should also be read as “and/or” unless expressly stated otherwise. Furthermore, although items, elements or components of the disclosed method and apparatus may be described or claimed in the singular, the plural is contemplated to be within the scope thereof unless limitation to the singular is explicitly stated.
The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent. The use of the term “module” does not imply that the components or functionality described or claimed as part of the module are all configured in a common package. Indeed, any or all of the various components of a module, whether control logic or other components, can be combined in a single package or separately maintained and can further be distributed in multiple groupings or packages or across multiple locations.
Additionally, the various embodiments set forth herein are described in terms of exemplary block diagrams, flow charts and other illustrations. As will become apparent to one of ordinary skill in the art after reading this document, the illustrated embodiments and their various alternatives can be implemented without confinement to the illustrated examples. For example, block diagrams and their accompanying description should not be construed as mandating a particular architecture or configuration. | Systems and methods for performing channel equalization in a communication system are presented. More particularly, embodiments of the disclosed method and apparatus are directed toward systems and methods for performing channel equalization in an OFDM system. One example of a method of negating the effects of IQ imbalance can include the operations of transmitting a channel estimation string across a channel. The channel estimation string comprises a plurality of known channel estimation symbols. The method further includes logically inverting predetermined symbols within the known channel estimation string; transmitting a second channel estimation string across the channel, the second channel estimation string including the logically inverted predetermined symbols; and estimating the IQ image noise based on received first and second channel estimation symbols. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 329998/2007, filed on Dec. 21, 2007; the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to an agricultural or horticultural composition for use as a novel systemic insecticide, and a control method using the same.
2. Background Art
The positive list system for residual agricultural chemicals and the like has recently come into effect, and a great deal of interest has been drawn to measures for prevention of drift of agricultural chemicals and the like. Unlike the conventional foliage application technology, systemic chemicals are usually applied, for example, to soil or nursery boxes for insect pest control purposes and thus can reduce drift of the chemicals into a surrounding environment. Also from the viewpoints of labor saving and ensuring of safety for agricultural chemical application, systemic insecticides are superior to the conventional foliage application technology. For example, since the insecticidal effect can be attained only by applying a systemic insecticide to plant nursery boxes, work necessary for agriculture workers to spend in chemical treatment can be suppressed. Further, systemic insecticides can be properly applied to crops and thus can prevent exposure of persons, who apply agricultural chemicals, to agricultural chemicals. Accordingly, systemic insecticides are also superior in ensuring safety. Furthermore, also from the viewpoint of efficacy, formulations having a longer residual activity than formulations for foliage application can be provided by adding, for example, release control properties to formulations containing a systemic insecticide. By virtue of the usefulness of systemic insecticides, the development of systemic insecticides as agricultural or horticultural technology different from conventional foliage application technology or the like mainly in paddy rice and vegetable markets has recently been expected.
On the other hand, WO 2004/060065 and Applied and Environmental Microbiology (1995), 61(12), 4429-35 describe that pyripyropene A has insecticidal effect against Plutella xylostella, Tenebrio molitor , and Helicoverpa armiger.
Further, WO 2006/129714 describes that a group of pyripyropene compounds including compounds of formula (1) has an insecticidal activity against Myzus persicae Sulzer, Trigonotylus caelestialium, Plutella xylostella , and Helicoverpa armigera . Furthermore, Japanese Patent Application Laid-Open No. 360895/1992, Journal of Antibiotics (1993), 46(7), 1168-69, Journal of Synthetic Organic Chemistry, Japan (1998), vol. 56, No. 6, pp. 478-488, WO 94/09147, Japanese Patent Application Laid-Open No. 259569/1996, and Japanese Patent Application, Laid-Open No. 269062/1996 describe pyripyropenes, which are naturally occurring products or derivatives thereof, and their inhibitory activity against ACAT (acyl CoA: cholesterol acyltransferase).
A plurality of literatures report the insecticidal activity of compounds related to pyripyropene. They, however, describe neither the fact that, among the compounds related to pyripyropene, a group of specific compounds has systemic properties, nor use of the group of specific compounds as systemic insecticides.
Up to now, a number of systemic insecticides have been reported. For all of them, however, drug resistant species and uncontrollable species exist, and the development of novel insecticides having high systemic control effect has been desired still.
SUMMARY OF THE INVENTION
The present inventors have now found that compounds represented by formula (1) or salts thereof have high systemic control effect. The present invention has been made based on such finding.
Accordingly, an object of the present invention is to provide a chemical which can be effectively and safely used for agricultural or horticultural applications and has high systemic properties, and a control method using the same.
According to the present invention, a systemic insecticide comprises as active ingredients one or more compounds represented by formula (1) or salts thereof:
wherein
R 1 represents hydroxyl,
optionally substituted C 1-6 alkylcarbonyloxy, optionally substituted C 2-6 alkenylcarbonyloxy, or optionally substituted C 2-6 alkynylcarbonyloxy;
R 2 represents a hydrogen atom,
hydroxyl, optionally substituted C 1-6 alkylcarbonyloxy, optionally substituted C 2-6 alkenylcarbonyloxy, or optionally substituted C 2-6 alkynylcarbonyloxy; and
R 3 represents a hydrogen atom,
hydroxyl, optionally substituted methylcarbonyloxy, or oxo in the absence of a hydrogen atom at the 7-position.
According to the present invention, there is also provided a method for controlling agricultural or horticultural insect pests, the method comprising:
applying an effective amount of one or more compounds represented by formula (1) or salts thereof to an object selected from the group consisting of soil, nutrient solution in nutriculture, solid medium in nutriculture, and seed, root, tuber, bulb, and rhizome of a plant; and
systemically translocating the compounds represented by formula (1) into a plant.
DETAILED DESCRIPTION OF THE INVENTION
Definition
The agent having systemic properties (known also as “systemic insecticide”) as used herein means an agent that can be systemically translocated into a plant and can poison pests, which suck or chew the plant to death (see New edition “Nouyaku No Kagaku (The Science of Agricultural Chemicals)” (BUNEIDO PUBLISHING CO., LTD, Kyohei Yamashita et al.), p. 14).
The terms “alkyl,” “alkenyl,” and “alkynyl” as used herein as a group or a part of a group respectively mean alkyl, alkenyl, and alkynyl that the group is of a straight chain, branched chain, or cyclic type or a type of a combination thereof unless otherwise specified. Further, for example, “C 1-6 ” in “C 1-6 alkyl” as a group or a part of a group means that the number of carbon atoms in the alkyl group is 1 to 6 and that, in the case of cyclic alkyl, the number of carbon atoms is at least three.
Further, the “optionally substituted” alkyl as used herein means that one or more hydrogen atoms on the alkyl group are optionally substituted by one or more substituents which may be the same or different. It will be apparent to a person having ordinary skill in the art that the maximum number of substituents may be determined depending upon the number of substitutable hydrogen atoms on the alkyl group. This is also true of alkenyl and alkynyl.
Compounds Represented by Formula (1) or Salts Thereof
The systemic insecticide according to the present invention comprises as an active ingredient a compound of formula (1) or a salt thereof. It is a surprising fact that compounds of formula (1) have high systemic insecticidal activity.
Preferably, in the compound of formula (1), “C 1-6 alkylcarbonyloxy” represented by R 1 and R 2 is C 1-4 alkylcarbonyloxy, more preferably acetyloxy, ethylcarbonyloxy, or C 3-4 cyclic alkylcarbonyloxy. The C 1-6 alkylcarbonyloxy group is optionally substituted, and examples of such substituents include halogen atoms, cyano, C 3-5 cycloalkyl, trifluoromethyloxy, or trifluoromethylthio. A halogen atom or C 3-5 cycloalkyl is preferred.
“Methylcarbonyloxy” represented by R 3 is optionally substituted, and examples of such substituents include halogen atoms, cyano, trifluoromethyl, or trifluoromethoxy, preferably a halogen atom or cyano.
Preferably, “C 2-6 alkenylcarbonyloxy” represented by R 1 and R 2 is C 2-4 alkenylcarbonyloxy. The C 2-6 alkenylcarbonyloxy group is optionally substituted, and examples of such substituents include halogen atoms, cyano, trifluoromethyloxy, or trifluoromethylthio.
Preferably, “C 2-6 alkynylcarbonyloxy” represented by R 1 and R 2 is C 2-4 alkynylcarbonyloxy. The C 2-6 alkynylcarbonyloxy group is optionally substituted, and examples of such substituents include halogen atoms, cyano, trifluoromethyloxy, or trifluoromethylthio.
In the compounds of formula (1), preferably, R 1 represents hydroxyl or optionally substituted C 1-6 alkylcarbonyloxy, more preferably hydroxyl or optionally substituted C 3-4 cyclic alkylcarbonyloxy.
Further, in the compounds of formula (1), preferably, R 2 represents optionally substituted C 1-6 alkylcarbonyloxy, more preferably optionally substituted C 3-4 cyclic alkylcarbonyloxy.
Furthermore, in the compounds of formula (1), preferably, R 3 represents hydroxyl, optionally substituted methylcarbonyloxy, or oxo in the absence of a hydrogen atom at the 7-position, more preferably hydroxyl.
According to a preferred embodiment of the present invention, in the compounds of formula (1), R 1 represents hydroxyl or optionally substituted C 1-6 alkylcarbonyloxy, and R 2 represents optionally substituted C 1-6 alkylcarbonyloxy.
According to another preferred embodiment of the present invention, in the compounds of formula (1), represents hydroxyl or optionally substituted C 1-6 alkylcarbonyloxy, and R 3 preferably represents hydroxyl, optionally substituted methylcarbonyloxy, or oxo in the absence of a hydrogen atom at the 7-position.
According to still another preferred embodiment of the present invention, in the compounds of formula (1), R 2 represents optionally substituted C 1-6 alkylcarbonyloxy, and R 3 represents hydroxyl, optionally substituted methylcarbonyloxy, or oxo in the absence of a hydrogen atom at the 7-position.
According to a more preferred embodiment of the present invention, in the compounds of formula (1), R 1 represents hydroxyl or optionally substituted C 1-6 alkylcarbonyloxy, R 2 represents optionally substituted C 1-6 alkylcarbonyloxy, and R 3 represents hydroxyl, optionally substituted methylcarbonyloxy, or oxo in the absence of a hydrogen atom at the 7-position.
According to another preferred embodiment of the present invention, in the compounds of formula (1), R 1 and R 2 represent optionally substituted C 3-4 cyclic alkylcarbonyloxy. According to another more preferred embodiment of the present invention, in the compounds of formula (1), R 3 represents hydroxyl. The compounds of formula (1) in the embodiments have significant systemic properties and can be particularly advantageously utilized for insect pest control applications.
More specifically, compounds 1 to 7 shown in Table 1 may be mentioned as preferred compounds of formula (1). In Table 1, substituents R 1 , R 2 , and R 3 correspond respectively to substituents R 1 , R 2 , and R 3 in formula (1).
TABLE 1
Test compounds in Test Example 3
Compound
No.
R 1
R 2
R 3
1
OCOCH 3
OCOCH 3
OCOCH 3
2
OCOCH 3
OCOCH 3
OH
3
OCOCH 2 CH 3
OCOCH 2 CH 3
OH
4
OCO-cyclopropyl
OCO-cyclopropyl
OH
5
OH
OCO-cyclopropyl
OH
6
OCO-cyclopropyl
OCO-cyclopropyl
O
7
OCO-cyclopropyl
OCO-cyclopropyl
H
Further, in the present invention, salts of compounds of formula (1) are also usable, and examples, of such salts include agriculturally or horticulturally acceptable acid addition salts such as hydrochloride salts, nitrate salts, sulfate salts, phosphoric salts, or acetate salts.
Compounds of formula (1) including compounds shown in Table 1 and compounds shown in Table 6 used in Comparative Test Examples can be produced by processes described in Japanese Patent No. 2993767 (Japanese Patent Application Laid-Open No. 360895/1992), Japanese Patent Application Laid-Open No. 259569/1996, WO 2006/129714, and Japanese Patent No. 4015182, or processes based on the processes.
Systemic Insecticide
As described above, the compounds of formula (1) or salts thereof have high systemic insecticidal activity and can be advantageously utilized, for example, in control of insect pests that suck or chew plants. Thus, according to another aspect of the present invention, there is provided use of compounds represented by formula (1) or salts thereof, as a systemic insecticide.
Agricultural or horticultural insect pests against which the systemic insecticide according to the present invention has control effect include lepidopteran insect pests, for example, Noctuidae such as Spodoptera litura, Spodoptera exigua, Pseudaletia separata, Mamestra brassicae, Agrotis ipsilon, Trichoplusia spp., Heliothis spp., and Helicoverpa spp., Pyralidae such as Chilo suppressalis, Cnaphalocrocis medinalis, Ostrinia nubilalis, Hellula undalis, Parapediasia teterrella, Notarcha derogata , and Plodia interpunctella , Pieridae such as Pieris rapae , Tortricidae such as Adoxophyes spp., Grapholita molesta , and Cydia pomonella , Carposinidae such as Carposina niponensis , Lyonetiidae such as Lyonetia spp., Lymantriidae such as Lymantria ssp. and Euproctis spp., Yponomeutidae such as Plutella xylostella , Gelechiidae such as Pectinophora gossypiella , Arctiidae such as Hyphantria cunea , and Tineidae such as Tinea translucens Meyrick and Tinea bissellinella ; hemipteran insect pests, for example, Aphididae such as Myzus persicae Sulzer and Aphis gossypii , Delphacidae such as Laodelphax stratella, Nilaparvata lugens Stal, and Sogatella furcifera , Cicadellidae such as Nephotettix cincticeps and Empoasca onukii , Pentatomidae such as Trigonotylus caelestialium, Plautia crossota stali, Nezara viridula , and Riptortus clavatus , Aleyrodidae such as Trialeurodes vaporariorum and Bemisia tabaci , Coccoidea such as Pseudaulacaspis pentagona, Pseudococcus comstocki Kuwana, and Aonidiella aurantii , Tingidae, and Psyllidae, Aphididae, Coccoidea, Aleyrodidae, and Cicadellidae being preferred; Coleoptera insect pests, for example, Curculionidae such as Sitophilus zeamais, Lissorhoptrus oryzophilus , and Callosobruchus chinensis , Tenebrionidae such as Tenebrio molitor , Scarabaeidae such as Anomala cuprea and Anomala rufocuprea Motschulsky, Chrysomelidae such as Phyllotreta striolata, Aulacophora femoralis, Leptinotarsa decemlineata, Diabrotica virgifera virgifera , and Diabrotica undecimpunctata howardi , Epilachna such as Oulema oryzae Kuwayama, Paederus fuscipes , Bostrychidae, and Epilachna vigintioctopunctata Fabricius, and Cerambycidae; Acari, for example, Tetranychidae such as Tetranychus urticae Koch, Tetranychus kanzawai Kishida, Panonychus citri, Panonychus ulmi , and Oligonychus spp., Eriophyidae such as Aculops lycopersici, Aculops pelekassi Keifer, and Calacarus carinatus , Tarsonemidae such as Polyphagotarsonemus latus , and Acaridae; hymenopteran insect pests, for example, Tenthredinidae such as Athalia rosae ruficornis ; Orthopteran insect pests, for example, Acrididae; Dipteran insect pests, for example, Agromyzidae such as Muscidae, Culex , Anophelinae, Chironomidae, Calliphoridae, Sarcophagidae, Fanniidae, Anthomyiidae, Liriomyza trifolii, Liriomyza sativae , and Liriomyza bryoniae , Tephritidae, Phoridae, Drosophilidae, Psychodidae, Simuliidae, Tabanidae, and Stomoxyini ; Thysanopteran insect pests, for example, Thrips palmi Karny, Frankliniella occidentalis Pergande, Thrips tabaci Lindeman, Thrips hawaiiensis, Scirtothrips dorsalis, Frankliniella intonsa , and Ponticulothrips diospyrosi ; and Plant Parasitic Nematodes, for example, Aphelenchoididae such as Meloidogyne hapla, Pratylenchus , Heteroderidae, Aphelenchoides besseyi , and Bursaphelenchus xylophilus . Among them, hemipteran insect pests are preferred as insect pests to which the systemic insecticide according to the present invention is applied.
The compounds of formula (1) or salts thereof as such may be used as an active ingredient of the systemic insecticide, but are generally mixed with suitable solid carriers, liquid carriers, gaseous carriers, surfactants, dispersants, or other adjuvants for formulations and formulated into any suitable dosage forms, for example, wettable powders, water dispersible granules, suspensions, flowables, granules, micro granule, dusts, emulsifiable concentrates, EW agents, liquid formulations, tablets, oils, and aerosols, for use as compositions.
Solid carriers include, for example, talc, bentonite, clay, kaolin, diatomaceous earth, vermiculite, zeolite, white carbon, calcium carbonate, acid clay, pumice, attapulgite, and titanium oxide.
Liquid carriers include, for example, alcohols such as methanol, n-hexanol, ethylene glycol, and propylene glycol; ketones such as acetone, methyl ethyl ketone, and cyclohexanone; aliphatic hydrocarbons such as n-hexane, kerosine, and kerosene; aromatic hydrocarbons such as toluene, xylene, and methylnaphthalene; ethers such as diethyl ether, dioxane, and tetrahydrofuran; esters such as ethyl acetate; nitriles such as acetonitrile and isobutyronitrile; acid amides such as dimethylformamide and dimethylacetamide; vegetable oils such as soy bean oil and cotton seed oil; dimethylsulfoxide; and water.
Gaseous carriers include, for example, LPG, air, nitrogen, carbon dioxide, and dimethyl ether.
Surfactants or dispersants usable, for example, for emulsifying, dispersing, or spreading include, for example, alkylsulfuric esters, alkyl(aryl)sulfonic acid salts, polyoxyalkylene alkyl(aryl)ethers, polyhydric alcohol esters, dioctyl sodium sulfosuccinate, alkyl maleate copolymer, sodium alkylnaphthalene sulfonate, sodium salts of β-naphthalene sulfonate formaldehyde condensate, lignin sulfonic acid salts, polyoxyethylene tristyryl phenyl ether sulfate, or phosphate.
Adjuvants usable for improving the properties of formulations include, for example, pregelatinized starch, dextrin, carboxymethylcellulose, gum arabic, polyethylene glycol, calcium stearate, polyvinyl pyrrolidone, sodium alginate, phenolic antioxidant, amine antioxidant, phosphorus antioxidant, sulfureous antioxidant, and epoxidized vegetable oil.
The above carriers, surfactants, dispersants, and adjuvants may be used either solely or in combination according to need.
The suitable content of the active ingredient in these formulations is generally 1 to 75% by weight for emulsifiable concentrate, generally 0.3 to 25% by weight for dust, generally 1 to 90% by weight for wettable powder, and generally 0.5 to 10% by weight for granules.
Preferably, the systemic insecticide according to the present invention is applied to seeds, roots, tubers, bulbs, or rhizomes of plants, more preferably seeds of plants. When the plants are an object to which the systemic insecticide is applied, the compounds of formula (1) can be advantageously efficiently absorbed and penetrated into the plants to attain systemic insecticidal effect.
Plants
Plants into which the compound of formula (1) has been systemically translocated as such have insecticidal activity and can be advantageously utilized in the control of insect pests that suck or chew the plants. Thus, according to a further aspect of the present invention, there is provided a plant treated with the systemic insecticide according to the present invention, wherein the plant is selected from seeds, roots, tubers, bulbs, and rhizomes. According to a preferred embodiment, the treatment includes systemic translocation of the compound of formula (1) into the plant
Control Method
According to another aspect of the present invention, there is provided a method comprising applying an effective amount of one or more compounds of formula (1) or salts thereof to an object selected from the group consisting of soil, nutrient solutions in nutricultures, solid media in nutricultures, and seeds, roots, tubers, bulbs, and rhizomes of plants, and systemically translocating the compound of formula (1) into the plant.
When the object is a seed, root, tuber, bulb, or rhizome of a plant, any application method that does not inhibit systemic translocation of the compound of formula (1) can be adopted without particular limitation, and examples of suitable application methods include dipping, dust coating, smearing, spraying, pelleting, or coating.
According to a preferred embodiment of the present invention, the object is a seed. When the object is a seed, application methods usable herein include dipping, dust coating, smearing, spraying, pelleting, coating, and fumigating. The dipping is a method in which seeds are dipped in a chemical solution. The dust coating is classified into two types, i.e., a dry dust coating method in which a powdery chemical is adhered onto dry seeds, and a wet dust coating method in which a powdery chemical is adhered onto seeds which have been lightly soaked in water. The smearing is a method in which a suspended chemical is coated on the surface of seeds within a mixer. The spraying is a method in which a suspended chemical is sprayed onto the surface of seeds. The pelleting is a method in which a chemical is mixed with a filler when seeds, together with a filler, are pelleted to form pellets having given size and shape. The coating is a method in which a chemical-containing film is coated onto seeds. The fumigating is a method in which seeds are sterilized with a chemical which has been gasified within a hermetically sealed vessel.
The compounds of formula (1) or salts thereof can also be applied to, in addition to seeds, germinated plants which are transplanted after germination or after budding from soil, and embryo plants. These plants can be protected by the treatment of the whole or a part thereof by dipping before transplantation.
The application of the compounds of formula (1) or salts thereof to soil used, for example, in planting of plants is also preferred. Any method for application to soil that does not inhibit the systemic translocation of the compounds of formula (1) may be adopted without particular limitation. Preferred application methods are as follows.
An example of such methods is one in which granules containing a compound of formula (1) or a salt thereof are applied into soil or on soil. Preferred soil application methods include spreading, stripe application, groove application, and planting hole application. The spreading includes surface treatment over the whole area to be treated, and mechanical introduction into soil following the surface treatment.
Drenching of soil with a solution prepared by emulsifying or dissolving the compound of formula (1) or salt thereof in water is also an advantageous soil application method.
Examples of other preferred application methods include application into a nutrient solution in nutrient solution culture systems such as water culture and solid medium culture, for example, sand culture, NFT (nutrient film technique), or rock wool culture, for the production of vegetables and flowering plants. It is also apparent that the compound of formula (1) can be applied directly to artificial culture soil containing vermiculite and a solid medium containing an artificial mat for raising seedling.
In the application step, the effective amount of the compound of formula (1) or salt thereof is preferably an amount large enough to tallow the compound of formula (1) to systemically translocated into the plant in the subsequent systemic translocation step.
The effective amount can be properly determined by taking into consideration, for example, the properties of compounds, the type and amount of the application object, the length of the subsequent systemic translocation step, and the temperature. For example, in the case of seeds, the compound of formula (1) or salt thereof is applied in an amount of preferably 1 g to 10 kg, more preferably 100 g to 1 kg, per 100 kg of seeds. On the other hand, in the case of application to soil, the compound of formula (1) or salt thereof is applied in an amount of preferably 0.1 g to 10 kg, more preferably 1 g to 1 kg, per 10 ares of cultivated land.
In the control method according to the present invention, the compound of formula (1) or salt thereof is applied to the object, followed by systemic translocation of the compound of formula (1) into the plant.
The systemic translocation method is not particularly limited. An example thereof is a method in which a plant such as seed, root, tuber, bulb, or rhizome is planted or dipped in soil or medium to which the compound of formula (1) has been applied, or a chemical solution containing the compound of formula (1) for a period of time long enough to allow the chemical to be systemically translocated into the plant. When the application amount of the chemical and duration sufficient for systemic translocation are selected, the systemic translocation step can also be carried out by applying the compound of formula (1) directly to the plant and allowing the plant to stand still. The present invention includes this embodiment.
The time and temperature in the systemic translocation may be properly determined by a person having ordinary skill in the art depending, for example, upon the object to be applied and the type and amount of the chemical. The systemic translocation time is not particularly limited and may be, for example, one hr or longer. The temperature in the systemic translocation is, for example, 5 to 45° C.
The compounds of formula (1) may be used as a mixture with other chemicals, for example, fungicides, insecticides, miticides, herbicides, plant growth-regulating agents, or fertilizers. Specific examples of other admixable chemicals are described, for example, in The Pesticide Manual, the 13th edition, published by The British Crop Protection Council; and SHIBUYA INDEX, the 10th edition, 2005, published by SHIBUYA INDEX RESEARCH GROUP.
More specific examples of other chemicals include insecticides, for example, acephate, dichlorvos, EPN, fenitothion, fenamifos, prothiofos, profenofos, pyraclofos, chlorpyrifos-methyl, chlorfenvinphos, demeton, ethion, malathion, coumaphos, isoxathion, fenthion, diazinon, thiodicarb, aldicarb, oxamyl, propoxur, carbaryl, fenobucarb, ethiofencarb, fenothiocarb, pirimicarb, carbofuran, carbosulfan, furathiocarb, hyquincarb, alanycarb, benfuracarb, cartap, thiocyclam, bensultap, dicofol, tetradifon, cyromazine, fenoxycarb, dicyclanil, buprofezin, flubendiamide, ethiprole, fipronil, imidacloprid, nitenpyram, clothianidin, acetamiprid, dinotefuran, thiacloprid, thiamethoxam, pymetrozine, flonicamid, spinosad, avermectin, milbemycin, nicotine, emamectinbenzoate, spinetoram, pyrifluquinazon, chlorantraniliprole, spirotetramat, lepimectin, metaflumizone, pyrafluprole, pyriprole, hydramethylnon, and triazamate. Preferred examples thereof include acephate, ethiprole, fipronil, imidacloprid, clothianidin, thiamethoxam, avermectin, and milbemycin. Acephate and imidacloprid are more preferred.
Examples of preferred admixable fungicides include strobilurin compounds such as azoxystrobin, kresoxym-methyl, trifloxystrobin, orysastrobin, picoxystrobin, and fuoxastrobin; azole compounds such as triadimefon, bitertanol, triflumizole, etaconazole, propiconazole, penconazole, flusilazole, myclobutanil, cyproconazole, tebuconazole, hexaconazole, prochloraz, and simeconazole; benzimidazole compounds such as benomyl, thiophanate-methyl, and carbendazole; phenylamide compounds such as metalaxyl, oxadixyl, ofurase, benalaxyl, furalaxyl, and cyprofuram; isoxazole compounds such as hydroxyisoxazole; benzanilide compounds such as flutolanil and mepronil; morpholine compounds such as fenpropimorph and dimethomorph; cyanopyrrole compounds such as fludioxonil and fenpiclonil; and probenazole, acibenzolar-S-methyl, tiadinil, isotianil, carpropamid, diclocymet, fenoxanil, tricyclazole, pyroquilon, ferimzone, fluazinam, cymoxanil, triforine, pyrifenox, fenarimol, fenpropidin, pencycuron, cyazofamid, cyflufenamid, boscalid, penthiopyrad, proquinazid, quinoxyfen, famoxadone, fenamidone, iprovalicarb, benthiavalicarb-isopropyl, fluopicolide, pyribencarb, kasugamycin, or validamycin. Particularly preferred examples thereof include strobilurin compounds, azole compounds, and phenylamide compounds.
EXAMPLES
The present invention is further illustrated by the following Examples that are not intended as a limitation of the invention. Compound 4 in the Examples was synthesized by the process described in WO 2006/129714.
Synthetic Examples
Synthetic Example 1
Compound 5
PR-3 (20 mg) synthesized by the process described in Japanese Patent Application Laid-Open No. 259569/1996 and cyclopropanecarboxylic acid (19 mg) were dissolved in anhydrous N,N-dimethylformamide (1 ml), and 1-ethyl-3-(3-dimethylaminopropyl)-carbodiimide hydrochloride (84 mg) and 4-(dimethylamino)pyridine (5 mg) were added to the solution. The mixture was stirred at room temperature for 6 hr. The reaction solution was poured into water, and the mixture was extracted with ethyl acetate. The ethyl acetate layer was washed with saturated brine and was dried over anhydrous magnesium sulfate, and the solvent was removed by evaporation under the reduced pressure to give a crude product of compound 5. The crude product was purified by preparative thin-layer column chromatography (Merck silica gel 60F 254 (0.5 mm), chloroform:methanol=10:1) to give compound 5 (9.0 mg).
Synthetic Example 2
Compound 6
Compound 4 (20 mg) was dissolved in dichloromethane (1 ml). Dess-Martin periodinane (21 mg) was added to the solution at 0° C., and, in this state, the mixture was stirred for 2 hr 40 min. A saturated aqueous sodium thiosulfate solution was added to the reaction solution, and the mixture was extracted with chloroform. The chloroform layer was washed with saturated brine and was dried over anhydrous magnesium sulfate. The solvent was then removed by evaporation under the reduced pressure, and the crude product thus obtained was purified by preparative thin-layer chromatography (Merck silica gel 60 F 254 (0.5 mm), acetone:hexane=1:1) to give compound 6 (5.4 mg).
Synthetic Example 3
Compound 7
Compound 4 (50 mg) was dissolved in toluene (3 ml). 1,1′-Thiocarbonyldiimidazole (90 mg) was added to the solution at room temperature, and the mixture was heated under reflux for 2.5 hr. The reaction solution was cooled to room temperature. Water was added to the reaction solution, and the mixture was extracted with ethyl acetate. The ethyl acetate layer was washed with saturated brine and was dried over anhydrous magnesium sulfate, and the solvent was then removed by evaporation under the reduced pressure. The crude product thus obtained was purified by preparative thin-layer chromatography (Merck silica gel 60 F 254 (0.5 mm), acetone:hexane=1:1) to give compound a (41.1 mg).
Compound a (41 mg) was dissolved in toluene (2 ml). Tri-n-butyl tin hydride (20 mg) was added to the solution at room temperature, and the mixture was heated under reflux for 2.5 hr. The reaction solution was cooled to room temperature. Water was added to the reaction solution, and the mixture was extracted with ethyl acetate. The ethyl acetate layer was washed with saturated brine and was dried over anhydrous magnesium sulfate, and the solvent was then removed by evaporation under the reduced pressure. The crude product thus obtained was purified by preparative thin-layer chromatography (Merck silica gel 60 F 254 (0.5 mm), acetone:hexane=1:1) to give compound 7 (3.5 mg).
1 H-NMR data and mass spectrometric data for compounds 5, 6, and 7 were as shown in Table 2.
TABLE 2
Mass spectrometric data
NMR data
Measuring
Compound
Solvent
1 H-NMR δ(ppm)
method
Data
5
CDCl 3
0.83 (3H, s), 0.88-0.95 (2H, m), 1.00-1.08 (2H, m),
ESI
528 (M + H) +
1.26 (1H, m), 1.33 (1H, m), 1.40 (3H, s), 1.43 (1H, m),
1.57-1.74 (2H, m), 1.67 (3H, s), 1.79-1.88 (2H, m),
1.93 (1H, m), 2.15 (1H, m), 2.97 (1H, s), 3.41
(1H, dd, J = 5.2, 11.2 Hz), 3.75 (1H, d,
J = 11.6 Hz), 3.82 (1H, dd, J = 5.2,
11.6 Hz), 4.28 (1H, d, J = 11.6 Hz), 5.00
(1H, d, J = 4.0 Hz), 6.53 (1H, s), 7.43
(1H, dd, J = 4.4, 8.0 Hz), 8.12 (1H, dt,
J = 8.4 Hz), 8.70 (1H, m), 9.02 (1H, m)
6
CDCl 3
0.83-1.00 (8H, m), 0.96 (3H, s), 1.44 (1H, m),
ESI
592 (M + H) +
1.53-1.61 (2H, m), 1.63 (3H, s), 1.76 (1H, d,
J = 3.7 Hz), 1.81 (3H, s), 1.87 (2H, m),
1.94-1.97 (1H, m), 2.21 (1H, m), 2.53 (1H, dd,
J = 2.6, 14.9 Hz), 2.78 (1H, t, J = 14.9 Hz),
2.91 (1H, d, J = 1.5 Hz), 3.66 (1H, d,
J = 12.0 Hz), 3.84 (1H, d, J = 12.0 Hz),
4.82 (1H, dd, J = 4.8, 11.7 Hz), 5.06 (1H, m),
6.71 (1H, s), 7.41 (1H, dd, J = 4.8, 8.0 Hz),
8.09 (1H, dt, J = 1.7, 8.0 Hz), 8.70 (1H, dd,
J = 1.7, 4.8 Hz), 9.02 (1H, d, J = 1.7 Hz)
7
CDCl 3
0.84-1.00 (8H, m), 0.90 (3H, s), 1.12-1.16 (1H, m),
ESI
578 (M + H) +
1.25 (1H, s), 1.35-1.46 (1H, m), 1.41 (3H, s),
1.56-1.70 (5H, m), 1.66 (3H, s), 1.78-1.89 (2H, m),
2.12-2.17 (2H, m), 2.82 (1H, d, J = 1.4 Hz),
3.69 (1H, d, J = 11.9 Hz), 3.91 (1H, d,
J = 11.9 Hz), 4.83 (1H, dd, J = 5.1, 11.5 Hz),
4.99 (1H, m), 6.46 (1H, s), 7.42 (1H, m), 8.11 (1H, dt,
J = 1.7, 8.0 Hz), 8.69 (1H, m), 9.01 (1H, m)
Formulation Examples
Formulation Example 1
Granules
Compound 4
0.5%
by weight
Alkyl sulfate
0.2%
by weight
Pregelatinized starch
5%
by weight
Clay
94.3%
by weight
The ingredients were homogeneously ground and mixed together, water was added to the mixture, and the mixture was thoroughly kneaded, granulated, and dried to prepare 0.5% granule.
Formulation Example 2
Wettable Powder
Compound 4
5%
by weight
Sodium lauryl sulfate
1%
by weight
White carbon
5%
by weight
Clay
80%
by weight
Sodium lignosulfate
9%
by weight
The ingredients were homogeneously mixed together and ground to prepare a 5% wettable powder.
Formulation Example 3
Water Dispersible Granule
Compound 4
20%
by weight
Alkyl sulfate
0.5%
by weight
Clay
68.5%
by weight
Dextrin
5%
by weight
Alkylmaleic acid copolymer
6%
by weight
The ingredients were homogeneously ground and mixed together. Water was added to the mixture, followed by thorough kneading. Thereafter, the kneaded product was granulated and dried to prepare a 20% water dispersible granule.
Formulation Example 4
Flowables
Compound 4
5%
by weight
Sodium lignosulfate
6%
by weight
Propylene glycol
7%
by weight
Bentonite
1.5%
by weight
1% Aqueous xanthan gum solution
1%
by weight
Silicone antifoam KM-98
0.05%
by weight
Water
To 100%
by weight
All the ingredients except for the 1% aqueous xanthan gum solution and a suitable amount of water were premixed together, and the mixture was then ground by a wet grinding mill. Thereafter, the 1% aqueous xanthan gum solution and the remaining water were added to the ground product to prepare 100% by weight flowables.
Formulation Example 5
Emulsifiable Concentrate
Compound 4
1%
by weight
Solvesso 150 (Exxon Mobil Corporation)
82.5%
by weight
Tayca Power BC2070M
8.25%
by weight
SORPOL CA-42
8.25%
by weight
The above ingredients were homogeneously mixed together and dissolved to prepare an emulsifiable concentrate.
Test Examples
<Soil Irrigation Treatment Test>
Test Example 1
Insecticidal Effect Against Aphis gossypii
Cucumber seedlings were treated by soil drenching treatment with a diluted solution of the formulation adjusted to a predetermined concentration with water. The chemical was absorbed through the root for six days, and five adult Aphis gossypii for each seedling were then released. Thereafter, the seedlings were allowed to stand in a thermostatic chamber of 25° C. The number of parasites on leaves was observed six days after the release, and the density index was calculated by the following equation.
Density index=(number of parasites in treated plot/number of parasites in non-treated plot)×100
As shown in Table 3, the 5% wettable powder, 20% water dispersible granule, and 0.5% granule each containing compound 4 prepared as described respectively in Formulation Example 2, Formulation Example 3, and Formulation Example 1 had systemically high density inhibitory effect against Aphis gossypii .
TABLE 3
Effect of formulation containing compound
4 against Aphis gossypii
Treatment amount
Name of
(mg of original
Density index
formulation
substance/root)
6 days after release
5% Wettable
10
0
powder
20% Water
10
0
dispersible
granule
0.5% Granule
10
0
Test Example 2
Insecticidal Effect Against Myzus persicae Sulzer
Eggplant seedlings were treated by soil drenching treatment with a diluted solution of the formulation adjusted to a predetermined concentration with water. The chemical was absorbed through the root for five days, and three adult Myzus persicae Sulzer for each seedling were then released. Thereafter, the seedlings were allowed to stand in a thermostatic chamber of 25° C. The number of parasites on leaves was observed five days after the release, and the density index was calculated by the same equation as in Test Example 1. The test was duplicated.
As shown in Table 4, the wettable powder containing compound 4 prepared as described in Formulation Example 2 had systemically high density inhibitory effect against Myzus persicae Sulzer.
TABLE 4
Effect of formulation containing compound
4 against Myzus persicae Sulzer
Treatment amount
Name of
(mg of original
Density index
formulation
substance/root)
5 days after release
5%
5.0
2.4
Wettable
powder
<Root Soaking Treatment Test>
Test Example 3
Insecticidal Effect Against Rhopalosiphum padi
The root of wheat seedlings 48 hr after seeding was soaked for 72 hr in a test solution (100 ppm) prepared as a 10% aqueous acetone solution. 72 hrs after the treatment, 10 larval Rhopalosiphum padi were released for each seedling. Thereafter, the seedlings were allowed to stand in a thermostatic chamber of 25° C. The number of parasites on stems and leaves was observed six days after the release, and the density index was calculated by the same equation as in Test Example 1. The test was duplicated.
As a result, as shown in Table 5, compounds 1, 2, 3, 4, 5, 6, and 7 described in Table 1 had systemically high density inhibitory effect against Rhopalosiphum padi .
TABLE 5
Effect of compounds 1 to 7 against Rhopalosiphum padi
Treatment
Compound
concentration
Density index
No.
(μg/seedling)
6 days after release
1
20
20
2
20
0
3
20
18
4
20
5
5
20
0
6
20
0
7
20
41
Comparative Tests: Insecticidal Effect Against Rhopalosiphum padi
For compounds 8 and 9 described in Table 6, a insecticidal effect against Rhopalosiphum padi was examined in the same manner as in Test Example 3. As a result, as shown in Table 7, compounds 8 and 9 did not have a density inhibitory effect.
In Table 6, substituents R 1 , R 2 , and R 3 correspond respectively to substituents R 1 , R 2 , and R 3 in formula (1).
TABLE 6
Comparative test compounds
Compound No.
R 1
R 2
R 3
8
OCOCH 2 CH 3
OCOCH 2 CH 3
OCOCH 2 CH 3
9
OCO-phenyl
OCO-phenyl
OCO-phenyl
TABLE 7
Effect of compounds 8 and 9 against Rhopalosiphum padi
Treatment
Compound
concentration
Density index
No.
(μg/seedling)
6 days after release
8
20
95
9
20
95
Reference Test: Insecticidal Effect Against Myzus persicae Sulzer
A leaf disk having a diameter of 2.8 cm was cut out from a cabbage grown in a pot and was placed in a 5.0 cm-Schale. Four adult aphids of Myzus persicae Sulzer were released in the Schale. One day after the release of the adult aphids, the adult aphids were removed. The number of larvae at the first instar born in the leaf disk was adjusted to 10, and 20 ppm of a test solution which had been prepared as a 50% aqueous acetone solution (0.05% Tween 20 added) was spread over the cabbage leaf disk. The cabbage leaf disk was then air dried. Thereafter, the Schale was lidded and was allowed to stand in a thermostatic chamber of 25° C. Three days after the release, the larvae were observed for survival or death, and the mortality of larvae was calculated by the following equation.
Mortality (%)={number of dead larvae/(number of survived larvae+number of dead larvae)}×100
As a result, it was found that, for all of compounds 1, 2, 3, 4, 5, 6, 7, 8, and 9 described in Table 1 or 6, spraying treatment exhibited a high insecticidal effect of 100% in terms of mortality.
<Seed Treatment Test>
Test Example 4
Insecticidal Effect Against Rhopalosiphum padi
Seeds of wheat were soaked for 6 hr in a diluted solution of the formulation adjusted to a predetermined concentration with water. The seeds were germinated in a thermostatic chamber for 3 days, and the seedlings were transplanted into soil. Two days after the transplantation, 10 larvae of Rhopalosiphum padi for each seedling were released. Thereafter, the seedlings were allowed to stand in a thermostatic chamber of 25° C. 6 days after the release, the number of parasites on the stems and leaves was observed, and the density index was calculated by the same equation as in Test Example 1. The test was triplicated.
As shown in Table 8, the 5% wettable powder containing compound 4 had high density inhibitory effect against Rhopalosiphum padi .
TABLE 8
Effect of formulation containing compound
4 against Rhopalosiphum padi
Treatment
Name of
concentration
Density index
formulation
(ppm of original substance)
6 days after release
5%
500
4.1
Wettable
powder
<Soil Drenching Treatment Test>
Test Example 5
Insecticidal Effect Against Trialeurodes uaporariorum
Adults of Trialeurodes uaporariorum were released on cucumber seedlings, grown in a pot, for egg laying purposes for two days. 10 days after the start of egg laying, it was confirmed that larvae were hatched from the delivered eggs. The soil in the cucumber pot was drenched with 5 mL of a test solution adjusted to a predetermined concentration with a 10% aqueous acetone solution. The cucumber pot was allowed to stand in a thermostatic chamber of 25° C. (light period 16 hr-dark period 8 hr). 9 days after the drenching, the number of survived larvae was measured, and the mortality of larvae was calculated by the following equation. The test was duplicated.
Mortality (%)={(number of larvae before treatment−number of survived larvae)/number of larvae before treatment}×100
As shown in Table 9, compound 4 had high systemic insecticidal activity against Trialeurodes uaporariorum.
Test Example 6
Insecticidal Effect Against Laodelphax stratella
Rice seedlings grown in a pot were provided. Soil in the pot was drenched with a test solution adjusted to a predetermined concentration with a 10% aqueous acetone solution. After standing for three days, 10 larvae at the second instar were released on the rice seedlings. Thereafter, the pot was allowed to stand in a thermostatic chamber of 25° C. (light period 16 hr-dark period 8 hr). 3 days after the release, the number of survived larvae was measured, and the mortality of larvae was calculated by the same equation as in the Reference Test. The test was duplicated.
As shown in Table 9, compound 4 had high systemic insecticidal activity against Laodelphax stratella.
Test Example 7
Insecticidal Effect Against Nephotettix cincticeps
Rice seedlings grown in a pot were provided. Soil in the pot was drenched with a test solution adjusted to a predetermined concentration with a 10% aqueous acetone solution. After standing for three days, 10 larvae at the second instar were released on the rice seedling. Thereafter, the pot was allowed to stand in a thermostatic chamber of 25° C. (light period 16 hr-dark period 8 hr). 3 days after the release, the number of survived larvae was measured, and the mortality of larvae was calculated by the same equation as in the Reference Test. The test was duplicated.
As shown in Table 9, compound 4 had high systemic insecticidal activity against Nephotettix cincticeps .
TABLE 9
Insecticidal activity of compound 4 against various insect pests
Treatment amount
Pest name
(mg/seedling)
Mortality (%)
Trialeurodes
0.5
67
uaporariorum
Laodelphax
0.5
34
stratella
Nephotettix
1.0
60
cincticeps
The treatment amount is expressed in terms of original substance.
<Test Example of Soil Drenching Treatment Using>Insecticidal Admixture
Test Example 8
Insecticidal effect against Aphis gossypii
Cucumber seedlings were treated by soil drenching with a single agent and an admixture adjusted to a predetermined concentration with water. The chemical was absorbed through the root for two days, and four adults of Aphis gossypii for each seedling were released on the seedlings. Thereafter, the seedlings were allowed to stand in a thermostatic chamber of 25° C. 2 days after the release, the number of parasites on the leaves was observed. The density index in each treated plot was determined by presuming the density in the non-treated plot to be 100. The preventive value was calculated by the following equation.
Preventive value=100−density index
The results were as shown in Table 10. When the density index exceeded 100, the preventive value was regarded as 0 (zero).
Further, theoretical values, which do not exhibit a synergistic effect, were calculated by the following Colby's formula, and the results are shown in Table 11.
Theoretical value= A+B −( A×B )/100 Colby's formula
where A: preventive value when treatment was performed only with compound 4, and
B: preventive value when treatment was performed only with each of acephate and imidacloprid.
Method for Determining Synergistic Effect
When the numerical value for the admixture in Table 10 exceeded the theoretical value calculated by the Colby's formula shown in Table 11, the admixture was determined to have a synergistic effect.
All the tested admixtures had preventive values beyond the theoretical values, demonstrating that they had a synergistic effect.
TABLE 10
Preventive value of single agent and
admixture against Aphis gossypii
Other
Compound 4
0
0.05
insecticide
mg/seedling
mg/seedling
—
0
0
Acephate
70
100
0.1 mg/seedling
Imidacloprid
16
43
0.005 mg/seedling
The treatment amount is expressed in terms of original substance.
TABLE 11
Theoretical value calculated by Colby's formula
Other
Compound 4
0
0.05
insecticide
mg/seedling
mg/seedling
—
0
0
Acephate
70
70
0.1 mg/seedling
Imidacloprid
16
16
0.005 mg/seedling
The treatment amount is expressed in terms of original substance.
Test Example 9
Insecticidal Effect Against Rhopalosiphum padi
The root of wheat seedlings 48 hr after seeding was soaked for 72 hr in an admixture solution, adjusted to a predetermined concentration, as a 10% aqueous acetone solution. 72 hrs after the treatment, 10 larval Rhopalosiphum padi for each seedling were released on the seedlings. Thereafter, the seedlings were allowed to stand in a thermostatic chamber of 25° C. The number of parasites on stems and leaves was observed six days after the release. The density index of each of the treated plots was determined by presuming the density of the non-treated plots to be 100, and the preventive value was calculated by the same equation as in Test Example 8.
The results are shown in Table 12. When the density index exceeded 100, the preventive value was regarded as 0 (zero).
Theoretical values, which do not exhibit a synergistic effect, were calculated by the following Colby's formula, and the results are shown in Table 13.
Theoretical value= A+B −( A×B )/100 Colby's formula
where A: preventive value when treatment was performed only with compound 4, and
B: preventive value when treatment was performed only with each of acetamiprid, acephate, and imidacloprid.
Method for Determining Synergistic Effect
When the preventive value against Rhopalosiphum padi for the admixture in Table 12 exceeded the theoretical value calculated by the Colby's formula shown in Table 13, the admixture was determined to have a synergistic effect. All the tested admixtures had preventive values beyond the theoretical values, demonstrating that they had a synergistic effect.
TABLE 12
Preventive value of single agent and admixture
against Rhopalosiphum padi
Other
Compound 4
0
0.5
insecticide
μg/seedling
μg/seedling
—
0
0
Acetamiprid
5.9
40.0
0.0078 μg/seedling
Acephate
55.6
100
0.5 μg/seedling
Imidacloprid
28.6
54.5
0.0078 μg/seedling
The treatment amount is expressed in terms of original substance.
TABLE 13
Theoretical value calculated by Colby's formula
Other
Compound 4
0
0.5
insecticide
μg/seedling
μg/seedling
—
0
0
Acetamiprid
5.9
5.9
0.0078 μg/seedling
Acephate
55.6
55.6
0.5 μg/seedling
Imidacloprid
28.6
28.6
0.0078 μg/seedling
The treatment amount is expressed in terms of original substance.
Test Example 10
Insecticidal Effect Against Laodelphax stratella
Rice seedlings grown in a pot were treated by soil drenching with a single agent or an admixture adjusted to a predetermined concentration with water. The seedlings were allowed to stand for two days. Ten larvae at the second instar were released on the rice seedlings. Thereafter, the rice seedlings were allowed to stand in a thermostatic chamber of 25° C. (light period 16 hr-dark period 8 hr). 4 days after the release, the number of survived larvae was observed, and the mortality of larvae was calculated by the same equation as in the Reference Test. The test was duplicated.
The results are shown in Table 14.
Theoretical values, which do not exhibit a synergistic effect, were calculated by the following Colby's formula, and the results are shown in Table 15.
Theoretical value (%)=100−( A×B )/100 Colby's formula
where A: 100—(mortality when treatment was performed only with compound 4), and
B: 100—(mortality when treatment was performed only with imidacloprid).
Method for Determining Synergistic Effect
When the numerical value for the admixture in Table 14 exceeded the theoretical value calculated by the Colby's formula shown in Table 15, the admixture was determined to have a synergistic effect.
The tested admixture had mortalities beyond the theoretical values, demonstrating that they had a synergistic effect.
TABLE 14
Mortality (%) of single agent and admixture
against Laodelphax stratella
Wettable powder
containing
Other
compound 4
0
1.0
insecticide
mg/seedling
mg/seedling
—
0
57
Admire wettable powder
60
93
0.01 mg/seedling
The treatment amount is expressed in terms of original substance.
TABLE 15
Theoretical value (%) calculated by Colby's formula
Wettable powder
containing
Other
compound 4
0
1.0
insecticide
mg/seedling
mg/seedling
—
0
57
Admire wettable powder
60
83
0.01 mg/seedling
The treatment amount is expressed in terms of original substance. | Disclosed are compounds that are utilizable as systemic insecticides and possess excellent systemic properties. Compounds represented by formula (1) have excellent systemic insecticidal activity. Accordingly, a composition comprising as an active ingredient the compound of formula (1) or salt thereof is useful as a systemic insecticide. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates generally to the installation of software on computers. More specifically, the present invention is directed toward the creation of customized disk images that may be installed in a turnkey fashion on multiple computers.
[0003] 2. Description of Related Art
[0004] Subscription computing, also known as IT Outsourcing, is a business model for providing information technology (IT) to a customer. Under this model, the provider provides a comprehensive package of hardware, software, services and support. Subscription computing can be thought of as one-stop shopping for an entire IT infrastructure. The provider delivers computing and network hardware to the customer and provides software, services, and support from one or more sites remote to the customer. This model is advantageous to the provider because it permits economies of scale. Subscription computing is particularly useful for customers without professional IT configuration and administration personnel. These customers are often small businesses.
[0005] A key capability required for subscription computing is the mass customization of workstation and server software for delivery to the customer. This customization step is referred to as preparation of a “disk image.” The disk image contains ready-to-run versions of the operating system, the applications, utility programs, and data. The disk image is copied onto the hard disks of the workstations and servers prior to their delivery to the customer, or it may be provided to a server on the customer's premises for distribution to the customer's workstations and servers. Distribution of a disk image avoids the complex, time-consuming and delicate process of installing each of the software components, one after the other, on each workstation or server. The work is done once under controlled conditions, resulting in a single disk image that may be applied to multiple machines in a “turnkey” fashion.
[0006] An image is created initially by dedicating a workstation to the image creation task. Many means of preparing such an image exist. The operating system, device drivers, patches, updates, and other configuration options are installed. Then individual applications and utilities are installed. The result is tested to see if the various components will coexist. When the image build is deemed satisfactory, programs such as Symantec Ghost (available from Symantec, Inc. of Cupertino, Calif.) can capture a disk image from the dedicated workstation so that it can be copied to other workstations. This process is labor-intensive, time-consuming (often taking weeks) and is limited to target workstations of the same type and configuration as the workstation on which the disk image was prepared. Little if any customization is possible for the target workstations.
[0007] A subscription computing service provider will serve many small customers, each with unique needs for software. These needs arise because of factors that include the specific training customer personnel have on specific software products, the industries that the businesses serve, differing workstation requirements of the businesses, and individual businesses' preferences. Hence, disk images must be customized for each customer. Because these customers are often small and represent a relatively small incremental revenue to the provider, however, it becomes costly to the provider to undertake the complex, labor-intensive and time-consuming process of preparing a unique disk image for each customer. In fact, the problem is even more complex, because different disk images may be required in a single customer organization, based on the customer's organizational structure.
[0008] Prompt service is also an important ability for a provider. A customer that must wait for service can cancel its subscription as easily as it subscribes. Any delay in creating customized disk images, therefore, has the potential to adversely affect revenue. A way to easily construct customized disk images in a subscription computing environment is needed.
SUMMARY OF THE INVENTION
[0009] The present invention is directed toward a method, computer program product, and data processing system for providing automatic, mass-customized preparation of disk images. The invention relies on a front end, which interacts with customers and sales personnel to acquire self-consistent provisioning requirements. These requirements are input to a provisioning engine, which uses a knowledge base of constraints and affinities to generate a set of provisioning orders. These orders are input to a disk image builder, which automatically creates the disk image and saves it for distribution. The disk image builder also consults a knowledge base concerning best practices established by the service provider for disk image builds. Finally, the requirements are used to drive a disk image tester, which exercises the image as a quality inspection.
[0010] One particular value of the present invention to subscription computing service providers is that it both reduces the cost of any customization required, and reduces the time to accomplish that customization. Minimum human labor is involved. Requirements can be captured directly from the customer, improving accuracy and increasing customer satisfaction through a better understanding of the customization options that are available. From a business perspective, the invention permits the service provider to serve more and smaller customers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
[0012] [0012]FIG. 1 is a diagram depicting components of an automatic provisioning system for subscription computing in accordance with a preferred embodiment of the present invention;
[0013] [0013]FIG. 2A is a diagram depicting the gathering of requirements information in accordance with a preferred embodiment of the present invention;
[0014] [0014]FIG. 2B is a diagram depicting a fragment of a customer requirement made in accordance with a preferred embodiment of the present invention;
[0015] [0015]FIG. 3 is a diagram depicting components of the automatic provisioning system that generate and test the disk image in accordance with a preferred embodiment of the present invention;
[0016] FIGS. 4 A- 4 D are diagrams depicting knowledge base rules in accordance with a preferred embodiment of the present invention;
[0017] [0017]FIG. 5 is a flowchart representation of the execution of software in a provisioning engine in accordance with a preferred embodiment of the present invention;
[0018] [0018]FIG. 6 is a flowchart representation providing a detailed view of a process of generating provisioning orders in accordance with a preferred embodiment of the present invention;
[0019] [0019]FIG. 7 is a flowchart representation of the execution of software on a disk image manufacturing server in accordance with a preferred embodiment of the present invention; and
[0020] [0020]FIG. 8 is a flowchart representation of the execution of software on a disk image testing server in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] [0021]FIG. 1 is a diagram depicting the components of an automatic provisioning system for subscription computing in accordance with a preferred embodiment of the present invention. A customer 10 is shown interacting with a graphical user interface 11 , preferably implemented using a personal computer (PC). This graphical user interface allows the customer to choose among alternative software components to customize the disk image for his or her needs. The PC supporting this graphical user interface is also connected to the Internet ( 15 ) so that the customer's selections may be transmitted to subscription computing service provider 20 . Subscription computing service provider 20 has facilities housing servers 22 , 23 and 24 capable of analyzing customer 10 's requirements and constructing a customized disk image 25 . Customized disk image 25 will be loaded onto PC 30 for shipment to the customer.
[0022] It is the intention of this invention to support the customer specification of disk images in terms of the customer's needs, rather than requiring the customer to list each and every software component that will be required in the disk image. For example, a customer may simply require that the disk image contain software capable of viewing files encoded in the Adobe Systems Portable Document Format (PDF), rather than specifying that the disk image contain Adobe Acrobat version 4.05, which is a particular program that can view such files. This permits the provisioning system to select components for the disk image of the appropriate version, functional characteristics, and resource consumption, also subject to cost constraints specified by the customer.
[0023] [0023]FIG. 2A elaborates FIG. 1 for the purposes of describing how the requirements for the disk image are gathered in a preferred embodiment of the present invention. In FIG. 2A are shown users 50 , 52 and 54 all presumed to be employees of an enterprise for whom the disk image will be constructed. For example, user 50 may be a manager or owner of the enterprise, user 52 may be the system administrator for information technology for the enterprise, and user 54 may be a representative of the department for which the disk image is being constructed. Each of users 50 , 52 and 54 creates some component of the requirements for the disk image using graphical user interfaces 60 , 62 and 64 attached to PCs 61 , 63 and 65 , respectively. The enterprise manager may select software relevant to the industry segment served by the enterprise, the system administrator may select software relevant to his needs in administering and maintaining all of the PCs in the enterprise, and the departmental representative may select software pertaining to the functional needs of his department. In a preferred embodiment of the invention, the graphical user interface is a hypertext browser. Server 70 , located on the premises of subscription computing service provider 20 , creates and transmits the elements of the graphical user interfaces 60 , 62 and 64 to PCs 61 , 63 and 65 , respectively using the HyperText Transfer Protocol (HTTP) and in the HyperText Markup Language (HTML). User selections are transmitted, preferably using the same protocol and language, to server 70 .
[0024] Server 70 is preferably a server running Web application server software, for example, the IBM WebSphere server software available from IBM Corporation of Armonk, N.Y. Mini-applications, or servlets, run in a context established by this software in response to user requirements received from users 50 , 52 and 54 , and cause the storage of these requirements in database 81 via database server 80 . Database server 80 is preferably a server running database software, for example, the IBM DB2 server software, also available from IBM Corporation. In this manner user requirements are acquired from users 50 , 52 and 54 and stored in database 81 .
[0025] Server 70 may customize the HTML that it generates to create the graphical user interfaces 60 , 62 and 64 in any manner, but preferably in response to information received prior to the requirements acquisition for a disk image, which is stored on disk 71 . This information may include, but is not limited to, the hardware and software of customer PCs that will receive the disk image, cost constraints, and past disk image requirements. This information may be used to limit the options presented to those that are compatible with the equipment configuration and cost constraints of the customer. It may be used to order the options presented in a manner consistent with past customer behavior. For example, more commonly selected options may be presented first.
[0026] Note that there is no need for the components of the requirements for the disk image to be transmitted to database 81 simultaneously. Rather, these requirements can be accumulated over time. Preferably, there are user interface elements displayed to users 50 , 52 and 54 requiring their signoff or approval of those components of the requirements that they are responsible for. When all of these signoffs have been received, database 81 triggers subsequent processing on the servers of subscription computing service provider 20 to create the disk image. Database 81 contents will also be used subsequently to test the disk image.
[0027] [0027]FIG. 2B gives an example of a fragment of a customer requirement in accordance with a preferred embodiment of the present invention. The fragment is represented in the eXtensible Markup Language (XML). XML is a well-known and largely user-defined language for imposing structure on textual data. The first part of the XML, between the “Word-processing” tags, concerns the choice of word processor. The customer is willing to use any word processor that can edit the .LWP document format and that costs less than $100. In the second part of the XML, the customer requires that presentation graphics software be Lotus Freelance, with a version later than 5.7.
[0028] [0028]FIG. 3 shows the components of the automatic provisioning system that generate and test the disk image in a preferred embodiment of the present invention. These components reside on the premises of subscription computing service provider 20 . As previously described, database server 80 maintains requirements database 81 in response to requirements received from the customer. Database server 80 , provisioning engine server 90 , disk image manufacturing server 110 and disk image testing server 130 communicate with each other over local area network 100 , which is preferably fast Ethernet adhering to the 100BaseT standard.
[0029] Provisioning engine server 90 retrieves customer requirements from database server 80 , using local area network 100 . Provisioning engine server 90 consults knowledge bases 91 , 92 and 93 to provide context for the analysis of customer requirements, and transmits a series of provisioning orders not shown to disk image manufacturing server 110 which will store them on disk 111 . These provisioning orders contain directions as to which software components are to be included in the disk image, together with configuration parameters.
[0030] The precise sequence and content of these orders is determined by provisioning engine server 90 , software in accordance with knowledge bases 91 , 92 and 93 . Knowledge base 91 may contain rules pertaining to the construction of disk images for specific PC operating systems, knowledge base 92 may contain rules pertaining to the construction of disk images for PC applications software that is used generally in business, and knowledge base 93 may contain rules pertaining to PC application software that is specific to the industry segment of the customer.
[0031] Disk image manufacturing server 110 creates disk images on disks 120 , 121 and 122 in a manner responsive to the provisioning orders stored on disk 111 and to a knowledge base 112 . Knowledge base 112 contains rules pertaining to the construction of disk images in general, as opposed to the knowledge bases 91 , 92 and 93 , which determine which components of software are to be included in the disk image.
[0032] [0032]FIG. 4A gives an example of a rule that may be found in knowledge base 92 of FIG. 3, the knowledge base concerning PC applications software that is used generally in business. This rule is of the “IF condition THEN action” form. The rule states that if the chosen presentation graphics software is Freelance then the word processing software should be chosen to be WordPro. Presumably this rule is in the knowledge base for reasons of compatibility and data exchange.
[0033] [0033]FIG. 4B gives an example of provisioning orders that may be created by provisioning engine 90 and stored on disk 111 . These orders specify that both Freelance and WordPro, of selected versions, be made components of the disk image to be manufactured by disk image manufacturing server 110 .
[0034] [0034]FIG. 4C gives two examples of rules that may be found in knowledge base 112 , pertaining to the construction of disk images in general. These rules specify where (in what subdirectory) and with what installation options the Freelance software is to be generated into the disk image.
[0035] [0035]FIG. 5 is a flowchart representation of the execution of software in provisioning engine 90 in FIG. 3 in accordance with a preferred embodiment of the present invention. In step 200 , the software waits for a signal from database 81 to the effect that all of the customer approvals have been received and the customer requirements are complete. Provisioning engine 90 then accesses these requirements by communicating with database server 80 over local area network 100 . When the requirements are received, the requirements are checked (step 201 ), typically by invoking an XML parser with an appropriate XML Schema. XML parsers are available from W3C (www.w3c.org). The xerces-j parser, a schema-driven parser is one example. The parser validates the requirements and if invalid control is transferred via branch 210 to step 200 to wait for another requirements document.
[0036] If valid, the requirements document entries are each resolved against knowledge bases 91 , 92 and 93 (step 203 ) to generate provisioning orders (step 204 ). A determination is made as to whether there has been an error (step 205 ) and if so branch 213 is taken to step 206 to inform supervisory personnel. Since this error may have occurred because of incomplete requirements from the customer, supervisory personnel may need to correspond with the customer to obtain updated requirements. Alternatively, direct contact with the customer may be initiated. In either case, the process cycles to step 200 to await a new set of customer requirements. If there has been no error, branch 212 is taken to step 200 to await the next requirements document.
[0037] [0037]FIG. 6 provides a detailed flow of program logic in steps 203 and 204 of FIG. 5. Processing begins at step 220 where the next requirement is received from the requirements document. The knowledge databases are then scanned to find applicable rules (step 221 ). If there are none, branch 230 is taken to step 220 to get the next requirement. If there is at least one rule step 222 is expected and the rule applied. Rules, as shown in FIG. 4B, generally change the requirements entries by filling in product names and versions. At step 223 a check is made to see if all requirements have been processed and if not, branch 231 is taken to step 220 to get the next requirement. If so, branch 232 is taken to the next step, generation of the provisioning orders.
[0038] In step 224 the next requirement is accessed. After all of the rules in knowledge bases 91 , 92 and 93 have been applied, the product and version attributes of every requirement should have been changed to specific products and versions. This is checked in decision step 225 . If product and version attributes of the entry are not specified, this is an error and branch 233 is taken. If they are specified, step 226 is executed to generate a provisioning order. It may be seen by reference to FIG. 4B that in a preferred embodiment, each provisioning order contains exactly a product and version, and these are obtained from the specified attributes of the requirement. Finally, at step 227 a check is made to see if all requirements have been processed. If not, branch 234 is taken to step 224 to get the next requirement. If so, branch 235 is taken, completing the process.
[0039] [0039]FIG. 7 provides a program flow for disk image manufacturing server 110 in FIG. 3. In step 240 , the arrival of provisioning orders on disk 111 of FIG. 3 is awaited. At step 241 , the order is received, then all applicable information about that order is looked up in knowledge base 112 of FIG. 3. This information is retrieved typically using the product name as the primary key and the product version as the secondary key, and knowledge base 112 is preferably organized as a database (such as a relational, object-oriented, object-relational, or other type of database) indexed by primary and secondary keys. The information retrieved from knowledge base 112 is used together with the base provisioning order to add a component to the disk image (step 243 ). There are several methods well known in the art for performing this process. A software program may be installed by invoking its installation procedure, and supplying installation parameters retrieved from knowledge base 112 . Or it may be the case that pre-installed images are available to disk image manufacturing server 110 , in which case the proper image must be chosen based on information retrieved from knowledge base 112 , and added to the disk image.
[0040] Once step 243 is complete, step 244 is executed to check to see if there are more provisioning orders. If so, branch 251 is taken and step 241 executed to get the next order. If not, branch 250 is taken and step 240 executed to await the next batch of provisioning orders.
[0041] In FIG. 3 is shown a disk image testing server 130 with access to generated disk images 120 , 121 and 122 . This access may be through a dual-port switch or through file sharing between disk image manufacturing server 110 and disk image testing server 130 . The access may also be realized through the introduction of a file server not shown attached to local area network 100 , on which disk image manufacturing server 110 writes disk images and from which disk image testing server 130 reads disk images. Disk image testing server 130 also requires access to the provisioning orders as created by provisioning engine 90 , written to disk 111 and augmented during disk image manufacturing with information from knowledge base 112 by disk image manufacturing server 110 . This list of provisioning orders is used to drive the testing process. During testing disk image testing server 130 makes reference to knowledge base 123 , which contains information about how to test the disk image.
[0042] [0042]FIG. 4D is a depiction of a rule that may be found in knowledge base 123 in FIG. 3. This rule is triggered by the presence of a provisioning order such as that shown in FIG. 4B, as augmented with information added by the disk image manufacturing server 110 as depicted in FIG. 4C. The rule checks the program and version and if these match the augmented provisioning rule then the disk image testing server 130 invokes the primary executable of Freelance (f32main.exe) from the directory where that program should have been stored by disk image manufacturing server 110 . The program is invoked with the S (“Silent”) option, which may indicate that any end user dialog is to be suppressed. In practice, additional rules subsequent to the rule shown in FIG. 4D would be present to check to see if the invocation of the required program produced the desired effect.
[0043] It should be appreciated that the form and language of the rules to be found in knowledge base 123 may differ from exact form of the rule shown in FIG. 4D. In particular, the language may be that of a batch or scripting language such as is found in Microsoft's DOS .BAT scripting facility.
[0044] [0044]FIG. 8 shows a program flow for disk image testing server 130 of FIG. 3. The arrival of testing orders (augmented provisioning orders from Disk image manufacturing server 110 of FIG. 3) is awaited (step 300 ), an order is received (step 301 ) and all applicable rules from knowledge base 123 of FIG. 3 are looked up (step 302 ). This information is retrieved typically using the product name as the primary key and the product version as the secondary key, and knowledge base 123 is preferably organized as a database indexed by primary and secondary keys. The information retrieved from knowledge base 123 is used at step 303 to test a component to the disk image, typically by invoking it with specific parameters.
[0045] Once the processing of step 303 is complete, step 304 is executed to check to see if there are more testing orders. If so, branch 311 is taken and step 301 executed to get the next order. If not, branch 310 is taken and step 300 executed to await the next batch of provisioning orders.
[0046] It may be the case that the task to be undertaken is to build a new disk image as a modification of an existing disk image rather than from scratch. This modification is initially represented as a modified set of requirements acquired from users and stored in database 81 of FIG. 2. The process as previously described can be followed without reference to any pre-existing disk image or set of requirements, and a new disk image will result. There is an optimization, however, that may be advantageous to the subscription computing service provider in reducing the time necessary to prepare the new disk image, or in reducing the resources necessary to prepare it.
[0047] In this optimization, the process as previously described is followed up to the point of generating the provisioning orders on disk 111 of FIG. 3, both for the old requirements and for the modified ones. This results in two sets of provisioning orders. Disk image manufacturing server 110 may then run a processing step to determine the difference between the two sets. Software for calculating the difference between two files is well known in the state of the art, examples being the UNIX diff utility and the TeamConsolidate feature of the Lotus WordPro word processor. Once these differences have been calculated, each difference is classified as either an addition, a deletion, or a modification of some component of the disk image.
[0048] Disk image manufacturing server 110 then runs software identical to that shown in FIG. 6 with the exception of step 243 . Rather than only adding components to the disk image, step 243 involves examining each difference and adding, deleting or modifying the designated component of the disk image. Addition has been previously described. Deletion can be performed in several ways; either as the “un-installation” of the software component, or in the case that modifications can be made directly to the disk image (e.g., by file deletion) without running the software's un-installation utility, by actions directly on the disk image. Modifications are typically done by deletion followed by addition, but some software installation facilities permit incremental changes to the installation without deletion and re-installation.
[0049] With reference to the process described it can be seen that this process can be fully automated, except in the case of incomplete specifications, in which case it may be necessary to obtain more complete requirements from users or in some other manner involving human intervention. Thus, by means of the processes herein described, economical mass-customized manufacture of disk images can be achieved. It is important to note that while the present invention has been described in the context of a fully functioning data processing system, those of ordinary skill in the art will appreciate that the processes of the present invention are capable of being distributed in the form of a computer readable medium of instructions and a variety of forms and that the present invention applies equally regardless of the particular type of signal bearing media actually used to carry out the distribution. Examples of computer readable media include recordable-type media, such as a floppy disk, a hard disk drive, a RAM, CD-ROMs, DVD-ROMs, and transmission-type media, such as digital and analog communications links, wired or wireless communications links using transmission forms, such as, for example, radio frequency and light wave transmissions. The computer readable media may take the form of coded formats that are decoded for actual use in a particular data processing system.
[0050] The description of the present invention has been presented for purposes of illustration and description, and is not intended to be exhaustive or to be limited to the form(s) of the invention disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. | The present invention is directed toward a method, computer program product, and data processing system for providing automatic, mass-customized preparation of disk images. The invention relies on a front end, which interacts with customers and sales personnel to acquire self-consistent provisioning requirements. These requirements are input to a provisioning engine, which uses a knowledge base of constraints and affinities to generate a set of provisioning orders. These orders are input to a disk image builder, which automatically creates the disk image and saves it for distribution. The disk image builder also consults a knowledge base concerning best practices established by the service provider for disk image builds. Finally, the requirements are used to drive a disk image tester, which exercises the image as a quality inspection. | 6 |
U.S. PATENTS CITED AS REFERENCES
[0001] [0001] 2,707,125 April 1955 Ritter 292/341.15 2,856,220 March 1957 Easley 292/148 2,963,895 December 1960 Thomas 70/14 3,656,789 April 1972 Ray 292/304 3,731,505 May 1973 Rosenberg 70/63 3,889,497 June 1974 Tuttle 70/14 3,926,018 June 1975 Joersz 70/19 3,988,031 October 1976 Meyer 292/153 4,085,599 April 1978 Fischer 70/14 4,240,278 December 1980 Linder 70/101 4,697,443 October 1987 Hillin 70/121 4,997,219 March 1991 Carter 292/153
BACKGROUND INFORMATION
[0002] Electrically powered gate-openers are currently installed or being considered at the entrance to enclosed areas such as estates, ranches, private clubs, private roadways, sport facilities, home sites, retirement areas, and other locations entered by authorized personnel or their guests. The typical way to actuate a powered gate-opener is to reach from a car window and use a key to operate a switch. Wireless monitors may also be used for the same purpose. After entry, the gate closes automatically. To exit later, a push-button or wireless monitor may be used, or the car itself may actuate a buried sensor that serves the purpose of an opening switch. The latter concept is becoming common.
[0003] In many cases where gate-openers are installed, there is a need to provide one or more keys to the opening switch for each of those who are authorized to enter. Inevitably this causes problems because such keys can be duplicated easily and given to friends, business associates, repair personnel, and others not authorized to enter regularly. The use of a combination lock does not mitigate such problems. When those who make their keys available to others are identified, correcting the problem involves difficulties when all authorized entrants use the same key. Since those at fault are likely to be either friends, neighbors, customers, or others who should not be offended, forceful action may be inappropriate. If such action must be taken, changing the keyed lock requires transmitting new keys to all others.
[0004] The rotary security system, herein described, can minimize such problems. Each authorized entrant is provided with one or more keys to a separate padlock. If one of those so authorized is found to be in repeated violation of stated rules, a single padlock can then be interchanged with one not yet in use, and a new key given to the miscreant. No change is required in keys held by other authorized personnel. To avoid harsh criticism of friends or customers who are at fault, such a change in locks can be made along with a simple statement such as “Your new key is sent because someone has gained access to your lock.”
[0005] The rotary security system can be erected for use from a car window, just as a key-operated switch is now utilized. Wiring is not visible. One feature involves a pointer that normally indicates the identity of an authorized individual who previously either entered personally or who gave a key to someone else.
[0006] Numerous patents have been issued regarding the use of multiple padlocks, any one of which, when opened, serves to permit entry to an enclosed area. The previous list of references identifies some of these, most of which have the following disadvantages in relation to the rotary security system: not adaptable to car-window usage; limitation as to number of padlocks accommodated; not adaptable to electrical sensing; no clear identification of specific padlocks; padlocks must in most cases be removed; and no means of identifying a previous entrant. Most of these previously patented devices are apparently intended to serve as manually operated links to secure a gate. The rotary system will accomplish that also, at low cost, and without the disadvantages just noted.
[0007] Many situations exist in which only a limited number of individuals are authorized to make use of specific equipment such as a boat, truck, farm equipment, snowmobile, expensive office equipment, locker rooms, remote housing facilities, large storage rooms, etc. Passing out the same key to those authorized to use such equipment involves the same problem that occurs with giving or lending keys to others for entry to enclosed areas. Corrective problems are also the same as noted. Where equipment of this kind can be chained at a specific point, or where an electrical opener can be installed, use of the rotary security system serves to minimize such problems.
SUMMARY
[0008] [0008]FIG. 1 is a top view of dual circular metal plates that can be rotated. Shackles of multiple padlocks are supported by a lower plate. An arbitrary number of thirty-two padlocks is shown in this drawing, identical in shape but keyed differently. A top plate surmounts all shackles. Numbers stamped on the top plate serve to identify each assigned padlock. A pointer can be turned by hand to aid in peripheral location of a specific padlock that has been opened, prior to action described below.
[0009] [0009]FIG. 2 shows how the lower plate is secured to a central hub for rotation. The swinging arm of each shackle extends through a hole in the lower plate. The other shackle arm fits within a half-circular hole at the edge of said plate. Both the complete hole and half-circular hole are on a radial line from the rotational center. Hole diameters are approximately {fraction (1/32)}-inch larger than shackle bars. Cap-screws secure the top plate to lower plate, with each screw passing through a metal sleeve that permits tightening screws so the top plate presses firmly against each shackle, thereby facilitating closure of an opened padlock by one hand. To avoid complexity of the drawing, only three of the multiple padlocks are pictured. Along an edge of the lower plate, the drawing indicates locations of others. All padlocks are evenly spaced, with minimal clearance between each. The padlock pictured on the right, at which the pointer has been located, is shown after being opened so as to increase length between shackle arms and base. Doing so permits movement of a slide that can actuate a powered gate-opener or initiate other action. A lamp provides for recognition of lock numbers at night.
[0010] FIGS. 3 - 5 : A bar with slotted end, bolted to a sliding plate, is defined by these three figures. When all padlocks are closed, as in FIG. 3, the bar and slide can only be moved a limited distance toward any portion of the rotary assembly. When one padlock is opened with a key, as in FIG. 4, the bar and slide can be moved with one hand so as to pass either or both arms of the padlock shackle, thus making possible a subsequent action. FIG. 5 illustrates how an electrical push-button can be depressed by movement of the bar and slide, thereby connecting the low-voltage circuit of a typical battery-powered gate-opener. Also shown is an electrical cord for the integral lamp. Typically, both cords extend through support columns into the ground, thence to a low-voltage gate-opener and to the 120-volt wiring for an underground sensor, commonly installed with powered gate-openers for cars to exit.
[0011] [0011]FIG. 6: An exploded view shows the construction of a typical automotive trailer hub, after minor changes so it can serve as a rotating hub that turns freely while minimizing vertical displacement of padlocks with respect to bar and slide described above. Other types of spindle/hub combinations that provide a firm support would be suitable.
[0012] [0012]FIG. 7: This is a simple pointer, one end of which fits the center of padlock rotation. The other end is formed so it will drop over the exposed edge of a padlock shackle. One purpose of the pointer is to facilitate rotating the assembly so an opened padlock will be opposite the slotted bar. Another purpose is to indicate a previous user of the rotary system, thereby helping to identify those not authorized to enter an enclosure.
[0013] [0013]FIG. 8: When a person is found to have violated stated rules about giving duplicate keys to others, or has gone elsewhere without returning a key, it may be determined that the lock corresponding to that person's key must be changed. If there were one lock and the same key for everyone, this would require transmitting a new key to all involved. By interchanging one padlock with another not yet in use, the rotary security system not only removes the need to change all keys but can help avoid damaged relations with the person at fault. FIG. 8 illustrates how specific padlocks can be removed easily from the lower rotating plate.
[0014] [0014]FIG. 9: Any desired number of padlocks can be utilized with the rotary system. In FIGS. 1 and 2, thirty-two padlocks of a wider type were shown. The resulting diameter of the rotating plate holding them was 12.4 inches. The lower illustration in FIG. 9 shows a commonly available brass padlock with narrower base. One hundred such padlocks can be arranged on a rotating plate with diameter of 21 inches. The top drawing of FIG. 9 shows the outline of a system of that size, mounted at car-window height.
[0015] [0015]FIGS. 10, 11. When used as a manually operated gate opener, the rotary security system can be simplified while retaining its basic functional method. FIG. 10 shows how the same 32-padlock system of FIGS. 1 and 2 can be installed in this way. FIG. 11 illustrates a manually operated gate latch, inexpensive to construct. By using a narrower spindle and hub, the system will function properly with about seven padlocks installed. Since not all of these must be assigned to a user, there is no lower limit to the number of those authorized to enter a gated enclosure protected by this system.
[0016] [0016]FIG. 12. This sketch of a drill jig shows how the holes in a circular plate can be drilled easily and precisely.
DETAILED DESCRIPTION
[0017] A keyed padlock is referred to herein as consisting of two components: the base, which includes a key insertion point plus internal lock mechanism, and the shackle, which consists of a hardened steel rod, formed near the center as a semicircle. The fact that some shackles are notched on only one end for grip within the base, and others are notched on both ends has no bearing on what is covered below.
[0018] All who have used a padlock know that its common purpose is to insert the open end of a shackle through one or more objects, such as a hasp or links of a chain, after which the padlock is closed, holding objects together or preventing separation. Unique features of the rotary security system evolve from the fact that the system makes use of a padlock function not ordinarily considered, rather than the usual function noted above. FIG. 1 illustrates that point. The closed padlock (base 1 and shackle 2 ) clearly has less distance between base and top of shackle than does the opened padlock (base 1 and shackle 3 ). The increased distance after opening varies somewhat according to padlock size and design. Commonly it is from ⅜ to {fraction (7/16)} of an inch. This difference in length is sufficient to provide for functions unique to this invention, as descriptions that follow will indicate.
[0019] Bar 4 , shown in FIGS. 2, 3, 4 , 5 , and 9 , has a slot about {fraction (1/32)}-inch wider than shackle rod diameter, so that the bar can be moved to enclose the outer arm of shackles that are held securely by plates 5 and 6 . Depending on the action intended after movement of bar 4 , this slot can be long enough for the bar to extend so it also encloses, or even passes, the second arm of shackle 3 . Both the vertical width and horizontal width of bar 4 must be such that the bar can move only a short distance unless a specific padlock has been opened and located in front of the bar. FIG. 3 shows that bar movement would be stopped by base 1 when the padlock is closed. FIG. 4 shows the bar extending past an arm of shackle 3 when the padlock is open. With reference to FIG. 1, horizontal width of bar 4 (not pictured in FIG. 1) must be narrow enough so it will pass easily between bases on either side of an opened padlock, such as bases 7 and 8 when the padlock between them is open. Horizontal width must be wide enough so it cannot be moved between any two adjacent padlocks that are closed. Vertical width of bar 4 must be such that the bar cannot pass between plate 5 and base 1 when the padlock is closed, but can easily pass between plate 5 and base 1 when the padlock has been opened. It is not possible to list specific vertical and horizontal width dimensions of bar 4 , since padlocks vary in design, and their assembly within rotary security systems may also vary.
[0020] All padlocks for a rotary security system must be of the same design and size, although the cut of their keys will vary, as is known to be true. Since there are numerous key-cut combinations, adhering to one design and shape can be termed an advantage, since choice and purchase of a padlock would not be required of individuals who are authorized to use the rotary system.
[0021] Various actions can be incorporated into the system when bar 4 is moved as described above. One recommended action is illustrated by FIG. 5, which consists of a top view and two sectional views. Bar 4 is secured with cap-screws to slide 9 , which is retained and guided by angular strips 10 . Rectangular block 11 , bolted to the base of slide 9 , serves four functions: Block 11 prevents the slide from being removed. Block 11 provides a push-point for spring-arm 12 , which acts to return the slide. Block 11 depresses push-button switch 13 after a predetermined movement distance of slide 9 , thereby making possible the actuation of an electrically powered gate-opener or other electrical device. Low-voltage wiring 14 connects to the push-button. Block 11 contacts adjustable bolt 18 , thus preventing damage to switch 13 . After bar 4 is moved with one hand until contact between block 11 and bolt 18 occurs, the hand is free to close the opened padlock by squeezing it between thumb and fingers.
[0022] A description follows next of the rotating assembly pictured first in FIGS. 1 and 2. The spindle and hub of this assembly is shown in the exploded view of FIG. 6. This specific design involves only minor alterations of what is commonly sold by auto parts stores as a trailer hub. Said hub was selected for three reasons: low cost; turning on roller bearings, and wide support so as to secure plate 5 with minimal vertical displacement as the assembly shown by FIG. 2 is rotated. One end of spindle 19 is shortened from its purchased length, for welding to plate 20 , which is later welded to support column 17 . Tapered roller bearings 21 and 23 , FIG. 6, fit on the spindle and within the machined center of hub 22 . Five bolts supplied with trailer hub are removed and replaced with shorter bolts 24 . The hub assembly is completed by attaching washer 25 , nut 26 , and cotter pin 27 . Some lubrication of bearings is required, though less than on a road vehicle. As shown in the partial cross-sectional view of lower plate 5 , FIG. 6, plate 5 is secured to the hub with nuts 28 .
[0023] Plate 5 , on which the selected padlocks are to be assembled, requires a dimensional layout for drilling two holes per padlock. Several variables must be considered in preparing for the layout. The number of padlocks required is determined from the maximum number required to accommodate personnel authorized to separately use the radial security system. If that number is between 20 and about 50, padlocks having a wider base are suitable, such as denoted by 1 in FIGS. 1 and 2. For a larger required number of padlocks, the selection of narrower brass padlocks will minimize plate diameter. These are depicted by 29 , FIG. 9. For numbers less than 20, a smaller hub design is normally required. Such a hub can be as simple as a straight spindle within a close-fitting tube having a projecting flange two or three inches in diameter.
[0024] Padlocks should hang on plate 5 with only enough clearance between their bases to permit a base to drop from its shackle when a padlock is opened. For example, if the center of the base for padlock 29 , FIG. 9, measures {fraction (9/16)} of an inch in width, then the inner holes of plate 5 can properly be ⅝ of an inch apart, center to center. If 50 locks were required, simple calculations show the circular diameter between centers of inner holes of plate 5 to be 9.95 inches. Continuing the example, if shackle width, center to center is 1.15 inches, then the outer diameter of plate 5 would be 12.25 inches. Note that outer holes of plate 5 are half-circles only, but such holes would normally be drilled before plates are cut to size.
[0025] After such routine calculations, the layout and drilling of holes in plate 5 can be simplified by first making the simple drill jig shown by FIG. 12. To continue above example, assume that shackle rod diameter was found to be 0.255 inches, and trial on a short strip of steel, equal in thickness to that of plate 5 , showed that {fraction (5/16)}-inch drilled holes would barely permit turning the shackle as in FIG. 8. Holes 31 , 32 , and 33 of FIG. 12 would then be carefully spaced and drilled to the {fraction (5/16)}-inch diameter. Hole 30 is needed only so the jig can be pivoted around a rod placed within a same-size hole at the center of plate 5 . Hole for such a rod is drilled in plate 5 before cutting a larger opening to fit hub 22 . To use the jig, holes 31 , 32 , and 33 are first used to drill through the plate, with jig clamped in place. Thereafter, the shank of a {fraction (5/16)} drill can be inserted in hole 31 of jig and plate 5 , after which a series of drilling holes 32 and 33 is continued. Such a procedure can be completed in little more time than that required to drill 100 holes randomly in quarter-inch steel plate, which is the recommended thickness for plates 5 and 6 . A suggested step to avoid layout problems with this technique is to allow for one more set of padlock holes than initially determined—51 rather than 50 in above example. By doing so, if hole spacing with the drill jig does not end precisely, then plugging the last hole with a short bolt will not hinder later use of the system.
[0026] Remaining steps for completion of plate 5 consist of smoothly cutting the diameter to produce half-circles in outer holes, cutting out the center to fit hub 22 , and drilling for the five bolt-holes. The center hole and bolt holes can be cut oversize, to assist in centering plate 5 when it is assembled. There should be no requirement for later removal of plate 5 to add or remove padlocks.
[0027] The diameter of plate 6 is such that the plate will extend slightly past the top center of all shackles. Plates 5 and 6 can be clamped together for drilling holes to be threaded in plate 5 for cap-screws 34 , after which a tap is run through the holes of plate 6 , and the holes in plate 5 are enlarged. If desired for security reasons, cap-screws can be inserted through plate 5 , with holes threaded in plate 6 . Sleeves 35 , through which cap-screws 34 are placed, need not fit the screws closely. The length of sleeves 35 should be slightly less than the height of padlock shackle tops above plate 5 . This will permit tightening cap-screws 34 to secure the shackles firmily. Pointer 36 , shown in FIG. 7, has few dimensional requirements. The slot at its end should fit loosely over the top of shackles, without binding on plate 5 . The width of pointer 36 at its end should be the same as that determined for horizontal width of bar 4 . Pointer 36 must be easy to grasp, easy to turn, and not obstructed by cap-screws 34 . One or more of cap-screw 37 , shown by FIG. 6, can be inserted into threaded holes at the top of hub 22 , thereby thwarting later removal of pointer. Insertion of grease-cap 38 completes assembly of the rotating unit.
[0028] Lamp 39 should be one selected for outdoor use, small, and not easily broken. Lamp-arm 40 can be of a shape best suited for attachment of the lamp. Lamp-arm 40 is secured to support-arm 16 either by cap-screws as shown in FIG. 5, or by welding. Wiring passes through support-arm 16 , support-column 17 , and normally into the ground. Such wires from the lamp can be routed to the nearest connection point, which may be the wiring to an underground sensor that opens the gate when a car exits the enclosed area.
[0029] [0029]FIG. 10 illustrates how the rotary security system can be adapted for manually locking and unlocking the entrance to an enclosure. No reference numbers are shown on the rotary system in the drawing of FIG. 10 because its size, as pictured by the drawing, is similar to that shown by FIG. 2. Gate and fence structures in this drawing are intended to be symbolic only. Support-column 40 differs from support-column 16 of FIG. 2, requiring only vertical cuts at the top. Cap 42 is welded to support-column 40 . Sliding bar 41 is configured the same as bar 4 on the end facing the rotary assembly, although the slot of bar 41 may require a longer length unless the gate or door is known to remain closely fitted against support-column 40 . Horizontal and vertical width dimensions for both ends of sliding bar 41 are configured the same. Rod 43 not only assists in gate entry or exit, but it also prevents removal of sliding bar 41 . Thus, rod 43 is peened after insertion in sliding bar 41 , or otherwise secured to prevent removal at the usage site. Adjustable pivot supports 44 are commonly available and may be required for gate adjustment to assure smooth latching action.
[0030] Recommendations are next listed concerning material requirements for specific parts. These recommendations are intended to be flexible, depending on where the rotary security system will be installed. In general, padlocks are known to be weather resistant, suitable for outdoor use. A simple cover for the rotating assembly can be made for use where climatic conditions are severe. As noted above, plates 5 and 6 can properly be ¼″ thick, with stainless steel preferable for appearance. Plate 6 can be of aluminum. Plate 5 can also be of aluminum if an experiment is made to determine the required thickness for rigidity and to permit insertion of shackle arms as in FIG. 8. All of the supporting columns and structures shown in FIGS. 1-11 can properly be made from 2×2-inch square steel tubing, welded where appropriate and painted to resist corrosion. Wall thickness of the square tubing should be selected to assure columnar support. The wall thickness of column 16 should be adequate for tapped holes shown by FIG. 5. Bar 4 can be of stainless steel, hardened tool steel, or brass, with material selection such that deformation of the slotted end is not likely to occur. Consider brass for slide 9 and angular strips 10 , to resist corrosion.
[0031] Operation of the rotary security system becomes routine and easy after a person not familiar with it is shown the simple steps required. To avoid possible questions by someone who has not used the system previously, it is recommended that brief instructions be made weatherproof and then affixed to support column 16 , where they can easily be seen. Wording can be somewhat like that shown below.
How to Use Rotary Security System
Location of Pointer Identifies Previous Entrant.
[0032] 1. Move pointer to your lock number.
[0033] 2. Insert key in base of lock and open it.
[0034] 3. Rotate so pointer is opposite slotted bar.
[0035] 4. Shove bar past arm of lock until it stops.
[0036] 5. Release bar and close lock with fingers.
[0037] 6. Without delay, drive through opened gate. | A sliding bar contains a slot on one end so that bar movement passes shackle rods of an opened padlock. The bar is positioned on a rigid arm extending from a column that also supports a plate which can be rotated. Shackles of multiple padlocks are held uniformly on the plate. Shape of bar is such that its effective movement cannot occur when padlocks are closed. When a specific padlock is opened with its required key and rotated so its lengthened shackle rods are in front of the bar, movement of bar can occur. The slot allows sufficient bar movement to actuate a powered gate-opener, release a gate latch, or initiate other action. Imprinted numbers identify each padlock, and a pointer aids shackle-arm location in front of slotted bar. Advantages include security, access from car-windows, identifying unauthorized key-holders, and elimination of multiple key replacements when only one lock is used. Equipment size can vary so as to service between 7 and more than 150 authorized individuals. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a method for the preparation of an α-ketoamide imine by the reaction of a halogen-containing organic compound, a primary amine and carbon monoxide in the presence of a carbonylation catalyst.
α-ketoamide imines include a class of compounds useful as intermediates for the synthesis of various medicines and agricultural chemicals or, in particular, industrially important compounds in the synthetic preparation of amino acids. The starting compounds for the synthetic preparation of the compounds of this class are, in the prior art, usually an α-keto-acid and a primary amine but this process has not yet been applied to the industrial preparation of amino acids due to the expensiveness of the α-keto-acids. On the other hand, amino acids are usually prepared either by fermentation or by chemical synthesis. In the latter method of chemical synthesis, one of the most important problems to be solved is in the synthetic route to form the portion ##STR2## in an amino acid ##STR3## in order to establish a generally applicable method for the preparation of amino acids. No generally applicable and economically advantageous method, however, has yet been established for the synthetic preparation of amino acids starting from a halogen-containing organic compound which is usually inexpensive and available in large quantities.
In view of the above mentioned problems in the synthetic preparation of amino acids, the inventors have conducted extensive research and, as a result thereof, have arrived at the discovery of a novel and very interesting reaction, in which one mole of a halogen-containing organic compound reacts in one step with two moles of carbon monoxide in the presence of a primary amine to form an α-ketoamide imine having a structure expressed by the formula ##STR4## as a precursory structure for the formation of the structure of the formula ##STR5## in the amino acid. The inventors concentrated on this novel reaction which resulted in the completion of the present invention.
SUMMARY OF THE INVENTION
The present invention provides a novel and efficient method for the preparation of an α-ketoamide imine comprising a reaction in which a halogen-containing organic compound, which is inexpensive and available in large industrial quantities, reacts with a primary amine and carbon monoxide.
Accordingly, an object of the present invention is to provide a method for the preparation of an α-ketoamide imine from inexpensive starting materials which are available in large industrial quantities.
Another object of the present invention is to provide a method in which a wide variety of α-ketoamide imines can be produced readily in a one-step reaction.
A further object of the present invention is to provide a method for the preparation of an α-ketoamide imine in a reaction which can be performed readily and without the necessity of undertaking a troublesome reaction procedure or using starting materials having too high reactivity.
Other and further objects, features and advantages of the invention will appear more fully from the following description.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
More particularly, the present invention relates to a method for the preparation of an α-ketoamide imine represented by the general formula ##STR6## in which R 1 is a monovalent hydrocarbon group selected from the class consisting of alkyl, aryl, aralkyl, cycloalkyl and alkenyl groups or a heterocyclic group and R 2 is a monovalent hydrocarbon group selected from the group consisting of alkyl, aryl, aralkyl and cycloalkyl groups or a heterocyclic group, which comprises reacting a halogen-containing organic compound represented by the general formula R 1 X, in which R 1 has the same meaning as defined above and X is a halogen atom, a primary amine represented by the general formula R 2 NH 2 , in which R 2 has the same meaning as defined above, and carbon monoxide in the presence of a carbonylation catalyst.
The above mentioned reaction for the synthetic preparation of an α-ketoamido imine according to the inventive method is expressed by the following reaction equation: ##STR7## in which the symbols R 1 , R 2 and X each have the same meaning as defined above.
The group denoted by R 1 in the halogen-containing organic compound used in the inventive method is a monovalent hydrocarbon group selected from the group consisting of alkyl, cycloalkyl, aryl, aralkyl and alkenyl groups or a heterocyclic group and these organic groups may be substituted with one or more of various kinds of functional groups or atoms excepting hydroxy, carboxyl, amino and monoalkylamino groups. Suitable substituent groups or atoms include, for example, dialkylamino groups, carbamoyl group, acyl groups, alkoxy groups, alkoxycarbonyl groups, halogen atoms, sulfonyl group, thioalkoxy groups, sulfinyl group, sulfenyl group, cyano group, acyloxy groups, silyl groups, nitro group, epoxy group, formyl group and the like. The halogen atom X in the halogen-containing organic compound R 1 X is preferably a chlorine, bromine or iodine atom.
Particular halogen-containing organic compounds suitable in the above mentioned reaction according to the invention are exemplified by halobenzene derivatives such as bromobenzene, iodobenzene, bromonaphthalene, 4-iodoanisole, 4-acetylbromobenzene and the like, halogenated derivatives of ethylene such as β-bromostyrene, ethyl β-bromoacrylate, 2-bromo-2- butene, 2-methyl-1-bromo-1-propene, 2-bromopropene, 2-methylthio-1-bromoethylene and the like, halomethane derivatives such as benzyl chloride, ethyl chloroacetate, chloromethylimidazole, chloroacetamide, 3-chloromethylindole and the like and halogen-containing heterocyclic compounds derived from furan, thiophene, pyrrole, pyridine and the like as well as various kinds of substituted compounds derived from the above named halogen-containing organic compounds.
Any kind of primary amines represented by the formula R 2 NH 2 can be used in the reaction of the inventive method without particular limitations and the primary amine can be selected freely according to the objective α-ketoamide imine. The organic group denoted by R 2 is exemplified by alkyl groups such as methyl, ethyl, propyl, butyl and the like groups, cyclohexyl group, benzyl group and aryl groups such as phenyl 4-tolyl and the like groups.
In the reaction according to the present invention, the formation of the α-ketoamide imine is accompanied by a hydrogen halide produced as a by-product, which is captured by the amine as the reactant. In this case, however, it is also an advantageous embodiment of the inventive method that a tertiary amine is added to the reaction mixture conjunctively with the primary amine as the reactant so that the hydrogen halide may be captured by this tertiary amine. Triethyl amine, tributyl amine and the like are named as the examples of such a tertiary amine although there is no particular limitations on the kind or structure of the tertiary amine provided that the tertiary amine has a stronger basicity than the primary amine used as the reactant.
The catalyst used in the present invention per se is a conventionally known carbonylation catalyst widely used in various kinds of carbonylation reactions such as the oxo reactions and hydroesterification reactions of olefins and the reactions for the syntheses of esters, amides, aldehydes and the like by the carbonylation of organic halogen compounds and suitable catalysts include various kinds of metal catalysts and metal compound catalysts. Particularly preferable catalysts in the reaction of the inventive method are the metals belonging to the VIIIth group in the Periodic Table such as iron, cobalt, nickel, ruthenium, rhodium, platinum, palladium and the like as well as compounds thereof. From the standpoint of the larger reaction velocities, more preferable are those containing palladium or nickel.
Suitable palladium catalysts are exemplified by metallic palladium such as palladium black, metallic palladium supported on a carbon carrier and the like; complexes of zero-valent palladium complex such as tetrakis(triphenylphosphine)palladium, tetrakis(triphynilarsine)palladium, dibenzylideneacetonepalladium, carbonyltris(triphenylphosphine)palladium, maleic anhydridebis(triphenylphosphine)palladium and the like; salts and complexes of divalent palladium such ad dichlorobis(triophenylphosphine)palladium, dichlorobis(benzonitrile)palladium, dibromobis(triphenylarsine)palladium, dichloro-1,1'-bis(diphenylphosphino)ferrocenepalladium, dichloro-1,1'-bis(diphenylarsino)ferrocenepalladium, dichloro-α,ω-bis(diphenylphosphino)alkanepalladium of which the alkane has a straight chain, branched chain or cyclic chain structure with 1 to 10 carbon atoms, dichloro-α,α'-bis(diphenylphosphino)-o-xylenepalladium, palladium chloride, palladium acetate, bis(acetato)bis(triphenylphosphine)palladium and the like; and complexes of organic palladium or hydrogenated palladium such as iodophenylbis(triphenylphosphine)palladium, iodo-p-tolylbis(triphenylarsine)palladium, chlorobenzoylbis(triphenylphosphine)palladium, iodomethylbis(tributylphosphine)palladium, dimethylbis(diphenylphosphino)ethanepalladium, dihydridobis(tricyclohexylphosphine)palladium and the like. Any precursor compounds also can be used provided that the compound may produce a organopalladium halide species in the reaction system by the reaction with the organic halogen compound. It is further optional that the above named catalysts are used in the reaction with admixture of a ligand such as phosphines, phosphinites, phosphites, arsines, stibines, tertiary amines, pyridine bases, bipyridyl and the like.
The nickel catalysts used satisfactorily in the reaction, on the other hand, include nickel carbonyl and the complexes thereof obtained by the substitution of a Lewis base such as amines, phosphines and arsines for part or all of the coordinating carbon monoxide therein. Exemplary of such catalysts are tricarbonyltriphenylphosphinenickel, dicarbonylbis(triphenylphospphine)nickel, carbonyltris(triphenylphosphine)nickel, tetrakis(triphenylphosphine)nickel, dicarbonylbis(triphenylarsine)nickel, dicarbonyl-α,ω-bis(diphenylphosphino)alkanenickel of which the alkane has a straight chain or branched chain or cyclic chain structure with 2 to 10 carbon atoms, dicarbonyl-1,1'-bis(diphenylphosphino)ferrocenenickel and the like. It is of course that a precursor compound capable of being readily converted into the above named complex in the reaction mixture is used as exemplified by metallic nickel, nickel chloride, dichlorobis(triphenylphosphine)nickel, dichlorobis(triphenylarsine)nickel, dibromo-1,1'-bis(diphenylphosphino)ferrocenenickel and the like. It is further optional that the above named precursor compound is replaced with a combination of a suitable salt of nickel and a Lewis base capable of readily forming the precursor compound in the reaction mixture. The nickel salts suitable in this case include inorganic salts of divalent nickel such as nickel chloride, nickel bromide and the like, and salts of nickel with organic acids such as nickel acetate and the like while the Lewis bases suitable in this case include various kinds of amines, phosphines, diphosphines, arsines and stibines. In addition, several carbonylation catalysts containing other kind of metals may be used in a similar form to the above. Examples of such catalyst include, for example, dichlorobis(triphenylphosphine)platinum, tricarbonylbis(triphenylphosphine)ruthenium, iron pentacarbonyl, dicobaltoctacarbonyl, cyclopentadienyldicarbonyl cobalt, chlorocarbonylbis(triphenylphosphine)rhodium, chlorodicarbonylrhodium dimer and the like.
The reaction according to the inventive method can proceed regardless of the presence or absence of a solvent in the reaction mixture. When the reaction is performed by diluting the reaction mixture with a solvent, hexane, benzene, ether, tetrahydrofuran, hexamthylphosphotriamide, dimethylformamide, acetonitrile, acetone and the like are used satisfactorily although any other kinds of conventional organic solvents can be used for the purpose provided that the solvent does not serve as a source of active protons such as alcohols, carboxylic acids and the like.
The reaction according to the inventive method can be carried out under about the same reaction conditions as in conventional carbonylation reactions. The partial pressure of carbon monoxide is determined depending on the type of the catalyst used in the reaction and it should be usually in the range from atmospheric or below to 200 atmospheres or, preferably, from atmospheric to 50 atmospheres. Higher partial pressures of carbon monoxide are in general advantageous due to the increase in the yield of the desired product although an excessively high partial pressure of carbon monoxide may result in the decreased reaction velocity in addition to the disadvantages caused by the increased investment for the apparatus. If desired, the carbon monoxide used in the reaction may be diluted with an inert gas such as nitrogen, methane and the like.
The molar ratio of the halogen-containing organic compound and the primary amine may deviate from the stoichiometry considerably since the proceeding of the reaction is not disturbed by the presence of an excess amount of either one of the reactants in the reaction mixture over the other. Usually the molar ratio of the halogen-containing organic compound to the primary amine is selected in the range from 50:1 to 1:500. It is also an advantageous embodiment of the inventive method that the amine is used in large excess over the halogen compound so that the amine serves also as a solvent for the reaction mixture.
The amount of the catalyst to be added to the reaction mixture should be determined in consideration of the reactivity of the halogen-containing organic compound though not particularly limitative. The molar ratio of the catalyst to the halogen compound is usually 1:10 or smaller or, preferably, in the range from 1:30 to 1:3000.
The reaction of the present invention can proceed even at room temperature though dependent on the structure of the halogen-containing organic compound but it is optional that the reaction mixture is heated at a temperature up to 300° C. when acceleration of the reaction is desired. It should be noted, however, that an excessively high temperature of the reaction mixture may cause formation of a carboxylic acid amid as a by-product, the amount thereof being larger at higher reaction temperatures. Furthermore, the α-ketoamide imine as the desired product may be gradually decomposed at an excessively high temperature. Therefore, the reaction temperature should be determined taking the side reaction and the thermal decomposition reaction into consideration, usually, in the range from 30° to 200° C.
The α-ketoamidoimine produced by the reaction of the inventive method is readily separated from the reaction mixture and purified by a procedure in which the reaction mixture is first subjected to the solid-liquid separation such as centrifugal separation or filtration or washing with water to remove the precipitated salt formed as a by-product followed by a conventional purification treatment such as distillation, recrystallization and the like.
In the method of the present invention, a wide variety of the halogen-containing organic compounds and the primary amines can be used in the reaction so that various kinds of the α-ketoamide imines can be readily obtained. In addition, the procedure of the reaction is very easy because no complicated or troublesome steps are involved in the reaction procedure and the reaction can be performed without the use of any highly reactive starting reactants such as organic lithium compounds, Grignard reagents and the like.
The method of the present invention will be more fully understood when the examples given below are referred to.
EXAMPLE 1
Into an autoclave of 27 ml capacity made of stainless steel were introduced 1.88×10 -2 mmoles of palladium chloride, 4 mmoles of iodobenzene and 3 ml of cyclohexyl amine under an atmosphere of nitrogen followed by the introduction of carbon monoxide up to a pressure of 40 atmospheres at room temperature and the reaction was undertaken for 2 hours at 100° C. The gas chromatographic analysis of the reaction mixture after completion of the reaction using a SE-30 column of 40 ml length gave a result that the N'-cyclohexylimine of N-cyclohexylbenzoylformamide had been formed in a yield of 81.4% accompanied by a by-product of N-cyclohexylbenzamide in a yield of 12.9%. The reaction mixture was added to a mixture of water and ether and the ether solution in the upper layer was taken and evaporated to dryness followed by recrystallization of the residue from ether solution to give crystals of N-cyclohexylbenzoylformamide N'-cyclohexylimine having a melting point of 160° to 163° C. The yield of the product after isolation was 78.1%.
EXAMPLES 2-14
Reactions were undertaken with a variety of combinations of the halogen compounds, amines and catalysts in substantially the same manner as in Example 1. The results of the experiments are summarized in the Table below. The values of the yield in the table were calculated from the gas chromatographic data.
__________________________________________________________________________ Yield of Ex. cpd.Halogen R.sup.2 NH.sub.2Amine (1.88 × 10.sup.-2Catalyst Reaction pressureCO timeReaction ##STR8##No. R.sup.1 X (4 mmol) (3 ml) mmol) temp. (°C.) (atm) (hrs.) (%)__________________________________________________________________________2 C.sub.6 H.sub.5 I n-C.sub.6 H.sub.13 NH.sub.2 PdCl.sub.2 100 40 2 393 C.sub.6 H.sub.5 I n-C.sub.4 H.sub.9 NH.sub.2 PdCl.sub.2 100 40 2 344 C.sub.6 H.sub.5 I n-C.sub.4 H.sub.9 NH.sub.2 PdCl.sub.2 (dppb)*.sup.1 60 40 3 175 C.sub.6 H.sub.5 I iso-C.sub.3 H.sub.7 NH.sub.2 PdCl.sub.2 100 40 3 79 6 C.sub.6 H.sub.5 Br ##STR9## PdCl.sub.2 (dppb)*.sup.1 100 20 46 75 7 C.sub.6 H.sub.5 CH.sub.2 Cl ##STR10## PdCl.sub.2 (dppb)*.sup.1 60 20 16 8 8 ClCH.sub.2 COOC.sub.2 H.sub.5 C.sub.6 H.sub.5 CH.sub.2 NH.sub.2 PdCl.sub.2 (dppb)*.sup.1 80 40 15 11 9 ##STR11## ##STR12## PdCl.sub.2 (dppb)*.sup.1 100 20 5 37 10 ##STR13## ##STR14## PdCl.sub.2 (dppf)*.sup.2 100 40 3 16 11 C.sub.6 H.sub.5 I ##STR15## Pd(OAc).sub.2 100 40 3 42 12 C.sub.6 H.sub.5 I ##STR16## PdCl.sub.2 (Asφ.sub.3).sub.2 80 40 2 21 13 ##STR17## ##STR18## PdCl.sub.2 (dppb)*.sup.1 80 30 10 45 14 ##STR19## iso-C.sub.3 H.sub.7 NH.sub.2 PdCl.sub.2 100 20 2 81*.sup.3__________________________________________________________________________ *.sup.1 dppb = 1,4bis(diphenylphosphino)butane *.sup.2 dppf = 1,1'-bis(diphenylphosphino)ferrocene ##STR20## | The invention provides a novel method for the preparation of an α-ketoamide imine having a characteristic structure expressed by the formula ##STR1## in which R is a group such as an alkyl, aryl or the like group, in a one-step reaction in which a halogen-containing organic compound reacts with a primary amine and carbon monoxide in the presence of a carbonylation catalyst. The product compound is useful as an intermediate for the synthesis of various kinds of organic compounds including medicines and agricultural chemicals. | 2 |
FIELD OF THE INVENTION
The present invention relates to the manufacture of composite reinforcement elements woven or knitted in three dimensions from textile, mineral, synthetic or other fibers impregnated with a resin which is then polymerized or otherwise hardened.
BACKGROUND OF THE INVENTION
Reinforcement elements of this type are principally, but not exclusively, employed in the aeronautic and space fields in which they have many applications, in particular for producing parts which must resist thermo-mechanical stresses, such as thermal protections of bodies re-entering the atmosphere, explosive-driven rocket nozzles, aircraft brakes, or parts which must withstand high mechanical stresses, such as the hubs of helicopter rotors, landing undercarriages, roots of wings, leading edges, etc.
Many processes and apparatus have been imagined and developed for producing such reinforcement elements, but the automatized manufacture of parts of complex shape encounters great difficulties which result in very complicated and consequently costly machines without the parts obtained always possessing the required qualities of homogeneity and resistance.
Moreover, the remarkable properties of these composite elements lead to the use thereof for producing parts having complicated, evolutive shapes that present machines are incapable of manufacturing.
It is known to produce hollow, composite reinforcement elements of revolution woven in two dimensions horizontally around rigid, perpendicular rods mounted in concentric ring arrangements on a rotatable support, which are subsequently replaced by threads, as described for example in U.S. Pat. Nos. 4,183,232 and 4,346,741 filed in the name of the applicant.
According to another method, a hollow support mandrel is used, parallel layers of threads are laid in two crossed directions on the surface of the mandrel and stitching lines are formed in a direction perpendicular to these layers, as described in particular in No.FR-A-2,355,936.
According to No. FR-A-2,315,562, the hollow support mandrel is of metal, capable of being taken apart, and formed by spaced-apart sectors having apertures in which are driven points about which are stretched out threads forming the different superimposed crossing layers which are thereafter sewn by rows of stitches formed in the gaps between the sectors of the mandrel.
All these processes disclosed in these documents require a hollow mandrel since the connection of the superimposed layers by stitching necessarily results in the introduction in the mandrel of a device for knotting the thread introduced from the exterior.
Moreover, the stitches are effected with needles with flaps or closed eyes which are delicate to use for fragile fibers requiring sometimes a double lapping of the thread.
Another process disclosed in No.FR-A-2,408,676 on the other hand employs a solid mandrel of foam material on which are mounted sections of rigid threads, termed "picots" around which the layers of threads are laid in two different directions and which constitute the threads of the third direction.
This process has various drawbacks. First of all, the "picots" must be previously subjected to a pre-rigidifying treatment, which increases their diameter, to permit the implantation thereof.
Secondly, the "picots" which must become an integral part of the part to be produced must consequently be provided in a considerable number, on the order of several tens of thousands, implanted very close together, which represents an extremely long operation requiring high precision.
Furthermore, in the case of a part having a complex shape whose surface forms corners or curves, the implantation of the neighboring "picots" which are excessively close together, is very difficult to achieve without interference therebetween, and the very narrow passageways defined therebetween do not permit an easy laying of threads in even layers, which laying is even found to be impossible in the regions where the threads change orientation.
Lastly, the "picots" excessively close together behave imperfectly, in particular in the curved parts, which results in defects in the homegeneity in the finished part.
SUMMARY AND OBJECTS OF THE INVENTION
An object of the invention is to overcome these drawbacks, and those of the other processes of the prior art, by providing a new process whereby it is possible to produce reinforcement elements which are not only in the form of a solid of revolution, but also have an evolutive profile (large variations in diameter and curvature) and shapes having flat surfaces or even flat shapes or blocks.
The invention therefore provides a process for manufacturing composite reinforcement elements woven in three dimensions from textile, mineral, synthetic or other fibers, of complex shape, having high resistance to thermal, mechanical or thermo-mechanical stresses, intended more particularly for applications in the aeronautic or space field. The invention includes the steps of employing a disposable mandrel; composed of foam or like material having externally the interior shape of the reinforcement element to be produced, implanting rigid members in the mandrel, and applying on the surface of the mandrel successive layers of threads or fibers, which layers are superimposed and crossed in at least two directions, connecting said layers to each other by means of threads or fibers which extend perpendicularly therethrough, impregnating the assembly with a hardenable binder, and removing the mandrel preferably by destroying the mandrel, wherein said rigid members are pins temporarily implanted in the mandrel so as to retain a continuous thread of fibers stretched out on said pins and in contact with the surface of the mandrel, the process further comprising stretching out a continuous thread on said pins so as to form in succession at least three even, superimposed and crossed layers, and introducing through said layers, from the exterior, a continuous thread forming successive open loops by means of a needle through which said thread passes, and withdrawing said pins.
According to another feature of the invention, said layers are maintained assembled by a conjugate gripping and friction action of the threads of said layers on said thread loops.
BRIEF DESCRIPTION OF THE DRAWINGS
The following description with reference to the accompanying drawings given by way of non-limitative examples will explain how the invention may be carried out.
FIG. 1 is a perspective view of an embodiment of a reinforcement element in process of being manufactured and showing the arrangement of the pins implanted in a mandrel and the arrangement of the thread stretched out on these pins.
FIG. 2 is a longitudinal sectional view to a reduced scale of the mandrel of FIG. 1, composed of a foam material and fixed on a mandrel support shaft.
FIG. 3 is a view to an enlarged scale of a needle employed for carrying out the process according to the invention.
FIG. 4 is a view similar to FIG. 3 of another embodiment of a needle.
FIGS. 5a to 5f are diagrammatic sectional views of the various stages of the introduction of the continuous thread loops through the layers laid on the surface of the mandrel according to the invention.
FIG. 6 is a longitudinal sectional view of the finished reinforcement element.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The process of the invention comprises implanting or inserting pins 25a . . . 25e in a mandrel 15 composed of foam material at points on the surface of the latter chosen as a function of its shape for retaining and maintaining a thread 33 stretched out against this surface between these pins so as to form an even layer.
In the embodiment illustrated in FIG. 1, the mandrel has a cylindro-conical shape corresponding to the internal shape of a reinforcement to be produced.
For example, a first series of pins 25a is implanted around the mandrel support shaft 14 on the roughly flat section of the mandrel. Thereafter, there are implanted, for example, two circumferential rows of pins 25b at the ends of the cylindrical body of the mandrel, pins 25c in staggered relation on the conical end part, pins 25d at the apex of this end part and lastly pins 25e in circumferential rows on the parts of the surface of the mandrel which are inclined with respect to its shaft 14.
Note that the pins 25b and all those implanted in the surfaces of the mandrel which are parallel, or nearly parallel, to its shaft are perpendicular to its surface, while the pins 25a, 25c, 25d and 25e and generally all those implanted in surfaces which are inclined and perpendicular to this shaft will be advantageously inclined in the desired direction so that the thread tends to slide thereon and comes to be lodged in an acute angle made by each of these pins with the associated surface of the mandrel.
When the pins have been implanted in all the chosen points, one end of a thread is for example fixed on one of the pins 25a and the thread is pulled between the pins 25b to beyond one of the pins 25d at the apex of the cone.
The mandrel is then rotated through one step and the thread 33 is brought back and passed around said pin 25d, between two pins 25b, then passed around in the same way a second pin 25a adjacent to that of the start of the operation.
In order to avoid an accumulation of thread in the vicinity of the apex of the cone, the thread is made to pass around intermediate pins 25c arranged in staggered relation on the cone.
When a first even layer of thread 33 has been laid in this way in the longitudinal direction, a second layer of thread is laid, for example at 90°, circumferentially.
This winding may be effected in a helical manner from, for example, one of the pins 25a by turning the mandrel.
The circumferential rows of pins 25e inclined in an appropriate manner are adapted to receive a thread and to retain it in contact with the surface of the roughly planar end of the mandrel, and on its rounded part up to the beginning of the cylindrical part.
Similarly, the circumferential rows of pins 25e on the conical part are adapted to prevent the thread from slipping toward the apex.
The pins 25b implanted in the parts of the surface which are parallel to the shaft of the mandrel are adapted to maintain an even spacing of the threads.
In this way, there is deposited on the mandrel the desired number of superimposed layers and it will be observed that if it is desired to have any part of the element reinforced, it is sufficient, in the first stage, to implant pins at the boundaries of this part, which will permit effecting one or more additional passes of thread within these pins by passing therearound in one direction and the other.
It should be stressed that, in the case of an evolutive surface having for example a concave part, there may be implanted, in the first stage, helical rows of pins against which the thread 33 is disposed.
When this second stage of the process according to the invention has terminated, a thread 50 is introduced in a third stage through the crossed layers and into the foam material of the mandrel.
For this purpose, a device of known type is employed which comprises a needle carrier and a thread-clamp and is adapted to effect a reciprocating to-and-fro movement in the longitudinal direction of the needle. This device is not part of the invention and will not be described in detail.
It has been found that the shape of the needle is of great importance for carrying out this third stage. Indeed, the threads employed are most often threads of fragile fibers which may tend to become separated.
Consequently, it has been observed that if a conventional needle is used with a throughway eye, the fibers of the thread disintegrate at the outlet of the eye on both sides of the latter causing cramming and breakage of the thread.
For this reason, a needle is used such as that shown in FIG. 3 or, as a modification, that shown in FIG. 4.
With reference to FIG. 3, the needle 43 comprises an oblique throughway eye 45 whose edge remote from the point 46 has an inner rounded portion 51 around which the thread is bent upon penetration of the needle, thereby avoiding damage to the thread or splitting liable to result in breakage.
Advantageously, the throughway eye 45 opens, at the end remote from the point 46, onto a longitudinal groove 44 which has a partly circular section and a depth which gradually decreases in the direction away from the point, through which groove the thread passes.
In the embodiment shown in FIG. 4, the needle 43a is hollow and defines an axial passage 44a which opens laterally and obliquely onto a non-throughway eye 45a whose edge remote from the point 46a has an inner rounded portion 51a similar to the rounded portion 51 of the needle 43, and the thread passes inside the needle.
A thread 50 is threaded through a thread-clamp 48 and the eye 45 of the needle 43 and introduced in the form of free loops by the needle 43 which is alternately thrust forward and withdrawn in accordance with the sequence represented in FIGS. 5a to 5f in the form of successive stitches to within the foam material.
The thread 50 is driven by the needle 43 through the layers, the thread-clamp 48 being tightened and the travel of the needle being so adjusted as to penetrate the foam of the mandrel to an extent a little beyond the eye 45 of the needle (FIGS. 5a, 5b, 5c).
The thread-clamp is then released (FIG. 5d) and the needle rises by gradually releasing the thread (FIG. 5e) through the layers and thus forming a small unclosed loop 53 which is retained solely by the action of the foam material and friction in the layers, just below the interface between the foam material and the first layer.
It will be understood that the elastic pressure exerted by the foam material in closing onto the loop after the withdrawal of the needle, on one hand, and the friction and gripping action of the threads in the superimposed layers, on the other hand, upon withdrawal of the needle, are sufficient to retain the thread 50 which freely travels along the groove 44 of the needle in the course of this withdrawal.
After having moved out of the layers of thread, the needle is raised above the surface of the layers a distance equal to the total thickness of the superimposed layers on the mandrel plus the stitching pitch, i.e. the desired spacing between two stitches (FIG. 5f).
The thread-clamp is then actuated for stopping the thread in the needle, the latter is advanced and the cycle is recommenced to form continuously a large number of loops 53 with the same thread 50.
The pins implanted in the mandril may be removed as the work progresses so as to avoid hindering this progression.
When the operation for introducing threads through the layers is terminated, the assembly is impregnated, either by leaving the reinforcement element on the mandrel or by previously removing the mandrel in the conventional manner.
In this respect, the essential feature of the element produced in accordance with the invention should be mentioned, namely the fact that the superimposed crossed layers of threads are maintained together, before the impregnation, solely by the conjugate gripping and friction actions of the threads of the superimposed layers on the continuous thread which passes therethrough and forms successive open loops interconnected on the outer surface of the element.
It has been found that these gripping and friction effects alone are sufficient to enable a reinforcement element constructed in accordance with the invention to be handled and to keep its shape after the extraction of the mandrel and before its impregnation. It will be understood that such a result can only be obtained with at least three crossed superimposed layers.
To remove the mandrel, the simplest method is to destroy the mandrel, for example by combustion.
FIG. 6 shows the shape of the finished element and reveals the arrangement of the threads in three dimensions.
The use of temporary pins according to the invention merely requires the implantation of a few hundreds thereof for laying the layers of a given element, while the use of picots of the prior art requires several tens of thousands of picots to be implanted as definitive threads of the same element.
Consequently, the larger space left free between the pins enables denser layers of threads to be laid, these threads being moreover placed still closer together by the introduction of the threads by means of the needle.
An element results whose features of resistance are much superior to those of elements of the prior art. | A plurality of parallel layers of fibers are laid in two crossed directions on a disposable support mandrel, pins are temprorarily implanted in the mandrel (15) composed of foam material in regions of evolution of its shape and at points where it is desired to change the direction of the fiber, a continuous thread (33) is stretched out between the pins so as to form crossed superimposed layers, and a continuous fiber (50) is introduced by means of a needle (43) through the layers and forms successive open loops (53). The loops (53) are maintained by the elastic pressure exerted by the foam material and the gripping action of said layers. The fibers are impregnated with a binder and the binder is hardened and the mandrel is destroyed. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a spindle motor. More particularly, the invention relates to a spindle motor with a soundproofing formed on a stator outside a peripheral surface of a rotor part for preventing noises and obtaining a slim-type motor.
2. Description of the Prior Art
FIG. 1 illustrates a schematic construction of a outer rotor-type DC spindle motor.
Referring to FIG. 1, the spindle motor comprises a rotor 1 and a stator 2. The rotor 2 includes a shaft 3, bearing 4, case 5 and magnet 6, while the stator 2 has a bearing holder 7 supporting the bearing 4 and the shaft 3. A core 9 with a wound coil 8 is fixed in the bearing holder 7 of the stator 2, and the bearing holder 7 is formed integrally with a mounting plate 10 fixed to a housing.
With this construction of the motor, the core 9 and the magnet 6 of the rotor 1 cooperate to rotate the rotor 1 when a current is applied to the coil 8 of the stator 2.
Noise inside the motor, however, escapes from the motor by way of a gap between the rotor 1 and the stator 2 during the rotation of the rotor 1. This noise is amplified by their reflection against the mounting plate 10 of the stator 2.
Furthermore, in the case of a motor mounted on a motor set, such noise is even further amplified by resonance, which is one critical problem in manufacturing current low-noise motor sets.
It is nearly impossible to eliminate the noise because of its irregular reflection on outer members when the rotor rotates due to friction of the motor bearings and eccentricity.
Many suggestions have been made in order to prevent the noise, for example, a method of precision manufacture of a motor and a method by providing an outer soundproofing. The precision motor manufacture, however, has its limitations, and the separate soundproofing requires a larger space for the motor installation and thus causes an increase in the cost of production and installation as well as presenting difficulties in manufacturing a slim-type apparatus or motor.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a spindle motor with soundproofing means for minimizing motor noise and realizing a slim-type motor manufacture.
The characteristic of the present invention for attainment of this object is that in a spindle motor having a rotor and a stator, the spindle motor comprises soundproofing means formed on the stator outside a peripheral surface of the rotor.
According to this characteristic, the noise generated inside the motor during operation is absorbed in or reflected on the soundproofing means so as to prevent resonance and reduce the noise intensity substantially, and the volume of the motor does not increase because the soundproofing means is formed on the stator, which means that a slim-type motor can be achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and advantages of the present invention will become more readily apparent upon consideration of the following description and drawings in which:
FIG. 1 is a schematic sectional view of a conventional spindle motor;
FIG. 2 is a schematic sectional view according to a first embodiment of the present invention;
FIG. 3 is a fragmentary plan view of a soundproof wall of the spindle motor according to a second embodiment of the present invention; and
FIG. 4 is a fragmentary front view of a soundproof wall of the spindle motor according to a third embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 2 is a sectional view of a spindle motor illustrating an embodiment of the invention. Referring to FIG. 2, the spindle motor comprises a rotor 1 including a shaft 3, bearings 4, case 5 and magnet 6, and a stator 2 including a bearings holder 7 for supporting the bearing 4 and the shaft 3 and a core 9 fixed in the bearing holder 7 for winding a coil 8. The bearing holder 7 is formed integrally with or fixed to a mounting plate 10. The case 5 has an upper, horizontal end wall 5a and a cylindrical perimetral wall 5b extending downwards from wall 5a. The shaft 3 is fixed to end wall 5a and extends downwardly and centrally therefrom. The magnet 6 is fixed to the inner cylindrical surface of the wall 5b and faces coil 8.
According to this embodiment, a soundproof wall 12 as a soundproofing is formed on the mounting plate 10 of the stator 2. The soundproof wall 12 has parallel, inner and outer circumferential surfaces extending downwardly from an upper horizontal edge of the wall, and the wall 12 projects upwardly from a planar upper surface of the mounting plate 10 and extends concentrically to the case 5 of the rotor 1. The soundproof wall 12 is preferably formed integrally with the mounting plate 10 of the stator 2 and, as seen in FIG. 2, has a rectangular cross-section.
Furthermore, the soundproof wall 12 is so formed that its height is correspondent to or more than a distance a between the the lower edge of cylindrical perimetral wall of case 5 of rotor 1 and the stator 2 and a distance c between the inner surface of soundproof wall 12 and the perimetral wall of case 5 of the rotor 1 is correspondent to or less than the distance a between the rotor 1 and the stator 2, i.e. a≦b and a≦c.
The soundproof function of the soundproof wall 12 is described below.
When the motor is operated, noise is generated inside the motor and this noise resonates outside through the gap a between the lower edge of the perimetral wall of the rotor case 5 and the mounting plate 10 of the stator 2. The noise, however, impacts against the wall 12 prior to its escape outside to return inside the motor, with the result that only very little noise is conducted outside.
Moreover, although the noise is generated and travels outward, it does not escape outside until it undergoes multiple reflection and refraction on the wall 12, thereby the noise is reduced considerably. In other words, the noise travelling outward is absorbed in or reflected on the mounting plate 10 of the stator 2 and thus the magnitude of noise is reduced substantially.
Additionally, since the wall 12 is formed integrally with the motor stator, a slim-type motor is realized due to the fact that the wall 12 has no effect on the volume of the motor.
In FIG. 3 there is seen a second embodiment of the invention. Referring to FIG. 3, the soundproof wall 12 is formed with a plurality of circumferentially spaced vertical grooves 13a of rectangular section forming alternating ribs 13b therebetween on its inner circumferential surface 13. These grooves 13a and ribs 13b optimize the soundproof effect by more effective reflection and refraction of the noise on the wall.
FIG. 4 illustrates a third embodiment of the invention. According to FIG. 4, the soundproof wall 12 is formed with a concave groove 14a forming a recess at the lower end of the inner circumferential surface. The groove 14a is formed by a first vertical portion 14b extending from the upper surface of mounting plate 10 and a second, tapered portion 14c forming a downwardly outward surface facing the rotor case 5. This groove 14a can conduct the reflection and the refraction of the noise to the mounting plate 10 of the stator 2 and prevent the noise from escaping outside along with the wall.
As described hereinbefore, the spindle motor according to the invention permits significant reduction of the motor noise and realization of the slim-type motor.
Although the present invention has been described with reference to preferred embodiments, it will be understood that various changes and modifications may be made by those of skill in the art without departing from the spirit and the scope of the invention as set forth in the following claims. | A spindle motor comprises a soundproof wall formed on a stator outside a peripheral surface of a rotor. Noise generated inside the motor during the operation is cut off by the wall to be reduced remarkably. Since the soundproof wall has no influence on the volume of the motor, a slim-type motor can be realized. | 7 |
CROSS-REFERENCE TO RELATED PATENT
This invention involves improvements in the construction of my free vortex aircraft set forth in U.S. Pat. No. 3,934,844, issued Jan. 27, 1976.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to heavier-than-air aircraft in which the lift is produced on the body of the aircraft by a free vortex and in particular to such an aircraft having a centrally mounted engine which produces both the forward thrust for the aircraft and intensifies the lift producing free vortex. More particularly, the invention relates to an aircraft in which a free vortex is produced to provide the lift for takeoffs and landings, and in which the free vortex is eliminated during normal flight to permit the speed of the aircraft to be substantially increased.
2. Description of the Prior Art
There are numerous types and styles of aircraft produced using conventional propeller-driven and jet engine-driven designs in which the lift is produced on the wings of the aircraft by the movements of the air currents. There alos are various constructions of wingless aircraft, usually having a saucer-like disc shape in which air currents rotate an annular member or are deflected through an open bottom to provide lift for the disc. Likewise, there are other styles of aircraft known as ground effect machines in which a cushion of air is provided beneath the craft to support the craft a short distance above the ground for movement therealong.
Many of the problems associated with these types of aircraft are described in and are eliminated by the free vortex aircraft construction described in my U.S. Pat. No. 3,934,844. Although the free vortex construction of this patent eliminates many of the problems, certain limitations exist. The use of a pair of spaced thruster and vortex pumping engines, if not fully synchronized, may produce an unbalance or yaw effect on the aircraft increasing the problems of maintaining its stability. Likewise, the use of two or more engines to produce and maintain the free vortex and to provide the forward thrust increases the cost of the aircraft in contrast to the use of a single engine which can provide both functions and achieve the same results.
Although the generation of the lift producing free vortex is highly desirable for takeoffs and landings, the vortex decreases considerably the cruising or flight speed of the aircraft. If too great a speed is reached by the aircraft, the vortex will "blow away", eliminating most of the lift being produced on the body of the aircraft, seriously affecting its airborn ability. Furthermore, the vortex producing thrust and pumping engines will continually attempt to create new lifting vortexes in the vortex producing region of the aircraft frame which are continuously "blown away", producing a serious drag on the aircraft.
Thus, the need has existed for an aircraft construction which produces a free vortex to provide the necessary lift for takeoffs and landings which reduces the runway length required and increases the safety of the aircraft, and which permits elimination of the vortex once the aircraft is in flight thereby increasing the flight speed, and which requires only a single engine for producing both the thrust and free vortex pumping action.
SUMMARY OF THE INVENTION
Objectives of the invention include providing an improved free vortex aircraft construction which requires only a single centrally mounted engine for producing both the forward thrust and pumping action for the lift producing free vortex, thereby eliminating undesirable yaw on the aircraft and reducing the cost thereof; providing such an improved aircraft construction in which the lifting vortex is eliminated between takeoff and landing procedures to increase the speed of the aircraft by retracting the vorticity-producing front shield and by eliminating the vortex core pumping action of the engine by covering of the vortex air duct inlets; providing such an aircraft construction in which the generated standing free vortex is maintained in a stable condition while being gradually eliminated during flight by decreasing the length of the vortex while decreasing its strength by controlling the size and location of the inlet air duct openings and the effective width of the shield; and providing such an aircraft construction which provides the advantage of greatly increased lift with a minimum amount of power for takeoffs and landings by generation of a free vortex, as well as providing an aircraft being able to travel at a high rate of speed during flight by eliminating the lifting free vortex.
These objectives and advantages are obtained by the improved free vortex aircraft construction, the general nature of which may be stated as including frame means; shield means mounted on the frame means to generate and shed a substantial amount of vorticity into the air when the aircraft moves forwardly through the air, with said shield means and frame means providing an upper vortex forming zone downwind of the shield means; the shield means being movably mounted for movement between extended and retracted positions; vortex duct means located within the frame means, generally beneath the upper vortex forming zone, and extending transversely across the frame means providing a lower vortex zone, with said duct means being provided with a pair of spaced inlet openings communicating with the ends of the upper vortex forming zone; thruster air duct means located within and extending longitudinally along the frame means and communicating with the vortex duct means intermediate the spaced inlet openings; engine means mounted centrally on the frame means and communicating with the thruster duct means to provide thrust for moving the aircraft forwardly through the air and for pumping air from the upper vortex forming zone through the inlet duct openings and vortex duct means to retain and concentrate the vorticity within said upper vortex zone to form a free vortex of low pressure air extending in a generally circular manner across the frame means and through the vortex duct means, with said free vortex acting on the frame means and vortex duct means to produce lift on the aircraft; closure means movably mounted with respect to the spaced inlet openings of the vortex duct means for opening and closing said inlet openings for creating the free vortex when the shield means is in extended position and the inlet openings are open, and for extinguishing the free vortex by moving the shield means to retracted position and closing the inlet openings.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the invention -- illustrative of the best mode in which applicant has contemplated applying the principles -- is set forth in the following description and shown in the accompanying drawings, and is particularly and distinctly pointed out and set forth in the appended claims.
FIG. 1 is a top plan view of the improved free vortex aircraft construction with the vortex producing shield in raised position and with the vortex inlet duct openings in closed position;
FIG. 2 is a front elevation of the improved aircraft shown in FIG. 1;
FIG. 3 is a rear elevation of the improved aircraft shown in FIGS. 1 and 2;
FIG. 4 is a right-hand side elevational view of the improved aircraft of FIG. 1;
FIG. 5 is an enlarged fragmentary top plan view with portions broken away and in section of the aircraft shown in FIG. 1 with the vortex inlet ducts in open position;
FIG. 6 is a fragmentary sectional view taken on line 6--6, FIG. 5, showing the formation of the free vortex;
FIG. 7 is an enlarged fragmentary view of the vortex producing front shield in extended raised position;
FIG. 8 is a greatly enlarged fragmentary sectional view taken on line 8--8, FIG. 7, showing the retracting mechanism for the vortex producing shield;
FIG. 9 is a fragmentary sectional view taken on line 9--9, FIG. 8; and
FIG. 10 is a fragmentary sectional view similar to FIG. 8 with the shield in fully retracted position.
Similar numerals refer to similar parts throughout the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The improved free vortex aircraft construction of the invention is indicated generally at 1 and is shown particularly in FIGS. 1 through 4. Aircraft 1 includes a front forwardly extending nose section 2 and a main body section 3. Nose section 2 is supported by a front wheel assembly 4, with main section 3 being supported by a pair of spaced rear wheel assemblies 5. Nose section 2 includes a cockpit area 6 for receiving a pilot and for housing the usual control mechanisms for aircraft construction 1.
Main body section 3 includes a pair of end stabilizing fins 7 extending in an inclined upwardly outwardly direction. A second pair of stabilizing fins 8 is mounted on the bottom of main fins 7 and extend downwardly outwardly at generally right angles with respect to fins 7. The front portion of main section 3 is formed by an upwardly rearwardly curved surface 9 (FIGS. 1 and 2), formed with a pair of thruster inlet openings 10 on the sides of nose section 2. Surface 9 terminates in a generally arcuate top deck surface 11 which terminates in a pair of flat side areas 12 adjacent main fins 7. The rear of surfaces 12 terminate in a downwardly curved portion 13. The rear of deck 11 also is curved downwardly at 14 and terminates along with curved surfaces 13 in a pair of inwardly downwardly projecting areas 15 which terminate and form thruster outlet opening 16 (FIGS. 1 and 3). A generally flat bottom wall 17 completes the general structure of main body section 3.
A vorticity-producing shield 18 is retractably mounted on the front portion of main section 3 and extends upwardly forwardly at an angle of approximately 20° with respect to the vertical, as shown in FIG. 4. Shield 18 forms a cavity-like region 19 behind shield 18 and located between fins 7 and main deck 11, the purpose of which is discussed more fully below. Shield 18 has an arcuate shape and a relatively sharp top edge 29.
In accordance with the invention, an air duct assembly, indicated generally at 20 (FIGS. 5 and 6), is mounted within main body section 3 between deck 11 and bottom wall 17. Duct assembly 20 consists of a vortex guiding duct 21 and a thruster duct 22. Vortex duct 21 is formed by a pair of cylindrically-shaped transversely extending ducts 23 which terminate in a pair of spaced outer circular inlet openings 24. Ducts 23 are formed by an outer generally 90° bend 25 (FIG. 6) and a tapered straight line cylindrical section 26. Inlet openings 24 are formed by the upper ends of bends 25.
Thruster duct 22 includes a front conical section 27 and a rear cylindrical section 28. The inner ends of vortex duct sections 26 are attached to cylindrical section 28 adjacent the rear of conical section 27 and provide communication with thruster duct 22 through openings 30 (FIG. 5). The rear end of cylindrical section 28 forms thruster outlet opening 16 with the front end of conical duct section 27 forming thruster inlet openings 10.
An engine 31 is mounted within thruster duct 22 and includes a power-driven shaft 32 and a propeller 33. Propeller 33 is located within cylindrical duct section 28 rearwardly of openings 30 which communicate with vortex ducts 23 in order to draw air through both inlet openings 10 and duct openings 24. Engine 31 is shown diagrammatically in FIG. 5 and may consist of a pair of engines in tandem or in side-by-side arrangement, if desired, and may be gasoline or jet powered without affecting the concept of the invention. If the aircraft were to be powered by a jet engine, the jet engine would have to be placed so that its air intake would pump air from the vortex ducts 23 as well as the thruster duct so it would have to be placed at the location of propeller 33 rather than the location of motor 31.
Vortex inlet openings 24 communicate with the vortex forming region 19 through openings 34 formed in flat side areas 12 of main body section 3. In further accordance with the invention, a pair of closure members 35 are slidably mounted within fins 7 and across openings 34 and duct inlet openings 24 for closing and opening duct inlet openings 24. Closure members 35 preferably consist of flexible panels 36, slidably mounted between a pair of spaced channels 37, mounted within fins 7 and adjacent openings 34. Panels 36 are operable by any suitable type of operating control means (not shown) for moving panels 36 between open and closed positions by actuation of control means within cockpit area 6. The panel control means may be hydraulic, pneumatic, electrical or the like. The surfaces 9, 11, 12, 13, 14, 15 and 17 of the main body 3, along with the closure members 35, are so shaped that the aircraft 1 becomes a streamlined lifting body aircraft when the shield 18 is retracted and the closure members 35 are closed.
A choke assembly 40 is mounted at the rear of nose section 2 at the inlet openings of thruster duct 22 for controlling the amount of air entering conical duct section 27 through thruster inlet openings 10. Assembly 40 includes a pair of closure flaps 41 pivotally connected to a hydraulic control unit 42 for moving flaps 41 between the fully open position (full lines, FIG. 5) to a partially closed position (dot-dash lines, FIG. 5). Choke assembly 40 controls the rate at which air is pumped by engine 31 through vortex duct openings 24 by regulating the airflow through thruster inlet openings 10.
Another main feature of the invention is the construction of shield 18, whereby it is retractable from its fully extended vorticity-producing position of FIG. 7 to a completely retracted concealed position of FIG. 10. One type of construction of shield 18 by which this can be accomplished is shown diagrammatically in FIGS. 7-10.
Shield 18 is formed by a plurality of shield segments which are indicated generally at 43, six of which are illustrated in the drawings. Each shield segment 43 is formed by a pair of spaced panels 44 and 45 (FIG. 8) which are secured at their lower ends by welds 46 to an associated piston 47. Pistons 47 preferably are hydraulically actuated and are telescopically mounted with respect to each other as are the individual pairs of shield panels 44 and 45. This telescoping arrangement enables shield 18 to be collapsed easily within main body section 3 and beneath deck 11 from its fully extended position of FIG. 8 to its collapsed or retracted position of FIG. 10. The pistons 47 are spring loaded by a compression spring 38 so that the shield segments do not separate from each other above the surface of the frame deck 11. Consequently, the shield preserves its smooth arcuate shape during the extension and retraction processes. The topmost shield segment 48 preferably has a V-shaped cross-sectional configuration. Shield 18 retracts within an elongated slot 49 formed in frame deck 11 when in retracted position to eliminate any wind resistance and drag due to an exposed upper shield end. Slot 49 may be covered by a flap or panel if desired, to provide a more streamlined construction.
The details of the theory of operation in forming a free standing vortex, indicated generally at 50 (FIG. 6), are described fully in my basic U.S. Pat. No. 3,934,844. Stated briefly, when the aircraft moves through the air or along the ground, powered by thrust engine 31, vorticity is shed from the relatively sharp top edge 29 or topmost shield segment 48 above vortex forming region 19. This vorticity is retained and concentrated into a strong lift-producing vortex 50 by the vortex stretching action of the pumping of the air from vortex region 19 through openings 24 of vortex guiding ducts 21. Vortex 50 forms downwind of shield 18 and has a generally flattened circular configuration, as shown in FIG. 6.
Vortex 50 has an upper, generally half-circular portion 51 which extends in an arcuate manner between inlet openings 24 across deck 11, and a lower or internal portion 52 which extends about duct bends 25 and through straight duct sections 26 and through openings 30 into cylindrical section 28 of thruster duct 22. The trailing end 53 of the vortex are discharged through thruster outlet opening 16.
Propeller 33 of thrust engine 31 draws a large volume of high-speed air through inlet openings 10 where it passes through thruster duct 22 and out of outlet opening 16 to provide the forward thrust for aircraft 1. Simultaneously with this thrust-producing movement of air by propeller 33, air is pumped from the core of the vortex 50 through vortex ducts 23 and openings 30 which strengthens and maintains vortex 50 to provide the necessary lift to aircraft 1. The lift force manifests itself as a lowering of the air pressure above any surface beneath the vortex (deck 11 and the outer curved inside surface of duct bends 25).
Shield 18 will be in fully extended position with inlet duct opening panels 36 being in retracted position when aircraft 1 is preparing for takeoff. Thrust engine 31 moves aircraft 1 down the runway producing free vortex 50 above deck 11 and through vortex guiding duct 21 providing the necessary lift for takeoff. After aircraft 1 has achieved sufficient altitude, shield 18 is retracted simultaneously with the closing of inlet cover panels 36 to extinguish vortex 50.
Closure panels 36 move inwardly across duct openings 24 when extinguishing vortex 50. Because of its arcuate shape, the effective width of the shield 18 decreases as it is retracted. Both of these make the vortex shorter as it gets weaker. Such a shorter vortex is more stable than a longer weaker vortex which would result if the closure panels moved from an inner to an outer position or if the shield did not have an arcuate shape. The inward or inboard movement of panels 36 instead of outward movement and the decreasing effective width of arcuate shield 18 as it is retracted, prevent an undesirable rapid extinguishing of the vortex and allow a more gradual transition from vortex generated lift to conventional lift, the conventional lift starting at the outboard areas of the aircraft and moving inboard. A more stable aircraft results. It may be desirable to set the choke 40 in a partially closed position during at least part of the time when the shield 18 is being retracted and the closure panels 36 are moved inwardly across the duct openings. This increases the rate at which air is pumped by engine 31 through the vortex duct openings and helps to stabilize the vortex. The speed of aircraft 1 can be increased considerably after extinguishing of vortex 50 by retraction of shield 18 with thruster engine 31 providing the power. Aircraft 1, after extinguishing vortex 50, becomes a usual streamlined lifting body aircraft.
Shield 18 is moved from its retracted position of FIG. 10 to its fully extended position of FIG. 8 simultaneously with the opening of inlet duct closure panels 36 prior to aircraft 1 starting its landing descent. A vortex 50 is formed above deck 11 in vortex forming region 19 and is stabilized and strengthened by the movement of air through duct inlet openings 24, as shown in FIG. 6. This recreated vortex 50 provides an increased lifting force with a minimum of speed for aircraft 1, enabling a shorter runway to be utilized and with increased safety due to the low landing speed.
Fins 7 and 8 perform the usual stabilizing functions while the aircraft is in flight. Fins 7, which may extend vertically if desired, also assist in strengthening vortex 50 by partially enclosing vortex forming region 19. This enclosing reduces the effect of side winds on vortex 50 and assists in maintaining a low pressure within region 19. Vortex guide duct 21 may be eliminated within main body section 3 with the hollow interior thereof providing the region through which lower vortex sections 52 are formed without affecting the concept of the invention. Cylindrical duct sections 23 and duct bends 25, as shown in the drawings, are preferable to such a hollow frame interior since less turbulence is produced and a stronger vortex created with the cylindrical duct sections.
One of the major differences between the construction and operation of aircraft construction 1 in contrast to the free vortex aircraft construction disclosed in my Patent No. 3,934,844 is that the vortex forms almost a complete circle or closed path. Half of the vortex is outside of the aircraft in vortex producing region 19, with the other half of the vortex being located inside the aircraft in vortex guiding duct 21. The core of vortex 50 also is pumped by a single propeller 33 located within thruster duct 22 eliminating a pair of pumping engines. Outside portion 51 or vortex 50 is similar to the vortex produced in my previous free vortex aircraft and causes most of the lift on aircraft 1.
In order to maintain the vortex at a low pressure, it is necessary continuously to pump air from the core of the vortex, which is guided to propeller 33 through openings 30 which provide passages between vortex ducts 23 and thruster duct 22. The main function of vortex guide duct 21 is to serve as a conduit to guide the vortex to propeller 33. Relatively little suction is created at inlet openings 24 of the vortex ducts. The main air motion in the ducts is in the rotational motion of the vortex and not in linear motion through vortex ducts 23 and into and out of thruster duct 22. In fact, the vortex tends to prevent air from entering the vortex ducts except to replace the relatively small amount of air pumped from the vortex by propeller 33 in comparison to the extremely high speed air flow through thruster duct 22.
Accordingly, the improved free vortex aircraft construction provides a wingless aircraft can have various simple external configurations and in which the frame is nonrotating, thereby being suitable for human occupants; provides an aircraft which uses the principle of a free vortex to provide the lift for the aircraft during takeoff and landing procedures and when moving at low speeds, and in which the vortex producing shield and pumping means can be eliminated, enabling the speed of the aircraft to be increased considerably after takeoff; provides an aircraft construction in which only a single centrally mounted engine is required to provide the forward thrust and the vortex core pumping action, thereby reducing the cost of the aircraft, and which eliminates synchronizing problems and undesirable yaw which occur when a plurality of spaced engines are used; and provides a construction which is effective, safe, inexpensive and efficient in assembly, operation and use, and which achieves all the enumerated objectives, provides for eliminating difficulties encountered with prior devices, and solves problems and obtains new results in the art.
In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed.
Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described.
Having now described the features, discoveries and principles of the invention, the manner in which the improved free vortex aircraft is constructed and used, the characteristics of the construction, and the advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts, and combinations, are set forth in the appended claims. | An aircraft which produces a free vortex to provide the lift for takeoff and landing procedures has a single centrally mounted engine which supplies both the forward thrust to the aircraft and the spaced pumping action for strengthening and maintaining the free vortex. A shield on the aircraft causes the shedding of vorticity into a cavity-like region behind the shield. A vortex guiding duct extends transversely beneath the aircraft frame and has a pair of inlet openings at the ends of the cavity region. A thruster duct extends longitudinally centrally of the frame and communicates with the vortex duct. An engine is mounted in the thruster duct and supplies forward thrust for the aircraft while simultaneously pumping air from the ends of the cavity region through the vortex duct. This pumping action retains, augments and concentrates the vorticity and results in the formation of a generally circularly-shaped free vortex stretching transversely across the cavity region and through the vortex duct. Means are provided for retracting the shield simultaneously with the closing of the vortex duct inlets to extinguish the free vortex after the aircraft is in flight to enable the aircraft speed to be substantially increased. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an engine system, especially for vehicles equipped with an engine start-stop automatic system.
[0003] 2. Description of Related Art
[0004] Modern vehicles are equipped with engine systems that have an engine start-stop function. The engine start-stop function is used to shut down the engine, especially when an internal combustion engine is involved, if no torque is to be called for. This applies, above all, if it is to be expected that the torque will not be requested for a certain period of time. If the internal combustion engine according to this engine start-stop function has been shut down, in the case of requests for a drive torque, the internal combustion engine starts automatically, without the driver of the vehicle having to give a start instruction, such as by turning the ignition key, to start the internal combustion engine.
[0005] The engine start-stop function is used to save fuel, and therewith particularly to reduce the CO 2 emissions. However, shutting down the internal combustion engine and, above all, switching on the internal combustion engine leads to an increased stress on engine components subject to wear, such as the starter or components in the hydraulic system (fuel injection system) which, as a rule, are designed or constructed for a certain number of working cycles or activations.
[0006] Based on the engine start-stop function, under certain circumstances it is possible that a large number of start-stop processes of the internal combustion engine are executed over its lifetime. Because of this, individual components of the internal combustion engine may experience increased stress, and this may even lead to the maximum number of working cycles or activations, specified by the manufacturer, being exceeded. This leads to an increased risk of failure for the respective component and it is consequently able substantially to lower the service life of the internal combustion engine. Increasing the robustness of the respective components leads to greater cost, and is not cost-neutral.
BRIEF SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to provide a method and a device for implementing an engine start-stop function for a driving engine, which take into account the susceptibility to wear and the service life of components of the internal combustion engine, and ensure that the engine start-stop function is assured over the entire specified service life of the driving engine of the vehicle, or for the specified total mileage of the vehicle that is operated by the driving engine.
[0008] According to one first aspect, a method is provided for operating an engine start-stop function for a driving engine of a motor vehicle, especially for an internal combustion engine. The engine start-stop function, in this context, executes engine start-stop interventions in the form of an automatic shutting down and a subsequent automatic switching on of the driving engine, as a function of one or more vehicle states. An engine start-stop intervention determined by the engine start-stop function is released as a function of a statement on the number of starting processes of the driving engine carried out.
[0009] One idea of the above method is to control the execution of an engine start-stop intervention by the engine start-stop function as a function of the number of starting processes carried out up to that point. This may enable the user, for instance, to have uniform utilization of the engine start-stop function over the entire service life of the driving engine, without having permanently to deactivate the engine start-stop function at a certain point in time before reaching the service life of the driving engine, to protect individual components of the driving engine. Instead, reaching the highest possible released number of engine start-stop interventions might be made possible to the user only at the end of the provided service life of the driving engine, or at the end of the provided overall mileage of a motor vehicle operated using the driving engine. This is done by distributing the engine start-stop interventions over the entire service life of the driving engine.
[0010] Moreover, the engine start-stop interventions may be released as a function of a statement concerning a current mileage of the motor vehicle operated using the driving engine.
[0011] The engine start-stop intervention determined by the engine start-stop function may be released as a function of a utilization profile of the engine start-stop function, the utilization profile stating when the engine start-stop function will be restricted.
[0012] The utilization profile may, in particular, give a statement as to the number of admissible starting processes, as a function of current mileage, the restriction of the engine start-stop function being only carried out if a number of executed starting processes exceeds the number of admissible starting processes.
[0013] In order to avoid that a certain utilization profile of the engine start-stop function could lead to the number of admissible starting processes being reached or exceeded before the service life of the driving engine is reached, a strategy may thus be employed, as a function of the manner of utilization, which occasionally prevents the starting processes that are effected by the engine start-stop function. This is able to take place if the activation of the engine start-stop function leads to a number of engine start-stop interventions which no longer agrees with the admissible utilization profile or which would, purely mathematically, lead to the exceeding of the total number of admissible starting processes before the expiration of the service life of the driving engine.
[0014] Furthermore, the statement on the number of admissible starting processes may be given with the aid of a specified function, which defines the number of admissible starting processes as a function of the mileage of the vehicle.
[0015] According to one specific example embodiment, the statement on the number of executed starting processes may be ascertained in that the number of the starting processes effected by the engine start-stop function, that are a function of an operating variable, are taken into account, in particular, a fuel temperature or an engine temperature, in a weighted manner.
[0016] Moreover, it may be provided that an engine start-stop intervention determined by the engine start-stop function be always released as a function of a temperature of the driving engine and/or as a function of an initial mileage of the motor vehicle.
[0017] According to one additional aspect, a device is provided for operating an engine start-stop function for a driving engine of a motor vehicle, especially for an internal combustion engine. The device includes:
The engine start-stop functional unit for carrying out the engine start-stop function, executing engine start-stop interventions in the form of an automatic shutting down and a subsequent automatic switching on of the driving engine, as a function of one or more vehicle states, a limiting unit, in order to release an engine start-stop intervention determined by the engine start-stop function, as a function of a statement on the number of starting processes of the driving engine carried out.
[0020] According to one further aspect, an engine system is provided having the above device and a driving engine.
[0021] According to a further aspect, a computer program is provided, which includes a program code, which implements the above method when it is run on a data processing unit.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWING
[0022] FIG. 1 shows a schematic representation of an engine system having an engine start-stop function for a driving unit.
[0023] FIG. 2 shows a functional block diagram of a function for operating an engine start-stop function for a driving unit.
[0024] FIG. 3 shows a limiting strategy matrix for establishing a strategy for suppressing an engine stop specified by the engine start-stop function.
[0025] FIG. 4 shows an illustration of a limiting curve for limiting engine start-stop interventions.
[0026] FIG. 5 shows an illustration of a limiting curve for limiting engine start-stop interventions according to a further specific embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0027] FIG. 1 shows a schematic representation of an engine system 1 for operating a vehicle (not shown). Engine system 1 includes a driving engine 2 , which is developed particularly as an internal combustion engine. Other driving engines may also be provided, and for implementing the advantages, according to the present invention, driving engine 2 corresponds to a type that consumes energy or power in a stand-by operation, so that, under certain circumstances, shutting down driving engine 2 and switching on driving engine 2 when required, is more energy-efficient.
[0028] In the specific embodiment described, driving engine 2 is developed as an internal combustion engine which is controlled by an engine control unit 3 . For the control of internal combustion engine 2 , engine control unit 3 receives sensor signals SS from sensors (not shown) situated in internal combustion engine 2 . Engine control unit 3 generates control signals AS for controlling internal combustion engine 2 .
[0029] The control of internal combustion engine 2 takes place, as a rule, as a function of torque requests, such as the driver's torque command specified via the accelerator, and as a function of other torque requests, such as from an air-conditioning system.
[0030] Furthermore, an engine start-stop functional unit 4 is provided, which instructs engine control unit 3 to shut down internal combustion engine 2 as required, or to start internal combustion engine 2 again with the aid of a starter 5 . For this, the engine start-stop function implemented in engine start-stop functional unit 4 provides a switch-on and a shut-down signal for engine control unit 3 . Engine start-stop functional unit 4 may be developed in integrated fashion together with engine control unit 3 . When starts or starting processes based on the engine start-stop function are discussed below, this implies the entire process of shutting down and subsequent switching back on by the engine start-stop function, beginning with an automatic shutting down of the internal combustion engine.
[0031] Engine start-stop functional unit 4 stops internal combustion engine 2 and restarts it again automatically, when certain vehicle states are present. Internal combustion engine 2 may, for instance, be stopped by the engine start-stop function of the engine start-stop functional unit 4 , if a vehicle state is detected in which the vehicle is standing still, and it is to be expected that the standstill of the vehicle will exceed a minimum time. Furthermore, engine start-stop functional unit may instruct engine control unit 3 to shut down internal combustion engine 2 , if the requested drive torque is to be provided completely by an additional driving motor, such as an electric motor. In addition, the engine start-stop function may provide switching on internal combustion engine 2 again, if a drive torque is to be called for, for instance, when the driver of the vehicle operates the accelerator. At this point, we shall not go further into the exact design or implementation of the engine start-stop function.
[0032] Depending on the handling characteristics or the operating conditions of the vehicle, it may happen that the engine start-stop function requests a frequent or less frequent switching on or shutting down of internal combustion engine 2 .
[0033] Since, above all, switching-on processes of internal combustion engine 2 mean great stress for the components of internal combustion engine 2 , and also for the entire engine system 1 , individual components of engine system 1 are greatly stressed by frequent switching on.
[0034] Each of the components of engine system 1 is designed for a specified maximum service life, in the form of a statement of a maximum service life or a maximum number of switching cycles, actuation cycles, operating cycles and the like, which is given on the part of the manufacturer. If, for instance, the specified number of maximum actuating cycles for a component has been exceeded, the risk of failure of this component is statistically increased. Since the performance reliability of the individual components of internal combustion engine 2 , as a rule, is essential for the working order of internal combustion engine 2 , it should be avoided at all costs that a component is operated at a greater number of actuating cycles, and the like, than has been specified by the manufacturer.
[0035] The engine start-stop function does not normally take into account the number of admissible switching on and shutting down processes, of internal combustion engine 2 and the components in it. Depending on the strategy of the engine start-stop function applied, this may lead to the number of admissible actuating cycles of individual components being exceeded.
[0036] In the functional representation of FIG. 2 , a strategy is shown, using which it may be avoided that, during the intended overall service life of the vehicle, the number of actuating cycles of the components exceeds the manufacturer's specified maximum number. The functional representation shown in FIG. 2 is implemented in engine start-stop functional unit 4 .
[0037] FIG. 2 shows the engine start-stop function (MSS) that is implemented in MSS block 21 . MSS block 21 receives vehicle state signals FZ, which give the vehicle state, so as to decide whether internal combustion engine 2 is to be shut down or switched on according to a strategy for saving fuel and avoiding CO 2 emissions. At this point we shall not go further into the exact functioning method and the implemented strategy. The engine start-stop function is a function which is carried out automatically, without additional action on the part of the driver or a user of internal combustion engine 2 , that is, internal combustion engine 2 is able to be started and shut down by the engine start-stop function.
[0038] MSS block 21 has an additional input for receiving a release signal MSS. Release signal MSS indicates whether the engine start-stop function is allowed to be carried out or not. If release signal MSS is at a high level, the function of MSS block 21 is allowed to be carried out, while at a low level the function is suppressed, i.e. no performance of an engine start-stop function takes place. MSS block 21 suppresses shutting down internal combustion engine 2 if release signal MSS is at a low level, but allows it at a high level. Release signal MSS that is present has no effect on switching on internal combustion engine 2 , that is, internal combustion engine 2 is always switched on according to the engine start-stop function if the engine start-stop function has itself automatically shut down internal combustion engine 2 before, and switching on is requested according to the state of the vehicle.
[0039] In a limiting block 22 , release signal MSS is generated corresponding to a current start number difference d_A between a start number A_zul, that is currently admissible according to a mileage, and a statement on component utilization. The statement of component utilization may be given, for example, in the form of a statement on the entire number of engine starts C_start_rel, carried out during the current service life of the engine system.
[0040] The starts per mileage ratio ratio_A_FL and the admissible number of starts A_zul are ascertained and provided with the aid of a reference variable block 23 . For this purpose, reference variable block 23 receives a statement on the maximum number of admissible starts A_str_max, which are to be admitted during the service life of the engine system, and a statement on the maximum mileage FL_max of the vehicle using the engine system, in a unit of route distance in kilometers or miles, for example. Alternatively, the statement on maximum mileage FL_max of the vehicle may also be given in a time duration, such as in hours or days. The ratio of the maximum number of admissible starts A_str_max and the maximum mileage FL_max corresponds to the starts per mileage ratio ratio_A_FL. From the product of starts per mileage ratio ratio_A_FL and a statement on a current mileage FL_akt, which is given in the same unit (kilometers, miles, time duration) as the maximum driving performance FL_max, one obtains the currently admissible number of starts A_zul, which are output to a difference block 24 .
[0041] The relevant number of starts C_starts_rel is subtracted from the admissible number of starts A_zul, to obtain a start number difference d_A_start. Start number difference d_A_start is provided to limiting block 22 , and it states whether the number of starting processes of the internal combustion engine, carried out at the current mileage, deviates from the admissible number of starting processes in the positive or the negative direction. If start number difference d_A_start is negative, the number of starting processes carried out exceeds the number of admissible starting processes.
[0042] The relevant number of starting processes C_start_rel, which represents a statement of component utilization, is ascertained in a component utilization block 25 . In component utilization block 25 , in a first start counter 31 , the number of starting processes of internal combustion engine 2 carried out overall is counted with the aid of a start signal S_start, which gives each engine start. First start counter 31 is able to be incremented by start signal S_start. Present at the output of start counter 31 is a total start number value C_start_tot, which is passed on to a subtraction block 32 . Using a second start counter 33 , the starting processes of internal combustion engine 2 effected by MSS block 21 are counted. For this purpose, MSS start signal S_start_MSS is applied at the input of second start counter 33 , so that the total number of engine starts generated by the engine start-stop function is given at its output. MSS start number C_start_MSS is subtracted from the total start number C_start_tot, and this gives the normal start number C_start_Norm, which is passed on to a summing element 35 . Normal start number C_start Norm corresponds to a statement of the number of normal starting processes (effected by the user) of internal combustion engine 2 . MSS start number C_start_MSS is supplied to a weighting unit 34 , in which the number of MSS starting processes is weighted as a function of a fuel temperature T_fuel.
[0043] For this purpose, a statement on current fuel temperature T_fuel is supplied to a characteristics map block 36 , by which a weighting value is assigned to each fuel temperature T_fuel. The weighting value is supplied to weighting block 34 . The output of weighting block 34 gives the weighted number of motor starts C_start_MSS' generated by the engine start-stop function, and is guided to summation block 35 . In summation block 35 , the relevant number of engine starts is output as a statement on component utilization.
[0044] Limiting block 22 includes a limiting unit 41 , in which a release signal MSS is generated corresponding to start number difference d_A_start and corresponding to MSS start signal S_start_MSS of MSS block 21 , which states that an automatic engine start is to be admitted or not. In principle, limiting unit 41 works in such a way that, in the case of a positive start number difference d_A_start or in the case of a start number difference d_A_start of 0, release signal MSS is set to a high level, so that each automatic engine start is admitted.
[0045] In the limiting strategy matrix of FIG. 3 , the columns correspond to start number difference d_A_start and the rows correspond to successive engine stops in a unit of route distance, such as 1 km or in a time unit, such as 1 min, requested by MSS block 21 . At the end of a unit of route distance or time unit, counting starts over again. The entries in the matrix correspond to release signal MSS. As may be seen from the matrix, in the case of a start number difference d_A_start of −1 to −3, only every other engine stop is admitted by the engine start-stop function, while in the case of a start number difference of −4 or −5, only every third, and, in the case of a start number difference of −6 only every fourth automatic engine stop is admitted. Beginning at a start number difference d A start of −7 or less, no further automatic engine stop is admitted according to the engine start-stop function. The specific assignment of start number difference d_A_start to the ratio and to the sequence of admitted engine stops and suppressed engine stops may be allocated almost at will. It is meaningful, however, not to admit any further automatic engine stops below a start number difference.
[0046] FIG. 4 shows the number of starts plotted against mileage FL. The solid line corresponds to the number of admissible starts A_zul plotted against the mileage, while the dashed line shows the actual number of engine starts. Furthermore, a release decision block 26 is provided which decides whether the engine start-stop function is controlled in limiting block 22 , that is, as a function of release signal MSS, or released permanently. This is carried out by providing a multiplexer 51 at whose first input release signal MS of limiting block 22 is applied, and at whose second input a permanent high level is applied. As a function of a control signal ST, the high level is either permanently applied to MSS block 21 as a release signal, in order to activate the engine start-stop function permanently, or release signal MSS is switched through by limiting block 22 to MSS block 21 , so as to activate or deactivate the engine start-stop function according to the limiting function that is implemented in limiting unit 41 .
[0047] Control signal ST is generated as a function of engine temperature T mot and as a function of current mileage FL_akt. The low level of control signal ST, which as release signal permanently outputs the high level to MSS block 21 , is generated with the aid of an AND block 52 if either engine temperature T mot is less than an engine temperature boundary value T mot —lim , as established by a first comparative unit 53 , or current mileage FL_akt is less than a minimum mileage FL_akt_lim (such as 1000 km), which describes a new state of the engine system or the motor vehicle. When these conditions are present, the limiting strategy is not to be executed. This means that restrictions of the function of MSS block 21 are only carried out at an engine temperature T mot above an engine limiting temperature TMot_lim and at a mileage FL above a minimum mileage FL_akt_lim.
[0048] In the abovementioned specific embodiment, reference variable block 23 generates the starts per mileage ratio ratio_A_FL according to the specified number of maximum starts A_str_max and maximum mileage FL_max, and ascertains the admissible number of starting processes A_zul as a function of the statement on current mileage FL_akt. Alternatively, a characteristics map unit may also be provided which, as a function of current mileage FL_akt reads out an admissible number of starting processes, so that, by contrast to characteristics curve of FIG. 4 , linear curves of the number of admissible starting processes A_zul plotted against mileage FL are also not possible. This is illustrated in FIG. 5 , for example, for the first one hundred thousand starting processes a higher slope, having 2.5 starts per kilometer being set, between the 100,000 th starting process and up to the 200,000 th starting process a reduced slope of 1.5 starting processes per kilometer being set, from the 200,000 th up to the 300,000 th starting process the slope being reduced to 1.2 starting processes per kilometer and the last starting processes being set within the admissible service life of the 300,000 th to 350,000 th starting process being set at a slope of one starting process per kilometer, in order to achieve the target of 350,000 starting processes per 240,000 kilometer. The limiting strategy of limiting block 22 is not impaired by this.
[0049] If the provided maximum mileage FL_max is reached or exceeded, it may be provided, on the one hand, completely to release the limitation by limiting block 22 , that is, to leave release signal MSS permanently at a high level, and thus to release the engine start-stop function generally, or it may be provided generally to prevent the engine start-stop function and thus to increase as much as possible the remaining service life of internal combustion engine 2 , by minimizing to the greatest extent possible additional wear of the components. Any other strategy for applying the engine start-stop function after the expiration of the maximum mileage is also conceivable. | In a method for operating an engine start-stop function for an engine of a motor vehicle, the engine start-stop function executes engine start-stop interventions in the form of an automatic shutting down and a subsequent automatic switching on of the engine, as a function of one or more vehicle states. An engine start-stop intervention determined by the engine start-stop function is selectively prevented as a function of a statement on the number of starting procedures of the engine carried out. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 12/334,257, filed Dec. 12, 2008, which is herein incorporated by reference in its entirety.
TECHNICAL FIELD
This invention relates in general to computing, and in particular, to search engines used in general computing environments. More specifically, but without restriction to the particular embodiments hereinafter described in accordance with the best mode of practice, this invention relates to methods and apparatus for obtaining result diversification when using a search engine in a computing environment to obtain a listing of results upon execution of a search query.
BACKGROUND
Today's search engines follow a decade old paradigm in presenting search results to a user. In response to a user query, typically expressed in the form of a few keywords and often times just one or two words, current search engines use a proprietary ranking algorithm to return documents deemed most relevant to the query. The factors that go into the computation of the relevance of a page include the authoritativeness of other pages on the web pointing to the page under consideration and the number of people accessing the page (via clicks) to name a few.
A key problem in the above paradigm is that the meaning of keywords used for expressing a query is often ambiguous. It is thus difficult for the search engine to correctly ‘guess’ user intent and return results that satisfy the actual intent of the specific user asking the query. For example, given the query flash, different users may be looking for very different information when they ask this query. A first user may be looking for the Adobe Flash player, while a second might may be interested in information about Flash Gordon, the adventure hero, and a third user may be interested in the location Flash, which happens to be the village with the highest elevation in England. In general, a very large number of queries, particularly the short, popular ones, belong to multiple categories of information and have multiple interpretations.
Current engines do not consider multiple possible intents of a query when presenting the search results. Consider again the query flash. In a recent sampling conducted by the inventors hereof, the first result page for this query on live contained eight documents related to Adobe Flash, one related to camera flash, and one related to the band, Grandmaster Flash. Similarly on Google, the first result page contained seven documents related to Adobe Flash, one related to the Stanford Flash project, one related to home security system, and one related to an online music store. Clearly, the first user described above would be satisfied with these search results, but the second and third would not.
SUMMARY
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to limit the scope of the claimed subject matter.
With the above thus in mind, an embodiment of the present invention is directed to a new paradigm for determining and presenting results of a search query that minimizes the risk of dissatisfaction with search results for any arbitrary user. The invention can easily be extended to the case of minimizing dissatisfaction of a respective particular user, taking into account interests of such a specific user. One specific embodiment of this invention includes the existence of a taxonomy of information. A user query can belong to one or more categories of this taxonomy. Similarly, a document can belong to one or more categories.
Thus, instead of presenting results in the order of one authority score computed by the ranking algorithm, an embodiment of the present invention determines the categories to which a query belongs, then ranks the categories, and finally presents relevant results in each category. Specifically, the invention includes a method that computes the number of categories to present for a given query; computes the number of results to show in each category; computes an ordering of categories; and for all the result pages beyond the first page uses user interface elements that optionally allow the user to quickly zoom in on a specific category and get more results belonging to that category. Alternatively, an embodiment of the present invention takes into account a user profile to order the categories.
More specifically now according to certain embodiments of the present invention, there is provided a method for listing documents found in a search given an input query. One specific embodiment of this method includes the steps of providing a taxonomy for categorizing documents and queries, providing an authority score for each document to be retrieved, receiving a search query from a user, assigning a probability that the search query is in at least a first category of the taxonomy, assigning a probability that the search query is in at least a second category of the taxonomy, retrieving at least one document from the first category, retrieving at least one document from the second category, and returning a search result for the search query by listing documents from the at least first and second categories in an order that takes into account the probabilities for each category and the authority score for each of the retrieved documents. This method may include the further the step of calculating a specified number of categories to present for a respective search query where the specified number of categories is two or greater. The method may also advantageously further include the step of calculating a specified number of documents to present within each of the specified number of categories. And in a particular embodiment thereof, the method may include the step of calculating an ordering of each of the specified number of categories. Generally, in performing this method, each of the specified number of categories is assigned a probability that the search query is in that particular category of the taxonomy. The sum of all the probabilities of each of the specified number of categories is equal to one for purposes of practicing this aspect of the present method. The method may also include the further step of retrieving at least one document from each of the specified number of categories. In practicing this embodiment of the method when a first document listed in a first ordered category has an authority score of 1.0, the next listed document is from the second ordered category. Here according to another particular aspect, the listed document from the second ordered category has the highest authority score of all documents retrieved in the second ordered category.
In accordance with another aspect of this invention, there is provided a networked computer system for use in listing documents found in a search given an input query. The system may advantageously include stored documents capable of being searched and retrieved electronically; memory for storing a search engine including a ranker and executable methods of searching for desired types of the stored documents; an input device for inputting a search query directed to retrieving a respective collection of the desired types of the stored documents; a processor operatively linked to the input device for processing the search query; and a browser operatively associated with the processor for cooperatively engaging the front end of the search engine so that when the search engine receives the search query from a user, the search engine retrieves a set of the stored documents relevant to the search query, each document within the set having an authority score and belonging to a category within a taxonomy and the ranker lists each document within the set in an order that takes into account the probability for each category being relevant to the search query and the authority score for each of the retrieved documents. In this system, the ranker calculates a specified number of documents to present within each of the categories, and may also calculate a specified number of categories to present to the user in response to processing the search query.
According to another aspect of certain embodiments of the present invention there is further provided a specific method of listing documents found in a search given an input query. This embodiment includes the steps of representing a probability of a respective query q in category c by P(c|q); representing by Q(d|q, c) a quality value of a document d for the query q belonging to the category c in the range [0,1] for each of the documents d; representing a utility vector by U(c|q) and setting its initial value to the P(c|q) wherein when a respective document is selected for display within the category c, the value of U(c|q) will decrease depending on the values of Q(d|q, c); and selecting k documents for displaying on a page where a set of k documents, S, out of a document set D is derived such that
max
S
(
D
∑
c
P
(
c
)
(
1
-
∏
d
∈
S
(
1
-
Q
(
d
|
c
)
)
)
.
Here the results produced by executing the respective query on a ranking algorithm are denote by R(q), and the ranking algorithm may advantageously be classical. Also here for an input q, C(q), R(q), ∀dεR(q), C(d) the following steps may be further are performed: (1)S={ }. U(c)=P(c) for all cεC(q); (2) choose an order of categories to be displayed based on U(c) and reorder C(q); and (3) for each category cεC(q) do; (a) for each document dεR(q), compute g(d, c)=U(c)Q(d|c); (b) add the document d* with the largest g(d, c) to S with ties broken arbitrarily; (c) for each category cεC(d*), update U(c)=(1−Q(d*|c)) U(c); and (d) set R(q)=R(q)\d*. And further this method may include, while |S|<k, the following steps (i) for each document dεR(q) compute g(d, c)=U(c)Q(d|c), for all cεC(d); (ii) add the document d* with the largest g(d, c) to S with ties broken arbitrarily; (iii) for each category cεC(d*), update U(c)=(1−Q(d*|c)) U(c); and (iv) set R(q)=R(q)\d*. Here the steps may be repeated for succeeding pages, and the distribution U(c) may carry over from the end of execution of a previous page and is not re-initialized at the beginning of every page.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
Further aspects and characteristics of the embodiments of the present invention together with additional features contributing thereto and advantages accruing therefrom will be apparent from the following description of certain embodiments of the invention which are shown in the accompanying drawing, wherein:
FIG. 1 is a block diagram representing typical elements in a computer operating environment in which embodiments of the present invention may be implemented;
FIG. 2 is a pictorial representation of a computer system network including a search engine and electronically stored and searchable documents;
FIG. 3 is a graphical representation illustrating categories and retrieved documents with authority scores and a listing of the results under prior art methods as compared to one method embodiment of the present invention;
FIG. 4 is a graphical representation of an initial step in a method hereof showing how the retrieved documents with authority scores of FIG. 3 are scaled according to one aspect of the present invention;
FIG. 5 is a graphical representation of a recalibration step utilized in the method initiated in FIG. 4 ;
FIG. 6 illustrates a scaled authority scoring step in a second iteration of the method continued from FIG. 5 ;
FIG. 7 is a graphical representation of a recalibration of a probabilities step utilized in the method continued from FIG. 6 ; and
FIG. 8 is a graphical representation of the reiterative scaling and recalibrating steps of this method illustrating final results thereof.
DETAILED DESCRIPTION
The subject matter of the embodiments of the present invention is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of the claims of any patents issuing hereon. Rather, the inventors have contemplated that the claimed subject matter might also be embodied in other ways, include different steps or combinations of steps similar to the ones described herein, or used in conjunction with other present or future technologies. Moreover, although the terms “step” and/or “block” may be used herein to connote different elements of methods employed, the terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly described.
Having briefly described above an overview of certain embodiments of the present invention, an exemplary operating environment for the various embodiments of this invention is next described. Referring now to FIG. 1 , an exemplary operating environment for implementing embodiments of the present invention is shown and designated generally as computing system or device 100 . Computing device 100 is just one example of a suitable computing environment and is not intended to suggest any limitation as to the scope of use or functionality of the invention. The inventors hereof envision that the inventions disclosed herein may be readily applied in a wide range of computing devices, systems, or environments whether networked or stand alone including for example, desktop PCs, hand-held computing devices, navigation systems, digital radios, home entertainment systems, and any other known or future computing environment where the display of the results of a query obtained by a search engine is desired. Thus the computing environment 100 should not be construed as having any particular dependency or requirement relating to any one or combination of the components or modules illustrated. Certain aspects and embodiments of the present inventions may be described in the general context of computer code or machine-useable instructions, including computer-executable instructions such as program components, being executed by a computer or other machine, such as a personal data assistant or other handheld device as discussed above. Generally, program components including routines, programs, objects, components, data structures, and the like, refer to code that performs particular tasks, or implement particular abstract data types. Embodiments of the present invention may be practiced in a variety of system configurations, including hand-held devices, consumer electronics, general-purpose computers, specialty computing devices, and so forth, whether known today or developed subsequently hereto. Embodiments of the invention may also be practiced in distributed computing environments where tasks are performed by remote-processing devices that are linked through a communications network.
With continued reference to FIG. 1 , computing system 100 includes a bus 110 that directly or indirectly couples a memory 112 , one or more processors 114 , one or more presentation components 116 , input/output (I/O) ports 118 , I/O components 120 , and an illustrative power supply 122 . Bus 110 represents what may be one or more buses such as those that may include an address bus, a data bus, or a combination thereof. Although the various blocks of FIG. 1 are shown with solid line connections which may represent a hard wire connection, any one or more of the elements may be wirelessly connected where desired, appropriate, or technically feasible. In addition thereto, certain hardware/software implementations hereof may include a wide variety of various components and functionalities so the elements illustrated in FIG. 1 are to be taken only as exemplary and not limiting in any intended or particular manner. For example, one may consider a presentation component such as a display to be both an input and output component since some current displays with touch features allows a user to manipulate on screen displayed items. Also, processors have memory as those skilled in the art would readily appreciate. The inventors hereof recognize that such is the nature of the art, and reiterate that the diagram of FIG. 1 is merely illustrative of an exemplary computing device or system that can be used in connection with one or more embodiments of the present invention. Distinction is not made between such categories as “workstation,” “server,” “laptop,” “hand-held device,” or the like, as all are contemplated within the scope of FIG. 1 and reference to as “computer”, “computing device”, or “computing system.”
Now more specifically, the computer 110 typically includes a variety of computer-readable media. Computer-readable media includes any available media that can be accessed by computer 110 and encompasses both volatile and nonvolatile media, as well as removable and non-removable media. By way of example, and not limitation, computer-readable media may include computer storage media and communication media. Computer storage media includes such volatile and nonvolatile, 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. More specifically, computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile discs (DVD) or other optical disc storage such as Blu-ray or HD-DVD, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which may be used to store the desired information and which can be accessed by computer 110 . Communication media typically embodies 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 includes 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, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared, and other wireless media. Combinations of any of the above should also be included within the scope and meaning of computer-readable media.
Memory 112 includes computer-storage media in the form of volatile and/or nonvolatile memory. The memory 112 may be removable, non-removable, or a combination thereof. Exemplary hardware devices include solid-state memory, hard drives, optical-disc drives, and other such current or future devices that would provide the desired functionality. Computing device 100 includes one or more processors 114 that read data from various entities such as memory 112 or I/O components 120 . Presentation component(s) 116 present data and/or sensory indications to a user or other device. Exemplary presentation components include a video display, speaker, printing component, vibrating component, and any such current or future presentation components. I/O ports 118 allow computing device 100 to be logically coupled to other devices, including I/O components 120 , some of which may be built in. Illustrative components include a microphone, joystick, game pad, satellite dish, scanner, printer, wireless device, and others as desired, appropriate, or technically feasible.
With reference next to FIG. 2 , there is shown a pictorial representation of a computer system network including a search engine and electronically stored and searchable documents. FIG. 2 shows a graphical representation of a search engine 124 , a taxonomy 126 , a representation of the Internet 128 , and a graphical representation of search results 130 . As would be apparent to those of skill in the art, there are various search engines available and such search engines are readily accessed via a computer device as enabled with Internet access. The typical search engine is a bundle of software components residing typically in a distributive computing system including a number of linked servers. The search engine may include a ranker or dynamic ranker component or module. As would be appreciated by those of skill in the art given the present disclosure, the methods hereof when embodied in software as executable code would reside with and interact with such a dynamic ranker. Further, the typical search engine has a front end which interacts with an Internet browser, for example, which browser would typically reside on the hard drive of a personal computer or hand-held computing device. Thus when a user of a personal computer types a search query, the processor of his personal computing devices interacts with the local browser, which in turn interacts with the front end of the search engine, which then engages the ranker to execute the required search over the various documents stored and available generally from the Internet.
As further understood by those of skill in the art, the taxonomy 126 provides a hierarchy and categorization for documentation which is electronically stored and retrievable from various websites and servers within a computer network such as the Internet. Search results 130 based on a search query are typically tabulated, listed, or otherwise presented in some fashion by search engines and their associated hardware and software including a dynamic ranker, on a video display monitor accessible by the user and part of the user's personal computing device.
Next with reference to FIG. 3 , there is presented a graphical representation of categories and retrieved documents with authority scores and a listing of the results under prior art methods as compared to one embodiment of the present invention. On the input side the documents have been categorized under two categories as shown. These include Category A and Category B. As indicated, Category A has a probability of 0.8 that the search query is within the Category A of the taxonomy and Category B has a probability of 0.2 that the search query is within Category B. As further indicated, Category A includes documents A1 with a priority score of 0.7, A2 with a priority score of 0.6, A3 with a priority score of 0.4, and document A4 with a priority score of 0.3. Similarly, Category B includes documents B1 with a priority score of 0.8, document B2 with a priority score of 0.5, and document B3 with a priority score of 0.2.
The output portion of FIG. 3 illustrates the listing of the retrieved documents on the input side under three different methodologies. Under the Proportional methodology know in the prior art, first document A1 is listed with an authority score of 0.7, next listed is A2 with an authority score of 0.6, then listed is A3 with an authority score of 0.4, next is document A4 with an authority score of 0.3, and lastly here under the Proportional methodology is document B1 with an authority score of 0.8.
Under the Authority method of the prior art methodologies, document B1 with the highest authority score of 0.8 listed first, document A1 with the next highest authority score of 0.7 is next listed, document A2 with the next highest authority score of 0.6 is then listed third, document B2 with the next highest authority score of 0.5 is then listed, and lastly listed is document A3 with an authority score of 0.4.
According to the methodologies of the current invention, referred to briefly herein for convenience as “Diversification”, the documents on the input side as show in FIG. 3 would be listed as illustrated which includes a first listing of document A1 having an authority score of 0.7, then listed second is document B1 with an authority score of 0.8, third listed is document A2 with an authority score of 0.6, next listed is then document A3 with an authority score of 0.4, and then lastly listed is document B2 with an authority score of 0.5. It will be readily appreciated by those with the skill in the art that listing the documents in accordance with the present methodologies departs from the traditional methods such as Proportional and Authority. Here, according to the present methodology document A1 is listed first since the probability of Category A being relevant to the search is 0.8. Under the present methodology, if a user is not interested in the Category A1 document with the authority score of 0.7, the next listed is document B1 with an authority score of 0.8. This gives better efficiency and user satisfaction since it is believed that a user bypassing document A1 would next be then interested in documents from Category B with higher authority scores notwithstanding the lower probability of 0.2 that the search query is within Category B. Thus in this manner if a users is actually looking for documents from Category A given the 0.8 probability associated therewith, the highest authority score document in Category A is listed first. However, if in fact the user is not interested in Category A documents then the user will find the highest ranked document from B1 next listed. Thus, according to the teachings hereof, in the case of a user desiring documents from B1 the user reaches the first document with the highest priority score without having to look through other documents from A1. Therefore, it should be understood that the present method of Diversification is based on importance as measured by authority score scaled by probability.
Now with reference to FIG. 4 , there is shown a graphical representation of an initial step in one embodiment of a method hereof showing how the retrieved documents with authority scores of FIG. 3 are scaled according to one aspect of the present invention. FIG. 4 shows the initial input under a 1st Iteration in that Category A has a probability again here as 0.8 with Category B having a probability of 0.2. The documents under Category A and Category B show the initial priority scores as presented above in FIG. 3 . Under a first step, the authority scores are scaled according to the relative probabilities in categories Category A and B. Here it should be understood by those skilled in the art that in the case of three categories, the same methodology would apply with the probabilities of the three categories adding to a total probability of 1.0. Thus as shown under the Scaled Authority Scores in FIG. 4 , in Category A with a probability of 0.8, document A1 will have a scaled score of 0.56 which is derived by taking its original priority score of 0.7 and as illustrated, multiplying it by 0.8 the probability associated with Category A. Next document A2 has a scaled authority score of 0.48 derived again by taking the original authority score of 0.6 and multiplying by the probability 0.8. Thus in this manner the scaled authority score for document A3 is 0.32 and the scaled authority score for document A4 is 0.24. Similarly now with Category B documents illustrated in FIG. 4 the original authority score of document B1 is multiplied by 0.2, the probability that the search query is in within Category B, which results in a new scaled authority score for document B1 of 0.16. Similarly, document B2 has the new scaled authority score of 0.10, and document B3 has a new scaled authority score of 0.04.
FIG. 5 is a graphical representation of a recalibration step utilized in the method initiated in FIG. 4 . Now as shown in FIG. 5 , document A1 is selected and the next step according to the present methodology is to recalibrate the probability of Category A. Thus, here according to an embodiment of the present invention, the initial probability of Category A which started at 0.8 is here reduced by the new authority score of document A1 such that the recalibrated probability of Category A becomes, as illustrated, 0.24. Here at this step as further illustrated in FIG. 5 the Category B probability remains at 0.2.
FIG. 6 next illustrates a scaled authority scoring step in a second iteration of the method continued from FIG. 5 . Now here as shown under the 2nd Iteration, the Category A probability stands at 0.24, and document A1 has been selected for listing first as shown in the Results Output of FIG. 8 . Thus the first document now remaining under Category A is document A2 with an original authority score of 0.6. Here as indicated the next step is to scale the authority score of each of the remaining documents in categories A and B. Thus with the new probability of 0.24 in Category A, the original authority score of 0.6 of document A2 is multiplied by the new scaled probability of 0.24 to result in a new priority score of 0.14. Similarly the original authority score of document A3 which was 0.4 is multiplied by the new 0.24 probability of Category A to result in a new 0.10 authority score for document A3. Finally, document A4's new authority score is 0.07 which is similarly derived by taking its original authority score of 0.3 and multiplying that by the revised probability of Category A as illustrated. Now similarly in continuing with reference to FIG. 6 , the new scaled authority scores for document B1 is derived by multiplying its original authority score of 0.8 by the current probability of 0.2 to result in a new scaled authority score of 0.16. In this manner the new scaled authority score for document B2 is 0.10 as illustrated and the new authority score for document B3 is 0.04.
Next shown in FIG. 7 is a graphical representation of a recalibration of probabilities step utilized in the method continued from FIG. 6 . As shown here in FIG. 7 , document B1 with a revised authority score of 0.16 is selected next for listing in the output search result shown in FIG. 8 under the Results Output. Now here the probability of Category B is recalibrated by taking the original probability of Category B which was 0.2 and reducing that by the new priority score of document B1 which is 0.16 to arrive at a new recalibrated probability for Category B which is 0.04, as illustrated. Thus, as finally illustrated in FIG. 7 at this point in this method embodiment of the present invention, Category A has a revised probability of 0.24 and Category B now has a recalibrated probability of 0.04.
FIG. 8 is a graphical representation of the reiterative scaling and recalibrating steps of this method illustrating final results thereof under the Results Output. As illustrated here in FIG. 8 , the methodology proceeds with a 3rd scaling. Here at this stage in the process, documents A1 and B1 have been consecutively listed, Category A has the revised probability of 0.24, and Category B has the revised probability of 0.04. Applying the recalibration methodology here at the 3rd stage, Category A then results in a new probability of 0.10. And as continued under the 4th scaling iteration document A3 now has an authority score of 0.04 and document A4 has a new authority score of 0.03. Thus document A3 is selected and next list in the Results Output.
Next at the 4 th recalibration, the probability of Category A is reduced to 0.06 and to complete the method the priority score of document A4 is reduced to 0.01. Since here it is desired to list only 4 documents in the Results Output, the method illustrated here discontinues at the 5 th scaling for completeness.
As indicated above for purposes of the present disclosure, the existence of a taxonomy of information is assumed and the queries and documents relevant thereto are categorized according to this taxonomy using well-known techniques. Next for purposes of illustration and discussion, we denote the set of categories to be C, and assume that each query belongs to certain categories according to a certain distribution which is known. For example, take the query flash.
TABLE 1
Categorization of the Keyword flash
Category
Probability
Technology
0.55
Fictional Characters
0.20
Popular Culture
0.13
People
0.12
Locations
0.05
Next we denote the probability of a query q in category c by P(c|q). Thus, P(flash|Technology) is equal to 0.55 in the above example.
A simple prior art scheme for determining the number of documents to show from a category on a page is proportional allocation. This scheme, however, is not satisfactory. Coming back to the Flash example, this scheme might suggest that we should show six documents related to the technology interpretation of the query, which would cause six documents related to Adobe Flash to be displayed on Live (or Google). On the other hand, having selected the Adobe Flash player as the first result to show, the utility of showing additional documents in this category is suspect.
For each document d, represent by Q(d|q, c) the quality (value) of a document d for query q belonging to category c in the range [0,1]. The quality of a document for a query belonging to a certain category is assumed to be independent of the quality of other documents. Quality is used as a proxy for various measures such as the likelihood of the document satisfying the user intent in issuing the query. Q is given a probability interpretation and it is assumed that
∑
c
Q
(
d
|
q
,
c
)
=
1.
In the allocation scheme according to the various embodiments hereof, a notion of the utility of a category in satisfying a user query q is employed. This utility vector is represented by U(c|q) and its initial value will be set to P(c|q). As a document is selected for display within category c, the value of U(c|q) will decrease depending on the values of Q(d|q, c).
Now consider an example where only two categories c 1 and c 2 for a given query q exist. Assume that the search engine corpus contains 10 documents each from the two categories. Furthermore, let the quality of documents in c 1 , Q(d|q, c 1 ), be described by the distribution 0.6, 0.20, 0.10, 0.05, 0.025, 0.0125, 0.00625, 0.003125, 0.0015625, while the quality of documents in c 2 , Q(d|q, c 2 ), is uniform, i.e., 0.1 for each of the 10 documents. Under these distributions, the utility of c 1 decreases more than the utility of c 2 from the user's perspective as documents each belonging to the respective categories are added to the result set. Having added a high quality document to c 1 , the marginal utility of adding a document of lower quality in c 1 is low. On the other hand, since documents belonging to category c 2 are of the same quality and therefore have equal chance of satisfying the user query, the marginal utility of adding another document to c 2 does not decrease.
Result diversification according to the teaching hereof is next present in a formal manner. Here it is assumed that the search engine shows at most k results on a page (k is usually 10).
For purposes of clarity and convenience henceforth herein, each query will be considered independently the reference to q will be dropped. Instead, P(c), Q(d|c), and U(c) will be employed with the knowledge that these quantities are defined with respect to a given query.
The problem if selecting k documents for displaying on a page is as follows:
Diversify(k)
Find: a set of k documents, S, out of the document set D, such that
max S ( D ∑ c P ( c ) ( 1 - ∏ d ∈ S ( 1 - Q ( d | c ) ) ) .
Denote by R(q) results produced by executing the query on the classical ranking algorithm. The documents from R(q) will be selected and displayed using the present methodology.
Greedy Algorithm:
Input: q, C(q), R(q), ∀d ∈ R(q), C(d)
1. S = { }. U(c) = P(c) for all c ∈ C(q).
2. Choose the order of categories to be displayed based on U(c) and
reorder C(q)
3. for each category c ∈ C(q) do
a. for each document d ∈ R(q), compute g(d, c) = U(c)Q(d | c)
b. add the document d* with the largest g(d, c) to S with ties
broken arbitrarily
c. for each category c ∈ C(d*), update U(c) = (1 − Q(d* | c))
U(c)
d. R(q) = R(q)\d*
4. while |S| < k do:
a. for each document d ∈ R(q) compute g(d, c) = U(c)Q(d | c),
for all c ∈ C(d)
b. add the document d* with the largest g(d, c) to S with ties
broken arbitrarily
c. for each category c ∈ C(d*), update U(c) = (1 − Q(d* | c))
U(c)
d. R(q) = R(q)\d*
The above algorithm is repeated for succeeding pages. It should be understood that the distribution U(c) carries over from the end of execution of the previous page and it is not re-initialized at the beginning of every page.
In the special case where each document belongs to a single category, i.e., Q(d|c)=v>0 for exactly one category, the algorithm described can be further simplified. Thus in this embodiment hereof, the method may be started by grouping the documents according to their category, and sorting these documents in decreasing order of Q(d|c). In step 3a, it is necessary only to compute g(d, c) for the documents in the head of the respective queues. In step 3c, it is only needed to update the U(c) for the category out of which a document is chosen in step 3b.
In further view of the detailed description discussed above, next provided are illustrative examples of some of the described methods which employ the variables so indicated therein. For purposes of further clarity each of the inventive examples is followed by a brief comparison to a typical naive allocation methodology as would be applied to the given parameters of the subject example.
Example 1
For the search query, let C1 represent the first category in the taxonomy, and C2 represent the second category in the taxonomy. Let P1 represent the likelihood that the user query belongs to C1, and for this example let P1 equal 0.9. Further let P2 represent the likelihood that the user query belongs to C2, and let P2 in this example equal to 0.1. Now according to the taxonomy, let the search query identify three documents in C1 which include D1 with an authority score of 1.0, D2 with an authority score of 0.4, and D3 also with an authority score of 0.4. Now further let the search query identify three documents in C2 which include D1 with an authority score of 0.5, D2 also with an authority score of 0.5, and a D3 with an authority score of 0.3. Now according to the methods hereof in the case where 3 documents are returned, the search result for the query given the above will first return C1D1 with authority score 1.0, then return C2D1 with authority score 0.5, and lastly return C2D2 also with an authority score of 0.5. Thus here, if the query does not belong to C1 given that C1D1 has an authority score 1.0, it is thus 100 percent certain that the user would next be interested in documents from C2. Now similarly, in the case where 4 documents are returned by this method under this Example 1, the results for the first, second, and third returns will be as above with C1D1, C2D1, and C2D2, consecutively listed, then in fourth position C2D3 with an authority score of 0.3 since we know with certainty that the user is not interested in C1.
In contrast to the above, the simple methods of the prior art (using, say, proportional allocation), given the above example parameters, would list C1D1, C1D2, and C1D3 in that order when limited to three returns; thus preventing any C2 returns. And when returning four returns, the prior art would list C1D1, C1D2, C1D3, and then C2D1 thereby forcing the user to look at C1D2 and C1D3 with authority scores of 0.4 and 0.4 respectively before listing C2D1 with a higher relative authority score of 0.5; thereby illustrating the absence of recognizing that if the user was not interested in C1D1 with an authority score of 1.0, such a user's query most likely does not fall with C1 and thus the next listed document should be from C2 which is more likely to satisfy the user's information need.
Example 2
Next for the search query of this Example 2, let C1 similarly represent the first category in the taxonomy, and C2 represent the second category in the taxonomy. Let P1 again represent the likelihood that the user query belongs to C1, but now for this example let P1 equal 0.6. Further let P2 again represent the likelihood that the user query belongs to C2, with P2 here in this example equal to 0.4. Now again according to the taxonomy, let the search query identify three documents in C1 which include D1 with the authority score of 1.0, D2 with the authority score of 0.4, and again a D3 also with an authority score of 0.4. Now again let the search query identify three documents in C2 which here again include a D1 with an authority score of 0.5, a D2 also with the authority score of 0.5, and a D3 with the authority score of 0.3. Now according to the methods hereof in the case where 3 documents are returned, the search result for the query given the above will again first return C1D1 with authority score 1.0, then return C2D1 with authority score 0.5, and lastly return C2D2 also with an authority score of 0.5. Thus here again, if the query does not belong to C1 given that C1D1 has an authority score 1.0, it is thus certain that the user would next be interested in documents from C2. Now similarly, in the case where 4 documents are returned by this method under this Example 2, the results for all the positions will be as above with C1D1, C2D1, C2D2, and C2D3 consecutively listed.
In contrast to the above, the naive allocation using proportional allocation methods of the prior art, given the above parameters in this Example 2 with P1 just greater than P2, would list C1D1, C1D2, and C2D1 in that order when limited to three returns; thereby still listing a second document from C1 before the first listed document from C2 even though it would be certain that a user bypassing C1D1 with the 1.0 authority score would next be interested in C2. And then when returning four returns, the prior art here would list C1D1, C1D2, C2D1, and then C2D2 thereby again illustrating the absence of recognizing that if the user was not interested in C1D1 with the absolute authority score of 1.0, such a user's query most highly likely does not fall within C1 and thus the next listed document should be from C2 to optimize user satisfaction.
Example 3
Now for the search query in this next Example 3, let again C1 similarly represent the first category in the taxonomy, and C2 represent the second category in the taxonomy. Let P1 again represent the likelihood that the user query belongs to C1, and again for this example let P1 equal 0.6. Further let P2 also represent the likelihood that the user query belongs to C2, with P2 here again in this example equal to 0.4. Now again according to the taxonomy, let the search query identify three documents in C1 which include D1 with a different authority score of 0.6, a D2 with an authority score of 0.4, and again a D3 also with an authority score of 0.4. Now again let the search query identify three documents in C2 which here again include a D1 but now with an authority score of 0.7, a D2 also with the authority score of 0.5, and a D3 with the authority score of 0.3 as in Examples 1 and 2 above. Now according to the methods hereof in the case where 3 documents are returned, the search result for the query given the above parameters will again first return C1D1 with authority score 0.6, then return C2D1 with authority score 0.7, and lastly return C1D2 with an authority score of 0.4. Thus here again, if the user has bypassed document C1D1, it is not fully certain that the user is not interested in C1 since the document has an authority score of 0.6 only. However, the attractiveness of other documents in C1 decreases with respect to other documents in C2 since the authority score of the bypassed document is rather high. Therefore, C2D1 is listed in the next position. Now according to the present method, D2 from C1 is next listed because if the user bypasses the second listing it is most likely the user may be interested in C1 even though the user may have skipped by the first listing of C1D1 which is not absolutely authoritative (as with the 1.0 scored document in Examples 1 and 2). Now in the case where 4 documents are returned by this method under the parameters of this Example 3, the results for the first, second, and third returns will be as above with C1D1, C2D1, and C1D2, consecutively listed, then next here in fourth position list C2D2 with the authority score of 0.5.
In contrast to the above, the naive allocation methods of the prior art, given the above parameters in this Example 3 with P1 again just greater than P2 as in Example 2 above, would list C1D1, C1D2, and C2D1 in that order when limited to three returns; thereby still listing a second document from C1 before the first list document from C2 even though it would be somewhat certain that a user bypassing C1D1 with the 0.6 authority score would next be interested in C2. And then when returning four returns, the prior art here would list C1D1, C1D2, C2D1, and then C2D2 thereby again illustrating the absence of recognizing that if the user was not interested in C2D1 given the indicated authority scores, such a user more likely would be interest next in a C1 document.
While this invention has been described in detail with reference to certain embodiments and examples, it should be appreciated that the present invention is not limited to those precise embodiments or in any way to the examples given by way of illustrative purposes. Rather, in view of the present disclosure which describes the current best mode for practicing the invention, many modifications and variations would present themselves to those of skill in the art without departing from the scope and spirit of this invention. The scope of the invention is, therefore, indicated by the following claims rather than by the foregoing description. All changes, modifications, and variations coming within the meaning and range of equivalency of the claims are to be considered within their scope. | Methods, apparatus, and systems directed to receiving search queries, retrieving documents, computing the number of categories to present for a given query, computing the number of results to show in each category, computing an ordering of categories, and for all the result pages beyond the first page employing user interface elements that optionally allow the user to quickly zoom in on a specific category and get more results belonging to that category. | 6 |
CROSS REFERENCE TO CO-PENDING APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 11/080,910 filed Mar. 14, 2005 and issuing as U.S. Pat. No. 6,946,588 on Sep. 20, 2005, which is a divisional of U.S. patent application Ser. No. 10/658,002, filed Sep. 9, 2003, now U.S. Pat. No. 6,896,311, issued May 24, 2005, the contents of both of which are incorporated herein in their entirety
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to interior components for vehicles and, more particularly, to a mounting assembly suitable for mounting a sun visor in a vehicle interior.
2. Description of the Related Art
Sun visors are typically mounted in a vehicle in a manner that allows a visor blade to pivot between a “stored” position adjacent an interior headliner and a “use” position adjacent a vehicle windshield. Since the sun may enter a side window of a vehicle, most sun visors are allowed to pivot between the windshield and the side window in the “use” position.
A number of methods have been proposed for moveably mounting a sun visor to a vehicle interior. One known method is a snap-in type mount. This type of mount is generally the easiest and most cost effective to install, since a mounting member simply snaps into a hole in an interior panel of a vehicle. A pivot rod supported visor blade is then moveably attached to the mounting member to complete the installation of the sun visor.
It has become increasingly more popular for vehicle manufacturers, particularly in the automotive industry, to require vehicle component suppliers to supply integrated vehicle systems. One such integrated system is a vehicle headliner assembly that includes, among other components, a vehicle headliner, a driver sun visor and a passenger sun visor. Conventional sun visor mounts are typically configured for use with a single headliner configuration. However, the ability to use a single mount with multiple headliner configurations would allow a supplier to streamline their product portfolio and reduce the various costs associated with providing multiple mount configurations. Accordingly, a need exists for a modular mount suitable for use with different headliner configurations.
SUMMARY OF THE INVENTION
In accordance with an embodiment of the invention, a mounting assembly is disclosed for mounting a sun visor to a vehicle panel having opposing faces and an aperture therethrough. The mounting assembly includes a mounting component mountable to the vehicle panel. The mounting component includes a first side having a number of spaced apart retaining members extending therefrom and a second side including at least one catch projecting therefrom. The opposing faces of the panel are gripped between the second surface and the catch to retain the mounting component against the vehicle panel. The mounting assembly also includes a bezel component moveably connected to the mounting component by the retaining members.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and inventive aspects of the present invention will become more apparent upon reading the following detailed description, claims, and drawings, of which the following is a brief description:
FIG. 1 is a fragmentary perspective view of a sun visor assembly installed in a vehicle;
FIG. 2 is a perspective view of a mounting assembly according to an embodiment of the invention, pre-installed in a vehicle headliner;
FIG. 3 is an exploded view of the mounting assembly and headliner of FIG. 2 ;
FIG. 4 is a top view of a mounting component according to an embodiment of the invention;
FIG. 5 is a cross-sectional view of the mounting component of FIG. 4 taken along line 5 — 5 ;
FIG. 6 is a bottom view of the mounting component of FIG. 4 according to an embodiment of the invention;
FIG. 7 is an exterior view of a bezel component according to an embodiment of the invention;
FIG. 8 is a cross sectional view of the bezel component of FIG. 7 taken along line 8 — 8 ;
FIG. 9 is an interior view of the bezel component of FIG. 7 according to an embodiment of the invention;
FIG. 10 is a detailed cross-sectional view showing a bezel component secured to a mounting component and sandwiching a headliner of first thickness “A” therebetween;
FIG. 11 is a detailed cross-sectional view showing a bezel component secured to a mounting component, and sandwiching a headliner of second thickness “B” therebetween;
FIG. 12 is the detailed cross-sectional view of FIG. 10 showing a fastener securing the mounting assembly to a vehicle panel; and
FIG. 13 is a partial cross-sectional view of a bezel component according to an embodiment of the invention, showing an elbow secured to a bearing portion of the bezel component.
DETAILED DESCRIPTION
Referring now to the drawings, the preferred illustrative embodiments of the present invention are shown in detail. Although the drawings represent some preferred embodiments of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated to better illustrate and explain the present invention. Further, the embodiments set forth herein are not intended to be exhaustive or otherwise limit or restrict the invention to the precise forms and configurations shown in the drawings and disclosed in the following detailed description.
Referring to FIG. 1 , a vehicle 20 is shown that includes a windshield 22 and a hidden sheet metal panel 24 that functions as a backing plate of limited size for attaching a sun visor 26 or as a larger sheet metal panel that defines the interior roof of vehicle 20 . Panel 24 is covered by a headliner 30 , such AS a cushioned fabric material, which may be colored to complement the decor of the vehicle interior. A layer of energy-absorbing material (not shown), such as foam and the like, may be disposed between panel 24 and headliner 30 to absorb the energy of an impact by the vehicle occupants during an accident.
A sun visor mounting assembly 32 secures sun visor 26 to panel 24 and/or headliner 30 and permits sun visor 26 to be pivoted about a substantially vertical axis from a position proximate windshield 22 to a position proximate a side window 34 of vehicle 20 . Sun visor 26 is rotatably supported on a visor shaft 36 extending from mounting assembly 32 and may be secured to a support hook (not illustrated) when not in use. It will be appreciated that the design of sun visor 26 is not material to the present invention and that other sun visor designs, including those that employ electrical circuitry to illuminate a lamp on the visor, may be used.
Referring to FIGS. 2 and 3 , an embodiment of mounting assembly 32 is shown that includes a mounting component 40 and a bezel component 42 . An elbow 44 is connectable with sun visor 26 via visor shaft 36 . A plurality of fasteners 45 , such as screws and the like, pass through bezel component 42 and mounting component 40 to secure components 40 , 42 to panel 24 . Panel 24 generally includes an inner surface 46 , an outer surface 48 and an aperture 50 through which a portion of mounting component 40 is inserted to retain mounting assembly 32 against panel 24 until fasteners 45 may be installed. Mounting component 40 and bezel component 42 cooperatively engage headliner 30 to support elbow 44 and sun visor 26 during transport of headliner 30 . Mounting component 42 also temporarily secures headliner 30 , bezel component 42 and sun visor 26 to panel 24 during installation into vehicle 20 until fasteners 45 can be secured to panel 24 .
Referring to FIGS. 4–6 , mounting component 40 may be molded as a one-piece structure from a polymeric material, such as ABS and other suitable plastics. In an embodiment, mounting component 40 includes a first side 52 configured to engage bezel component 42 and a second side 54 configured to engage panel 24 . In a particular configuration, second side 54 includes a catch 56 that extends outwardly therefrom. In the illustrated configuration, catch 56 includes a pair of resilient catch members 58 and 60 , each including a tapered arm portion 62 and a ledge 64 having a surface that is generally parallel to and slightly spaced apart from second surface 54 . Tapered arm portions 62 engage panel 24 during installation, deflect inwardly as catch 56 is inserted into hole 50 in panel 24 and snap-back once fully inserted therein to grasp panel 24 between ledge 64 and second surface 54 . An aperture 66 may extend through mounting component 40 adjacent each of catch members 58 , 60 to provide an opening though which to view the location of ledge 64 relative to panel 24 .
With particular reference to FIGS. 5 and 6 , first side 52 includes a number of spaced apart towers 68 that extend therefrom. Towers 68 each include a duct 70 that extends from a distal end 72 through second side 54 . Each duct 70 may include at least one inwardly extending catch feature 73 that engages fastener 45 as it is inserted therein. In the illustrated embodiment, catch feature 73 is a radially inwardly directed protrusion that engages one or more threads on fastener 45 . Catch features 73 temporarily retain fasteners 45 in ducts 56 so that mounting assembly 32 and fasteners 45 can be shipped as a single unit. Upon assembly into a vehicle, each fastener 45 is received in an aperture 74 (shown in FIG. 3 ) in panel 24 to secure mounting component 40 and bezel component 42 to panel 24 . While fasteners 45 are shown in the illustrated embodiment as being screws, it is recognized that other suitable fasteners or fastening methods, such as rivets and the like, may also be employed to secure components 40 , 42 to panel 24 .
Referring still to FIGS. 5 and 6 , mounting component 42 also includes a number of spaced apart retaining members 76 extending therefrom. In an embodiment, each retaining member 76 includes at least one leg 78 that extends downwardly from distal end 72 of towers 68 . When retaining member 76 includes more than one leg 78 , each leg 78 may be spaced apart from the other, as shown in FIG. 6 . Legs 78 are resiliently deflectable relative to tower 68 and include a foot 80 . As will be described in detail below, feet 80 are configured to engage bezel component 42 to attach bezel component 42 to mounting component 40 .
As illustrated in FIG. 5 , mounting component 40 may also include at least one separator member 82 that extends from first side 52 . In an embodiment, mounting component 40 includes a number of separator members 82 , one or more of which are positioned between towers 68 . Separator members 82 are longer than towers 68 by a predetermined length and selectively engage bezel component 42 , as will be described below.
Referring to FIGS. 7–9 , bezel component 42 may also be molded as a one-piece structure from a polymeric material, such as ABS or other suitable plastic. In an embodiment, bezel component 42 includes a main body portion 84 and an integrally formed bearing portion 86 . The shape of body portion 84 preferably corresponds to the polygonal shape of mounting component 40 . An exposed outer surface 88 of bezel component 42 is aesthetically attractive and may be provided with a patterned texture. An interior surface 90 of bezel component 42 is hidden from view once installed in vehicle 20 . At least one opening 91 may be provided through bezel component to allow passage of electrical wires for powering a sun visor vanity mirror light (not shown).
In an embodiment, body portion 84 includes a number of apertures 92 that correspond in number to ducts 70 in mounting component 40 . In a particular configuration, each aperture 92 is defined by a tower 94 that extends upwardly from interior surface 90 . Each tower 94 creates a recess 96 that extends away from exposed outer surface 88 . Apertures 92 are partially enclosed by a generally semi-circular flat 98 , which may be oriented such that an open portion of each aperture 92 is positioned inward of flat 98 in a direction extending from a corner 100 of bezel component 42 . The remaining circumference of aperture 92 is not covered by flat 98 , but includes a ledge 102 . The edge of aperture 92 is slightly tapered to deflect legs 78 and feet 80 as bezel component 42 is attached to mounting component 40 . As feet 80 cam over the taper to aperture 92 , legs 78 snap back allowing feet 80 to lock behind ledge 102 to attach bezel component 42 to mounting component 40 until fasteners 45 can be applied (see, e.g., FIGS. 10 and 11 ).
Referring now to FIGS. 10 and 11 , attachment of bezel component 42 to mounting component 40 allows headliner 30 to be sandwiched therebetween, enabling mounting assembly 32 to be transported with headliner 30 . Particularly, body portion 84 of bezel component 42 engages one side of headliner 30 and a raised peripheral edge 104 of mounting component 40 engages the other side of headliner 30 . Unlike prior art mounting assemblies, bezel component 42 is movable relative to mounting component 40 once attached thereto. Among other things, movement of bezel component 42 relative to mounting component 40 allows mounting assembly 32 to accommodate various headliner thicknesses. For example, FIG. 10 illustrates mounting assembly 32 secured to a first headliner 30 ′ having a thickness “A”. In FIG. 11 , mounting assembly 32 is secured to a second headliner 30 ″ having a thickness “B” that is less than thickness “A” in FIG. 10 .
Once the headliner assembly (i.e., headliner 30 , mounting assembly 32 , etc) is secured in a vehicle interior and fasteners 45 are attached to panel 24 , as in FIG. 12 , body portion 84 of bezel component 42 is movably drawn by fasteners 45 against headliner 30 , which in turn is drawn against the raised peripheral edge 104 of mounting component 32 to tightly sandwich headliner 30 therebetween. As will be appreciated, various headliner thicknesses can be accommodated with this design by permitting movement of bezel component 42 relative to mounting component 40 . The amount of movement between bezel component 42 and mounting component 40 is limited by separator members 82 so that fasteners cannot overdraw bezel component 42 , thereby crushing or otherwise deforming headliner 30 .
Referring to FIGS. 8 and 13 , an embodiment of elbow 44 and bearing portion 86 are shown in detail. Elbow 44 is configured to be received in bearing portion 86 about a pivot axis 110 . In an embodiment, elbow 44 is retained in bearing portion 86 by two or more resilient legs 112 that are at least partially separated by a slot 114 ( FIG. 8 ). In the illustrated embodiment, a distal end 116 of elbow 44 includes a flange 118 having a conical surface 120 , which forces expansion of legs 112 during insertion of elbow 44 into bearing portion 86 . As flange 118 moves above a distal end 122 of legs 112 , legs 112 contract and engage an underside of flange 118 to rotatably retain elbow 44 in bezel component 42 .
The structure of mounting assembly 32 will be further understood in view of the following description of an embodiment of a method of installation. Mounting assembly 32 is first attached to headliner 30 as described above. Elbow 44 is secured to bezel component 42 prior to or subsequent to attachment of bezel component 42 with mounting component 40 . With headliner 30 sandwiched between bezel component 42 and mounting component 40 , fasteners 45 may then be inserted through apertures 92 in bezel component 42 into ducts 70 in mounting component 40 . Fasteners 45 are temporarily engaged and retained within ducts 70 by catch feature 73 . During installation of the headliner assembly into a vehicle interior, catch 56 on mounting component 40 is inserted into aperture 50 of panel 24 to retain mounting assembly 32 against panel 24 , as described above. Finally, fasteners 45 are attached to panel 24 to secure mounting assembly 32 to panel 24 (see FIG. 12 ).
While the present invention has been described with reference to the illustrated embodiments, it is recognized that various modifications to the embodiments of the present invention will be apparent to those skilled in the art without departing from the scope of the claimed invention. For example, those modifications include, but are not limited to, modifying the shape of bezel component 42 and mounting component 40 , modifying the degree of movement permitted between bezel component 42 and mounting component 40 , and modifying the shape, number and orientation of retaining members 76 . Moreover, the inventive mounting component 40 may also be utilized to secure other components in a vehicle, for example, to attach door panels to a vehicle door.
Although certain preferred embodiments of the present invention have been described, the invention is not limited to the illustrations described and shown herein, which are deemed to be merely illustrative of the best modes of carrying out the invention. A person of ordinary skill in the art will realize that certain modifications and variations will come within the teachings of this invention and that such variations and modifications are within its spirit and the scope as defined by the claims. | A mounting assembly is disclosed for mounting a sun visor to a vehicle panel having opposing faces and an aperture therethrough. The mounting assembly includes a mounting component mountable to the vehicle panel. The mounting component includes a first side having a number of spaced apart retaining members extending therefrom and a second side including at least one catch projecting therefrom. The opposing faces of the panel are gripped between the second surface and the catch to retain said mounting component against the vehicle panel. The mounting assembly also includes a bezel component moveably connected to the mounting component by the retaining members. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to a semiconductor memory device; and, more particularly, to a delay locked loop using a bi-directional ring oscillator and a counter unit.
DESCRIPTION OF THE PRIOR ART
[0002] In general, a delay locked loop (DLL) circuit reduces or compensates a skew between a clock signal and data or between an external clock and an internal clock, which is used in synchronizing an internal clock of a synchronous memory to an external clock without incurring any error. Typically, a timing delay is occurred when a clock provided externally is used within the apparatus. The delay locked loop controls the timing delay to synchronize the internal clock to the external clock.
[0003] The synchronization between the internal and external clocks requires operations of compensating a jitter of the external clock with an internal delay locked loop, controlling a time delay unit such that a delay of the internal clock is less sensitive to noise introduced by a power supply or random noises, and fastening a locking time at maximum through the control of the time delay unit. A delay locked loop with a reduced jitter and an easily controllable time delay unit to overcome the foregoing requirements has been recently presented in ISSCC paper on 1999, entitled “A 250 Mb/s/pin 1 Gb Double Data Rate SDRAM with a Bi-Directional Delay and an Inter-Bank Shared Redundancy Scheme” by NEC Corporation.
[0004] [0004]FIG. 1 is a connection diagram of a conventional linear bi-directional delay DLL proposed by NEC Corporation.
[0005] Referring to FIG. 1, the conventional DDL includes an input unit 100 , a first to a third D-flip flop 101 , 103 and 104 , an first inverter 102 , a dummy delay unit 105 , a first and a second AND gate 106 and 107 , a first and a second bi-directional delay block 108 and 109 , a first and a second pulse generation unit 110 and 111 , and an OR gate 112 .
[0006] The input unit 100 receives a clock signal CLK and a non-clock signal CLKB via positive and negative terminals respectively and comparing received signals to produce a rising clock Rclk. The first D-flip flop 101 receives the rising clock Rclk as a clock signal and outputs a control signal with a pulse duration corresponding to one cycle of the rising clock Rclk. The first inverter 102 inverts the output of the first D-flip flop 101 to produce an inverted signal to be fed back as input to the first D-flip flop 101 . The second D-flip flop 103 receives the output of the first D-flip flop 101 and the rising clock Rclk from the input unit 100 and produces a first forward signal FWD_A having a pulse duration corresponding to one cycle of the output of the first D-flip flop 101 and a first backward signal BWD_A having an opposite phase to the first forward signal FWD_A. The third D-flip flop 104 receives an inverted value for the output of the first D-flip flop 101 and the rising clock Rclk, and produces a second forward signal FWD_B having a pulse duration corresponding to one cycle of the output of the first D-flip flop 101 and a second backward signal BWD_B having an opposite phase to the second forward signal FWD_B.
[0007] The dummy delay unit 105 delays the rising clock Rclk by a skew to compensate the clock signal CLK. The first AND gate 106 logically combines the outputs of the second D-flip flop 103 and the dummy delay unit 105 to produce a combined output. The second AND gate 107 logically combines the outputs of the third D-flip flop 104 and the dummy delay unit 105 to produce a combined output.
[0008] The first bi-directional delay block 108 including a multiplicity of unit bi-directional delays which are connected serially, receives the output of the first AND gate 106 and controls a time delay in a first or second direction under the control of the first forward signal FWD_A and the first backward signal BWD_A.
[0009] The second bi-directional delay block 109 including a multiplicity of unit bi-directional delays which are connected in series, receives the output of the second AND gate 107 and controls a time delay in the first or second direction under the control of the second forward signal FWD_B and the second backward signal BWD_B.
[0010] The first pulse generation unit 110 generates a pulse at a rising and a falling edge of the output of the first bi-directional delay block 108 . The second pulse generation unit 111 generates a pulse at a rising and a falling edge of the output of the second bi-directional delay block 109 . The OR gate 112 performs an OR operation on the outputs of the first and second pulse generation units 110 and 111 .
[0011] [0011]FIG. 2A is connection diagram of a conventional unit bi-directional delay, which has been proposed by FUJITSU Ltd.
[0012] As shown in FIG. 2A, the unit bi-directional delay proposed by FUJITSU includes four three-phase buffers 200 , 201 and 203 .
[0013] The first three-phase buffer 200 receives one of the outputs of the first and second AND gates as a first input signal A m to produce a second control signal B m , wherein the gate of a PMOS transistor is controlled by the first or second backward signal (hereinafter called BWD) and the gate of a NMOS transistor is controlled by the first or second forward signal (hereinafter called FWD). The second three-phase buffer 201 receives the second output signal B m , wherein the gate of a PMOS transistor is controlled by the BWD signal and the gate of a NMOS transistor is controlled by the FWD signal.
[0014] The third three-phase buffer 202 receives the output of an unit bi-directional delay at a previous stage as a second input signal B m+1 , to produce a first output signal A m+1 , wherein the gate of a PMOS transistor is controlled by the backward signal BWD and the gate of a NMOS transistor is controlled by the forward signal FWD.
[0015] The fourth three-phase buffer 203 receives the first output signal A m+1 to produce the second output signal B m , wherein the gate of a PMOS transistor is controlled by the forward signal FWD and the gate of a NMOS transistor is controlled by the backward signal BWD.
[0016] When the forward signal FWD is logic high and the backward signal BWD is logic low, the first and second three-phase buffers 200 and 201 are activated to provide input signal to the first direction (i.e., the forward direction). When the forward signal FWD is logic low and the backward signal BWD is logic high, the third and fourth three-phase buffers 202 and 203 are activated to provide input signal to the second direction (i.e., the backward direction).
[0017] [0017]FIG. 2B is a symbolic diagram of the unit bi-directional delay shown in FIG. 2A. The construction and operation in FIG. 2B is similar that of the previously described in conjunction with FIG. 2A and therefore a further description thereof is omitted herein.
[0018] [0018]FIG. 2C is a connection diagram of the unit bi-directional delay proposed by NEC Corporation.
[0019] As shown in FIG. 2C, a difference between NEC and FUJITSU is that the PMOS transistor is removed in the first and fourth three-phase buffers 200 and 203 , and the NMOS transistor is removed in the second and third three-phase buffers 201 and 202 , preventing both of the first and second input signals A m and B m+1 with a logic low value from being transmitted to corresponding buffers.
[0020] Although the construction of the delay locked loop described above shows that generates a DDL signal at the rising clock Rclk of the clock signal CLK, the construction for the rising clock Rclk is similar to that of a delay locked loop for outputting the DDL signal at the falling clock Fclk of the clock signal CLK except that the output signal of the input unit 100 is a falling clock.
[0021] [0021]FIG. 3 is a timing diagram illustrating the operating principle of the first and second bi-directional delay blocks.
[0022] Referring to FIG. 3, in case the first forward signal FWD_A is logic high and the first backward signal BWD_A is logic low, when the first output signal A 0 _A is rendered to a logic high after a compensation skew t dm , the logic high signal A 0 -A is propagated to the first direction (i.e., the forward direction). In this case, it requires a prior condition that all the forward nodes (Am_A, m=0, 1, 2, . . . , 40) should be set to logic low and all the backward nodes (Bm_B, m=0, 1, 2, . . . , 40) should be set to logic high. Since rendering of the forward node to logic high allows the backward node corresponding thereto to be rendered to logic low, it is necessary to set the backward node to logic low till a position to which the logic high is transmitted.
[0023] Thereafter, if the first forward signal FWD_A is rendered to a logic low and the first backward signal BWD_A is rendered to a logic high, at the same time that the logic high signal is propagated to the second direction (i.e., the backward direction) to thereby render the first output signal B 0 _A to a logic high after an interval t clk -t dm , wherein t clk is one clock cycle. That is, the signal preceding by t dm from a rising edge of a subsequent clock. As mentioned above, since a signal preceding by t dm per two cycles may be obtained, an additional bi-directional delay line is provided and both of the delay lines are alternatively operated, allowing a DDL clock to be obtained at each cycle. The logic high of the second output signal B 0 _A means that all the backward nodes have been rendered to logic high and also all the forward nodes have been rendered to logic low. In short, a reset operation may be automatically performed for subsequent processes without any reset operation.
[0024] The delay locked loop may be implemented with the bi-directional delay. However, in low frequency applications, the interval t clk -t m increases with an increase in one clock cycle t clk , so that a length of the bi-directional delay line should be lengthened by an increased interval. That is, many unit bi-directional delays are additionally required.
[0025] The first and second bi-directional delay blocks 108 and 109 of the delay locked loop shown in FIG. 1 include 40 stages of unit bi-directional delays to adjust a time delay in low frequency applications, and four control signal lines to be used in controlling each of the unit bi-directional delays.
[0026] Accordingly, the prior art places greater chip area requirements, which, in turn, may decrease the number of an wafer net die, thereby leading to increase in cost for the apparatus.
SUMMARY OF THE INVENTION
[0027] It is, therefore, a primary object of the present invention to provide a delay locked loop, which is capable of achieving a reduced jitter and a stable time delay adjustment, to thereby perform a bi-directional time delay with a small area even at low frequency applications.
[0028] In accordance with a preferred embodiment of the present invention, there is provided a delay locked loop for use in a semiconductor memory device, which comprises: an input unit for receiving a clock signal and a non-clock signal and comparing received signals to produce an internal clock signal; a controller for receiving the internal clock to produce a first forward signal and a second backward signal each having a pulse duration corresponding to one cycle of the clock signal, a first backward signal and a second forward signal each having an opposite phase to the first forward signal and the second backward signal, and a first and a second start signal each having a pulse duration corresponding to a time delay to be compensated; a bi-directional oscillator, responsive to the second forward signal, the second backward signal and the second start signal, perform a ring oscillation in a first or second direction and fulfilling an addition and subtraction adjustment function for a time delay; a counter for receiving an output signal of the bi-directional oscillator, and counting the number that the output signal is passed therethrough; and an output means for performing a combination operation on the outputs of the bi-directional oscillator and the counter, to produce the result as a final internal clock signal.
[0029] By changing a linear structure into a ring structure, the present invention employs only four-stages of unit bi-directional delay block and a three-bits counter to allow an operation to be performed up to 40 MHz in frequency. Also, the present invention employs only four-stages of unit bi-directional delay block and a four-bits counter to allow the operation to be performed up to 20 MHz in frequency. Accordingly, the present invention has the ability to implement a delay locked loop with a reduced layout requirement even at a low frequency 25 MHz corresponding to a wafer test frequency.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The above and other objects and features of the present invention will become apparent from the following description of the preferred embodiments given in conjunction with the accompanying drawings, in which:
[0031] [0031]FIG. 1 shows a connection diagram of a conventional linear bi-directional delay DLL proposed by NEC Corporation;
[0032] [0032]FIG. 2A is connection diagram of a conventional unit bi-directional delay which has been proposed by FUJITSU Ltd.;
[0033] [0033]FIG. 2B is a symbolic diagram of the unit bi-directional delay shown in FIG. 2A;
[0034] [0034]FIG. 2C is a connection diagram of the unit bi-directional delay proposed by NEC Corporation;
[0035] [0035]FIG. 3 is a timing diagram illustrating the operating principle of the first and second bi-directional delay blocks;
[0036] [0036]FIG. 4 is a connection diagram of a delay locked loop in accordance with preferred embodiments of the present invention;
[0037] [0037]FIG. 5 is a timing diagram illustrating a flow of control signals outputted from the controller 410 of the present invention;
[0038] [0038]FIG. 6A is a block diagram showing that an unit bi-directional inverter is inserted at the linear bi-directional delays;
[0039] [0039]FIG. 6B is a schematic block diagram illustrating the principle of the bi-directional ring oscillator 421 in accordance with a preferred embodiment of the present invention;
[0040] [0040]FIG. 7A is a connection diagram of the unit bi-directional delay 426 in a first stage in accordance with the present invention;
[0041] [0041]FIG. 7B is a symbolic diagram of the unit bi-directional delay shown in FIG. 7A in accordance with the present invention;
[0042] [0042]FIG. 8A is a connection diagram of the unit bi-directional inverter 429 of present invention;
[0043] [0043]FIG. 8B is a connection diagram in which three unit bi-directional inverters are connected in series for simulation; and
[0044] [0044]FIG. 9 is a timing diagram of signal waveforms in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0045] There is shown in FIG. 4 a connection diagram of a delay locked loop in accordance with preferred embodiments of the present invention.
[0046] As shown in FIG. 4, the delay locked loop of the present invention comprises an input unit 400 , a controller 410 , a first and a second bi-directional delay blocks 420 and 430 , and an OR gate 440 .
[0047] The input unit 400 receives a clock signal CLK and a non-clock signal CLKB and compares received signals to produce a rising clock Rclk. The controller 410 receives the rising clock Rclk as a clock signal, and outputs a first forward signal FWD_A and a second backward signal BWD_A each having a pulse duration corresponding to one cycle of the clock signal CLK, a first backward signal BWD_A and a second forward signal FWD_B each having an opposite phase to the first forward signal FWD_A and the second backward signal BWD_B, and a first and a second start signals START_A and START_B each having a pulse duration corresponding to a time delay to be compensated.
[0048] The first bi-directional delay block 420 , which includes a bi-directional ring oscillator and a counter unit, receives the first forward signal FWD_A, the first backward signal BWD_A and the first start signal START_A from the controller 410 to perform an addition and subtraction adjustment function for a time delay. Similarly, the second bi-directional delay block 430 , which includes a bi-directional ring oscillator and a counter unit, receives the second forward signal FWD_B, the second backward signal BWD_B and the second start signal START_B from the controller 410 to perform an addition and subtraction adjustment function for a time delay. The OR gate 440 performs an OR operation on the outputs of the first and second bi-directional delay blocks 420 and 430 , to generate the result as a final rising clock Rclk_DLL.
[0049] The controller 410 includes a first to third D-flip flops 411 , 412 and 414 , a dummy delay unit 413 , and a first and a second AND gates 415 and 416 .
[0050] The first D-flip flop 411 receives the rising clock Rclk as a clock signal to produce a first forward signal FWD_A having a pulse duration corresponding to one cycle of the clock signal CLK and a first backward signal BWD_A having an opposite phase to the first forward signal FWD_A. The second D-flip flop 412 receives the rising clock Rclk as a clock signal to produce a second forward signal FWD_B having a pulse duration corresponding to one cycle of the clock signal CLK and a second backward signal BWD_B having an opposite phase to the second forward signal FWD_B.
[0051] The dummy delay unit 413 delays the rising clock Rclk by a skew to compensate the clock signal CLK. The third D-flip flop 414 receives the output of the dummy delay unit 413 as a clock signal to produce a first delay rising clock Rclk_A and a second delay rising clock Rclk_B having an opposite phase to the first delay rising clock Rclk_A. The first AND gate 415 logically combines the first delay rising clock Rclk_A and the first forward signal FWD_A to produce a combined output. The second AND gate 416 logically combines the second delay rising clock Rclk_B and the second forward signal FWD_B to produce a combined output.
[0052] The first bi-directional delay block 420 includes a bi-directional ring oscillator 421 , a forward counter 422 , a backward counter 423 , a counter comparator 424 and an AND gate 425 . The bi-directional ring oscillator 421 receives the first start signal START_A and to perform a ring oscillation in a first and a second directions.
[0053] Specifically, the bi-directional ring oscillator 421 receives the first start signal START A to perform a ring oscillation in a first and a second direction. The forward counter 422 receives a forward loop signal from the bi-directional ring oscillator 421 to count the number of the oscillations. The backward counter 423 receives a backward loop signal from the bi-directional oscillator 421 to count the number of the oscillations. The counter comparator 424 compares the outputs of the forward counter 422 and the backward counter 423 to determine if the outputs (i.e., counted numbers) are identical each other. The AND gate 425 logically combines the outputs of the bi-directional ring oscillator 421 and the counter comparator 424 to produce a combined value.
[0054] By the afore-mentioned construction, a simplified bi-directional ring oscillator has the capacity to function as the multi-stages of delay line formed by unit bi-directional delays in the prior art.
[0055] The construction of the second bi-directional delay block 430 is similar to that of the first bi-directional delay block 420 except that the second start signal START_B is fed to the bi-directional ring oscillator.
[0056] The bi-directional ring oscillator 421 includes three unit bi-directional delays 426 , 427 and 428 , and a bi-directional inverter 429 . The unit bi-directional delays 426 , 427 and 428 , which are connected in series, receives a first output signal A 0 _A from the bi-directional inverter 429 to output the forward loop signal in the first direction, and receives the backward loop signal from the bi-directional inverter 429 to output a second output signal B 0 _A in the second direction, under the control of the first start signal START_A, the first forward signal FWD_A and the first backward signal BWD_A. The bi-directional inverter 429 receives the forward loop signal to output the first output signal A 0 _A in the first direction and receives the second output signal B 0 _A to produce the backward loop signal in the second direction, under the control of the first forward signal FWD_A and the first backward signal BWD_A.
[0057] [0057]FIG. 5 is a timing diagram illustrating a flow of control signals outputted from the controller 410 of the present invention.
[0058] Referring to FIG. 5, in the controller 410 of the present invention, the first forward signal FWD_A and the first backward signal BWD_A are out-of-phase and two cycle signals, and similarly the second forward signal FWD_B and the second backward signal BWD_B are out-of-phase and two cycle signals. Accordingly, the first forward signal FWD_A and the second backward signal BWD_B are identical and the first backward signal BWD_A and the second forward signal FWD_B are identical. The first and second delay rising clocks Rclk_A and Rclk_B are a signal reflecting a dummy delay (t dm in FIG. 4). The rising of the first start signal START A is controlled by the first delay rising clock Rclk_A and the falling thereof is controlled by the first forward signal FWD A. The first and second bi-directional delay units 420 and 430 have the same structure and alternatively operate every one cycle.
[0059] In operation, the delay locked loop generates a clock preceding by the compensation skew t dm for an external clock, wherein t dm is a fixed value ranging several nanoseconds. Accordingly, these delay locked loops are common to measure the interval between t clk and t dm and delay a clock by a measured interval.
[0060] [0060]FIG. 6A is a block diagram showing that an unit bi-directional inverter is inserted at the linear bi-directional delays.
[0061] Referring to FIG. 6A, the inverting operation of the unit bi-directional inverter allows a logic low and a logic high to be alternatively rendered to thereby transmit a corresponding signal via an unit delay line. In FIG. 6A, the bi-directional delay unit is indicated by a white block and the bi-directional inverter is indicated by a black block. The overall operation of FIG. 6A is similar to that of the linear bi-directional delay discussed above, except that a phase of the signal is inverted each occasion that it is passed through the unit bi-directional inverter. That is, a delay to a backward direction may be occurred in correspondence to a time proceeded to a forward direction. FIG. 6A shows that the signal is periodically passed through the unit bi-directional inverter, so FIG. 6A is contemplated as FIG. 6B as will be explained below.
[0062] [0062]FIG. 6B is a schematic block diagram illustrating the principle of the bi-directional ring oscillator 421 in accordance with a preferred embodiment of the present invention.
[0063] Referring to FIG. 6B, the bi-directional ring oscillator 421 includes a plurality of unit bi-directional delays and the bi-directional inverter which are connected in a ring fashion, and two counter. Each of the counters serves to count the number that a signal is rounded through the ring oscillator. By constructing as the above, a simplified bi-directional ring oscillator has the ability to act as the conventional bi-directional delay with a long length. The present invention requires only one bi-directional inverter, a very small number of unit bi-directional delays and two counters, thereby drastically reducing chip area requirements and covering even in low frequency applications (i.e., a larger clock cycle), while maintaining the merits of the linear bi-directional delay block. Further, since the bi-directional ring oscillator oscillates its own, what is need is a reset operation before that the first start signal START_A is inputted.
[0064] [0064]FIG. 7A is a connection diagram of the unit bi-directional delay 426 in a first stage in accordance with the present invention.
[0065] Referring to FIG. 7A, the unit bi-directional delay 426 used in the present invention includes a first to a fourth three-phase buffer 700 , 710 , 720 and 730 , and a PMOS transistor 740 . The first three-phase buffer 700 receives the output of an unit bi-directional delay in the previous stage to produce a second output signal B m , wherein the gate of a PMOS transistor is controlled by the first and second backward signals (BWD) and the gate of a NMOS transistor is controlled by the first and second forward signals (FWD) and the first and second start signals (START) for applying a start input to the bi-directional ring oscillator line forming a ring.
[0066] The second three-phase buffer 710 receives the second output signal B m to produce a first output signal A m+1 , wherein the gate of a PMOS transistor is controlled by the backward signal BWD and the gate of a NMOS transistor is controlled by the forward signal FWD.
[0067] The third three-phase buffer 730 receives the output of the unit bi-directional delay in the previous stage to produce a first output signal A m+1 , wherein the gate of a PMOS transistor is controlled by the forward signal FWD and the gate of a NMOS transistor is controlled by the backward signal BWD.
[0068] The fourth three-phase buffer 720 receives the first output signal A m+1 to produce the second output signal B m , wherein the gate of a PMOS transistor is controlled by the forward signal FWD and the gate of a NMOS transistor is controlled by the backward signal BWD.
[0069] The gate of the PMOS transistor 740 receives the first and second start signals START_A and START_B, and its source and drain are formed between a line input voltage and the second output signal B m .
[0070] [0070]FIG. 7B is a symbolic diagram of the unit bi-directional delay shown in FIG. 7A in accordance with the present invention.
[0071] Referring to FIG. 7B, a configuration in which the inverters diametrically opposite each other is similar to that of the unit bi-directional delay proposed by FUJITSU Ltd., except that the PMOS transistor 740 is added for a reset operation.
[0072] [0072]FIG. 8A is a connection diagram of the unit bi-directional inverter 429 of present invention.
[0073] Referring to FIG. 8A, the unit bi-directional inverter 429 of the present invention includes a first and a second three-phase buffer 800 and 810 . The first three-phase buffer 800 receives the first output signal A m of the unit bi-directional delay in the previous stage to produce a forward loop signal and the second output signals A m+1 and B m , wherein the gate of a PMOS transistor is controlled by the backward signal BWD and the gate of a NMOS transistor is controlled by the forward signal FWD. The second three-phase buffer 810 receives a backward loop signal of the unit bi-directional delay in the previous stage to produce the second output signal A m+1 and the forward loop signal B m .
[0074] [0074]FIG. 8B is a connection diagram in which three unit bi-directional inverters are connected in series for simulation.
[0075] [0075]FIG. 9 is a timing diagram of signal waveforms in accordance with a preferred embodiment of the present invention.
[0076] Referring to FIG. 9, if the forward signal FWD is rendered to logic high and a reset signal “Resetb” is rendered to logic low for prior to the start signal “Start” being inputted, then the bi-directional ring oscillator is reset. If the start signal “Start” is rendered to logic high, the signal is transmitted in a first direction, and the forward counter 422 counts the number of rising edges of the transmitted signal based on a forward loop signal A 3 .
[0077] Alternatively, if the backward signal BWD is rendered to logic high, the signal is conversely transmitted to allow the backward counter to be activated. The counter comparator 424 compares the outputs of the backward counter and the forward counter and produces a counter match signal “count_match” with a logic high value if the outputs are equal each other. According to the counter match signal “count_match”, rising edges of the output signal B 0 of the bi-directional ring oscillator is outputted as a final rising clock Rclk_DLL. Since one bi-directional ring oscillator produces one DDL clock every two clock cycle, obtainment of one DDL clock per each clock cycle requires an additional bi-directional ring oscillator.
[0078] As mentioned above, the present invention employs a bi-directional ring oscillator, a forward counter and a backward counter to thereby reduce chip area requirements in contrast with the prior art delay locked loop and operate in low frequency applications, which, in turn, achieve a fast locking and a reduced jitter.
[0079] Although the preferred embodiments of the invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. | It is provided a delay locked loop for obtaining a reduced jitter and a stable time delay adjustment to thereby perform a bi-directional time delay with a small area even at low frequency applications. The delay locked loop includes an input unit for receiving a clock signal and a non-clock signal and comparing received signals to produce an internal clock signal, a controller for receiving the internal clock to produce a control signal, a bi-directional oscillator, responsive to the control signal from the control means, for performing a ring oscillation in a first or second direction and fulfilling an addition and subtraction adjustment function for a time delay, a counter for receiving an output signal of the bi-directional oscillator and counting the number that the signal is passed therethrough, and an AND gate for performing a combination operation on the outputs of the bi-directional oscillating means and the counting means, to produce the result as a final internal clock signal. | 7 |
FIELD OF THE INVENTION
This invention relates to a carburetor for small engines, and more particularly to a carburetor having a fuel shut off solenoid device.
BACKGROUND OF THE INVENTION
The use of solenoid devices to control a variety of fuel flow transients within a carburetor of a small engine is known. One particular application consists of a fuel shut off solenoid device of a carburetor capable of blocking fuel flow from entering a mixing passage of the carburetor when an ignition switch is turned off, thereby preventing engine dieseling and after boom. When the ignition switch is on, the solenoid device is energized and thereby held in a retracted position. If retracted, fuel flows from a fuel bowl, through a main tube or nozzle where the fuel premixes with air, and into the carburetor mixing passage to mix with more air. When the ignition switch is off, the solenoid device is de-energized and a head at a distal end of a shaft of the solenoid device is extended upward thereby isolating the fuel bowl from the main tube and effectively cutting off fuel flow.
The solenoid device is typically mounted in an upright position below the carburetor body. A solenoid chamber defined by an encasement of the device is usually disposed below the fuel bowl. When the head extends, the shaft of the solenoid device moves upward out of the solenoid chamber and the head mates with the bottom side of the main tube to cut off fuel flow. Because the solenoid chamber is located beneath the fuel bowl of the carburetor and a clearance exists between the shaft and the encasement of the solenoid device, fuel migrates via gravity into the solenoid chamber.
SUMMARY OF THE INVENTION
Although the migrating fuel was thought to be useful in cooling the energized solenoid device, it has been found that heat emitted by the coil of the energized solenoid device vaporizes the fuel contained within the solenoid chamber. The heat generated by the solenoid valve heats the fuel thereby creating vapor bubbles which migrate up through the main nozzle, interfering with steady or smooth operation of the engine. The bubbles interfere with the mixing of fuel and air causing a noticeably rough engine idling or light load condition. Accordingly, the present invention is a carburetor having a fuel shut off solenoid device which does not inject fuel vapor into the liquid fuel.
A carburetor body of the carburetor has an inner sidewall defining a mixing or lower chamber disposed above the fuel shut off solenoid device. A fuel chamber containing a constant level of fuel is defined by a fuel bowl engaged to an outward or underside of the carburetor body. Fuel flows through an orifice communicating between the fuel chamber and the lower chamber. The lower chamber communicates with an elongated main tube or nozzle defining an enriched fuel bore and extending longitudinally upward from the lower chamber and tranversely into a mixing passage. The main tube has a mating surface on a lower end facing downward and extending radially outward thereby engaging the sidewalls of the lower chamber.
The fuel shut off solenoid device has an encasement which threadably engages a bottom portion of the carburetor body. The encasement defines a solenoid chamber which houses an extendable shaft having a head at a distal end disposed above the encasement. The solenoid chamber contains migrating fuel thought to cool the solenoid coil. The shaft is disposed vertically within the solenoid chamber and extends upward through an outward face extending radially outward from an inner brim which circles the shaft. Mounted on top of the outward face and also circling the shaft, is a washer. When the solenoid is energized and in a retracted position, a head of the shaft engages to an outward face of the washer. The outward face of the encasement engages to the inward or opposite face of the washer.
The head of the shaft has an annular trailing surface expanding radially outward from an inner perimeter edge congruent to the surface of the shaft, to a peripheral edge. The trailing surface of the head confronts the outward face of the encasement. The peripheral edge of the trailing surface has a diameter larger than the diameter of a hole of the washer.
A clearance is defined radially between the shaft and the inner brim of the encasement. Fuel flows or migrates through the clearance between the lower chamber of the carburetor body and the solenoid chamber. While energized, the fuel shut off solenoid device has a tendency to heat the fuel in the solenoid chamber thereby creating vapor bubbles which can interfere with the idle or light load fuel mixture of the carburetor. The engagement of the washer between the trailing surface of the head and the outward face of the energized solenoid device partially blocks or stops the migration of fuel vapor bubbles from the solenoid chamber into the lower chamber.
Objects, features and advantages of this invention include the elimination of fuel vapors migrating from the solenoid chamber into the lower chamber of the carburetor body, a smoother operating engine, particularly noticeable during engine idling or light load conditions, and which is rugged, durable, economical to manufacture and assemble, and has a long useful service life.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features and advantages of this invention will be apparent from the following detailed description of the preferred embodiments and best mode, appended claims and accompanying drawings in which:
FIG. 1 is a broken cross sectional side view of a carburetor according to the present invention;
FIG. 2 is a partial cross sectional view of the carburetor taken along line 2 — 2 of FIG. 1;
FIG. 3 is a longitudinal cross sectional view of the fuel shut off solenoid of the carburetor;
FIG. 4 is a partial cross sectional view of the carburetor taken along line 4 — 4 of FIG. 2;
FIG. 5 is a plain top view of a washer of the fuel shut off solenoid device; and
FIG. 6 is a side view of the washer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring in more detail to the drawings, FIG. 1 illustrates a carburetor 10 embodying the present invention with a carburetor body 12 having a mixing passage 14 through which air flows in the direction of the arrows. An air inlet portion 16 of the mixing passage 14 is positioned downstream of an air filter unit (not shown). The air inlet portion 16 houses a pivoting choke plate 18 having a pivotal axis 19 perpendicular to the longitude of the mixing passage 14 . The choke plate 18 is substantially closed during cold engine start conditions thereby controlling or limiting the air intake. Downstream of the air inlet portion 16 is a fuel and air mixture outlet portion 18 of the mixing passage 14 . The outlet portion 18 houses a pivoting throttle plate 20 , similar to the choke plate 18 , but which controls the amount of fuel and air mixture entering a running engine. With the engine running, the air pressure at the air inlet portion 16 is near atmospheric minus the pressure drop across the air filter unit (not shown).
Referring to FIGS. 1 and 2, the longitude or axis of the mixing passage 14 is preferably horizontal. A fuel bowl 22 engages the carburetor body 12 from beneath thereby defining a fuel chamber 24 between them. The fuel chamber 24 maintains a consistent level of fuel via a float mechanism. In operation, fuel flows from the fuel chamber 24 through an orifice 30 and into a lower or mixing chamber 26 of the carburetor body 12 . A preferably cylindrical side wall 28 of the carburetor body 12 defines in part the lower chamber 26 . The orifice 30 penetrates a dividing portion of the carburetor body 12 through the side wall 28 thereby communicating between the fuel chamber 24 and the lower chamber 26 , as shown in FIGS. 2 and 4.
During engine operation under non-idle conditions, fuel and air flows upward via negative pressure from the lower chamber 26 , through a bore 32 defined by an elongated main or nozzle tube 34 , and into the mixing passage 14 between the choke plate 18 and the throttle plate 20 . An upper end portion 38 of the main tube 34 extends substantially perpendicular into the mixing passage 14 . The main tube 34 has an outer surface 36 which engages the carburetor body 12 at the upper end portion 38 of the main tube 34 . The carburetor body 12 and the tube 34 define an upper annular chamber 40 disposed above the lower chamber 26 and beneath the upper end portion 38 of the main tube 34 . The main tube 34 has a lower end 42 which flares radially outward to sealably engage the carburetor body side wall 28 beneath the upper chamber 40 , thereby isolating the lower chamber 26 from the upper chamber 40 . The lower chamber 26 is generally filled with fuel and the upper chamber 40 is approximately half filled with fuel during steady state engine operating conditions.
Air enters into the upper chamber 40 , through a choke bore 44 which communicates with the air inlet portion 16 of the mixing passage 14 at the downstream side of the choke plate 18 and upstream from the protruding upper end portion 38 of the main tube 34 , shown in FIG. 1 . In operation, the upper chamber 40 is slightly below atmospheric pressure and fuel and air flows from the upper chamber 40 into the bore 32 through a plurality of transverse holes 46 which penetrate the wall of the main tube 34 near the lower end 42 . An overly rich fuel-to-air mixture flows through the bore 32 and into the mixing passage 14 to mix with additional air. In operation, because the fuel bore 32 is below atmospheric pressure, the combination of choke bore 44 , upper chamber 40 and plurality of holes 46 function together (as a fuel pump) to cause fuel to flow from the fuel chamber 24 into the mixing passage 14 for mixing with flowing air between the choke plate 18 and the throttle plate 20 .
During engine idle running conditions, fuel flows not via the “fuel pump” but from the lower portion of the bore 32 into an idle fuel feed tube 48 by a vacuum drawn from the intake manifold, not shown. Feed tube 48 extends transversely across the mixing passage 14 between the choke and throttle plates 18 , 20 and generally longitudinally into the main tube 34 through the upper end 38 . A distal or intake nozzle end 50 of feed tube 48 terminates slightly above the flared lower end 42 of the main tube 34 .
Referring to FIGS. 2-4, turning off the ignition of the running engine causes a fuel shut-off solenoid device 52 to isolate fuel flow from the lower chamber 30 into the enriched-fuel bore 32 , preventing engine dieseling and after boom. The solenoid device 52 mounts to carburetor body 12 from beneath and has a shaft 54 which moves vertically from an energized or retracted position 56 (shown in FIG. 2) to a de-energized or extended position 58 (shown in FIG. 1) into the lower chamber 26 . A mid portion of the shaft 54 moves transversely through an outward face 60 of an encasement 62 of the solenoid device 52 . In assembly, the outward face 60 defines the bottom of the lower chamber 26 , and the encasement 62 defines a solenoid chamber 64 which houses a substantial portion of the shaft 54 . An electrical coil 66 is encased within the encasement 62 and winds about the solenoid chamber 64 .
When the electrical coil 66 is energized, the shaft 54 is moved to and retained in the retracted position 56 and fuel is free to flow from the lower chamber 26 to the enriched-fuel bore 32 . However, when the electrical coil 66 is de-energized the shaft 54 is moved to and retained in the extended position 58 . When extended, a head 68 of at a distal end of the shaft 54 engages a downward facing mating surface 70 formed by the radial flaring of the lower end 42 of the main tube or nozzle 34 . The nozzle end 50 of the idle fuel feed tube 48 is suspended slightly above the head 68 . Therefore, fuel flow is not completely isolated from the idle fuel feed tube 48 when the head 68 engages the mating surface 70 . Of course, if tolerances can be achieved within a reasonable manufacturing cost, it is preferable to seal off the nozzle end 50 in addition to the main tube 34 utilizing the head 68 .
Fuel migrates from the lower chamber 26 into the solenoid chamber 64 through a clearance 72 defined radially between an inner brim 74 of the outward face 60 of the encasement 62 and a cylindrical surface 75 of the shaft 54 . The fuel within the solenoid chamber 64 cools the constantly energized solenoid device 52 of a running engine.
The head 68 of the shaft 54 flares laterally outward thereby forming a trailing face 76 . The trailing face 76 is preferably annular and is defined radially between an inner perimeter edge 78 which is congruent to the cylindrical surface 75 of the shaft 54 and a peripheral edge 80 of the radially enlarged head 68 . Preferably, the trailing face 76 is substantially parallel to the outward face 60 of the encasement 62 . When shaft 54 is in retracted position 56 , the trailing face 76 is interconnected sealably to the outward face 60 to prevent the release of vaporized fuel or bubbles from the solenoid chamber 64 into the lower chamber 26 .
Referring to FIGS. 3, 5 and 6 , when in use heat generated by the electrical coil 66 within the solenoid 52 creates vapor bubbles within the solenoid chamber 64 . Without a sealing engagement between the head 68 and the encasement 62 of the solenoid 52 , large bubbles would be emitted through the clearance 72 and into the lower chamber 26 causing rough idle or light load conditions of the running engine. To complete the sealing engagement, preferably a washer 82 is utilized about the shaft 54 between the head 68 and the outward face 60 of the encasement 62 . The washer 82 has an inner perimeter edge 84 which is slightly larger than the inner perimeter edge 78 of the shaft 54 . This permits the washer 82 to move freely up and down the shaft 54 without interfering with the extending and retracting movement of the shaft 54 . The inner perimeter edge 84 however is smaller than the peripheral edge 80 of the head 68 . Therefore, when the shaft 54 is in the retracted position 56 the trailing face 76 mates with the upward surface of the washer 82 , and the lower surface of the washer 82 mates with the outward face 60 of the encasement 62 . In short, preferably the diameter of the hole 86 of the washer 82 is larger than the diameter of the shaft 54 and smaller than the outside diameter of the face 76 of the head 68 .
Preferably, the head 68 is an elastomer grommet, and the washer 82 is of a non-corrosive material having a low heat capacity such as plastic and provides a seal with the face 60 of the encasement 62 .
In one embodiment of the invention, utilizing a fuel cut-off solenoid valve manufactured by Bicron, Inc. (Walbro Engine Corporation part number 76-521) and utilizing a Walbro Engine Corporation Carburetor Assembly part number LMK-106, a central hole 86 defined by the inner perimeter edge 84 of the washer 82 has a diameter 88 equal to 0.136 plus or minus 0.005 inches. An outer diameter 90 of the washer 82 is equal to 0.300 plus or minus 0.005 inches, and the thickness length 92 of the washer 82 is 0.031 plus or minus 0.003 inches. The washer is made of plastic.
While the forms of the invention herein disclosed constitute a presently preferred embodiment many others are possible. For instance, the trailing face 76 of the head 68 or elastomer grommet can seal directly to the outward face 60 of the solenoid 52 thereby eliminating the need for the washer 82 . Regardless, it is not intended herein to mention all the possible equivalent forms or ramifications of the invention. It is further understood that the terms used herein are merely descriptive rather than limiting, in that various changes may be made without departing from the spirit or scope of this invention. | A fuel shut off solenoid device of a carburetor has a solenoid chamber which typically fills with fuel. When the solenoid device is energized, fuel flows from a fuel chamber into a mixing passage of the carburetor to mix with air. During the energized state, heat from the solenoid tends to vaporize the fuel within the solenoid chamber. Also when energized, the solenoid device is held in a retracted position whereby a head at a distal end of the shaft mates with or seals to a washer which in turn seals to an upward face of the encasement of the fuel shut off solenoid device. Thus the potential migration of large vapor bubbles from the solenoid chamber to the mixing passage of the carburetor is eliminated, providing a smoother idling or running engine at light loads. | 5 |
BACKGROUND OF THE INVENTION
(1) Field of Invention
The present invention pertains to an adjustable nozzle that is attached to the end of a garden hose and is also attached to a separate product container, for example, a bottle containing a garden fertilizer or a bottle containing a cleaning soap concentrate. More specifically, the present invention pertains to an adjustable nozzle that receives a flow of water from a garden hose and dispenses a product from a container attached to the nozzle, where the nozzle has a simplified construction with a reduced number of component parts and where the operation of the nozzle is simplified yet enables a user to selectively discharge a flow of water or a mixture of water and product from the nozzle, control the ratio of water to product when the nozzle is employed in dispensing the mixture of water and product, and to direct the discharge as a stream or disburse the discharge in an upwardly or downwardly directed fanned spray pattern.
(2) Description of the Related Art
A typical hose end sprayer has two connections, one of which is connected to the end of a garden hose that serves as a supply of water under pressure to the sprayer and the second of which is connected to a separate product container to be selectively dispensed from the sprayer. Sprayers of this type are often used in the home garden or yard for dispensing chemicals such as weed killer or fertilizer mixed with the flow of water passing through the sprayer. In addition, sprayers of this type are used with a soap product contained in the separate container where the flow of water mixes with the soap product as it passes through the sprayer. Sprays of this type are often used to wash automobiles, housing siding and windows of a home. In the typical operation of these sprayers, the flow of water through the sprayer interior creates a venturi effect in the sprayer that draws the product contained in the product container into the flow of water where it is mixed with the water before being discharged from the sprayer.
Because the sprayers of the type described above are sold as household products that are used to spread chemicals in the home garden or yard or to wash the siding, windows or automobile of the homeowner, it is very desirable that the sprayers be constructed inexpensively and be easy to operate. In addition, it is also desirable that the sprayers provide features that enhance their usefulness without detracting from the ease of operating the sprayers. In many prior art hose end sprayers that have several useful features, for example, a control valve that has the options of stopping the flow of water through the sprayer nozzle, or opening the flow of water through the sprayer nozzle without mixing with the contents of the separate product container, or opening the flow of water through the sprayer nozzle while mixing with the contents of the separate product container, the control valve that is simple to operate requires additional component parts for the sprayer nozzle, or the control valve that has a reduced number of component parts is difficult to operate. Increasing the component parts of the sprayer nozzle increases its cost, making it unattractive to consumers. In addition, sprayer nozzles that are difficult to operate, although reduced in cost, are still not attractive to consumers.
What is needed to overcome the disadvantages of prior art hose end sprayer nozzles is a simplified construction of a nozzle with a reduced number of component parts that is also simple to operate and provides a number of desirable features. Such a sprayer nozzle would be attractive to consumers for both having a reduced cost due to its reduced number of component parts as well as its ease of operation.
SUMMARY OF THE INVENTION
The hose end sprayer nozzle of the present invention overcomes the several disadvantages associated with prior art sprayer nozzles by providing a nozzle with simplified construction and a reduced number of component parts that is easy to operate and yet provides many options that are desirable to consumers.
The sprayer nozzle of the invention is assembled from a total of twelve component parts. In the preferred embodiment, the component parts are molded of various types of plastics. The component parts of the sprayer nozzle include a two-piece housing, a three-piece control valve assembly contained in the housing, a two-piece manual actuator mounted on the housing, a two-piece hose connector mounted on the housing, a dip tube, a product port control valve and a spray deflector.
The two-piece housing includes a housing front piece that is snap-fit to a housing back piece. Together, the two pieces define a housing having an interior bore that passes between an inlet end of the housing and an outlet end of the housing. The interior bore defines a fluid flow path through the housing between the inlet and outlet ends.
An internally screw threaded hose connector containing a sealing washer or gasket is mounted to the housing inlet end for rotation of the connector relative to the housing. The interior threading of the hose connector mates with the typical exterior threading of a home garden hose. The housing also has a second connector that is connectable to a separate product container. In the preferred embodiment, the second connector is a bayonet type connector that can be releasably attached to a separate bottle of product having a complementary bayonet connector. A product port in the separate container connector and the dip tube extending from the product port communicate the separate container with the fluid flow path in the housing interior bore.
The control valve assembly is mounted in the fluid flow path in the housing interior bore. The control valve assembly includes a control valve that has an interior bore that functions as a portion of the fluid flow path through the nozzle. The control valve is mounted in the housing for reciprocating movement of the control valve along the flow path. A back flow check valve is mounted in the interior bore of the control valve and is operable to permit liquid flow along the flow path from the inlet end of the nozzle housing to the outlet end, but to prevent reverse flow through the flow path from the housing outlet end to the housing inlet end.
The two-piece manual actuator is mounted on the exterior of the nozzle housing and is operatively connected with the control valve. The manual actuator causes the control valve to reciprocate forwardly and rearwardly along the flow path in the housing interior bore in response to manual rotation of the actuator in opposite directions about the housing exterior. Manual rotation of the actuator in opposite directions moves the control valve through the housing interior bore between three positions of the control valve relative to the housing and the flow path. In the first position of the control valve relative to the housing interior, the control valve blocks the flow of liquid through the housing flow path. In the second position of the control valve relative to the housing it opens or unblocks the flow path through the housing but blocks the product port of the housing that communicates with the separate container of product connected to the housing. In the third position of the control valve relative to the housing, the valve unblocks both the fluid flow path through the housing and the product port, communicating the product container attached to the housing with the fluid flow path. This third position of the control valve and the flow of liquid through the housing interior creates a venturi in the flow path that draws product from the connected product container into the flow of liquid through the housing.
The product port valve is mounted to the housing for movement of the valve between first and second positions. The valve includes a center bore that forms a portion of the fluid flow path through the housing. The product port valve also has a pair of valve openings with a first of the valve openings having a smaller opening area than the second of the valve openings. In the first position of the product port valve, the first, smaller valve opening is aligned with the product port. In the second position of the product port valve, the second, larger valve opening is aligned with the product port. By selectively choosing which valve opening of the product port valve is aligned with the product port, the concentration of the product contained in the separate container that is mixed with the flow of water channeled through the housing interior bore can be changed.
A discharge deflector is mounted to the valve housing at the housing outlet end. The deflector is mounted to the housing for pivoting movement between three positions of the deflector relative to the housing. In the first position the deflector extends straight from the housing and a stream of water discharged from the housing will pass through the deflector without being deflected. In the second position the deflector is pivoted downwardly relative to the housing and the stream of water discharged from the housing impacts against the deflector and is deflected downwardly in a fanned out spray pattern. In the third position the deflector is pivoted upwardly relative to the housing and the stream of water discharged from the housing impacts with the deflector and is directed upwardly in a fanned out spray pattern.
The twelve component parts of the sprayer nozzle of the invention described above provide the nozzle with a simplified, reduced cost construction. In addition, they provide the nozzle with several desirable features, i.e., the ability to stop liquid flow through the nozzle, open liquid flow through the nozzle without mixing with the separate product, and open liquid flow through the nozzle while mixing with the separate liquid product. In addition, the concentration of the separate product mixed with the liquid passing through the nozzle can be adjusted. Still further, the discharge from the nozzle can be directed as a stream from the nozzle or can be deflected in a fan pattern downwardly and upwardly. By providing valves that rotate about the center axis of the nozzle housing, the different options available to alter the discharge of liquid from the housing are easily controlled.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
Further features of the present invention are set forth in the following detailed description of the preferred embodiment of the intention and in the drawing figures wherein:
FIG. 1 is a side elevation view of the sprayer nozzle of the invention;
FIG. 2 is an exploded view of the component parts of the nozzle;
FIG. 3 is a cross-section view of the nozzle shown in FIG. 1, with the nozzle flow path closed;
FIG. 4 is a view similar to that of FIG. 3, but with the nozzle flow path opened;
FIG. 5 is a view similar to that of FIG. 4, but with the nozzle flow path opened and in communication with the separate product container;
FIG. 6 is a perspective view of the nozzle with its deflector positioned upwardly;
FIG. 7 is a side elevation view of the nozzle with its deflector positioned downwardly;
FIG. 8 is an enlarged view of the housing front piece;
FIG. 9 is an enlarged view of the housing back piece;
FIG. 10 is an enlarged view of the control valve;
FIG. 11 is an enlarged view of the backflow valve;
FIG. 12 is an enlarged view of the backflow valve seat;
FIG. 13 is an enlarged view of the manual actuator front piece; and
FIG. 14 is an enlarged view of the manual actuator back piece.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As stated earlier, the adjustable sprayer nozzle ( 10 ) of the present invention is assembled from a total of 12 component parts. In the preferred embodiment, the component parts are molded of various types of plastics. The component parts of the adjustable sprayer nozzle include a two piece housing, a three piece fluid flow control valve assembly contained in the housing, a two piece manual actuator mounted on the housing and operatively connected with the control valve assembly, a two piece hose connector mounted on an inlet end of the housing, a dip tube, a product port control valve mounted at an outlet end of the housing and a spray deflector also mounted at the outlet end of the housing. The front of the sprayer nozzle is to the left in FIGS. 1-5 and the rear of the nozzle is to the right.
The two piece housing includes a housing front piece ( 12 ) and a housing back piece ( 14 ). The front piece ( 12 ) and back piece ( 14 ) are snap-fit together to define the sprayer housing. The sprayer housing has an interior bore ( 16 ) with a center axis ( 18 ) that extend through the housing from an inlet end ( 18 ) of the housing to an outlet end ( 22 ) of the housing. The interior bore ( 16 ) of the housing also defines the flow path of liquid supplied to the adjustable sprayer nozzle ( 20 ) and channeled through the nozzle housing as will be explained.
The housing front piece ( 12 ) has a hollow interior that defines a portion of the housing interior bore ( 16 ). The front piece ( 12 ) of the housing has a pair of pivot pins ( 24 ) projecting from opposite sides of the housing exterior surface. The pivot pins ( 24 ) are employed in mounting the spray deflector on the housing as will be explained. A detent pin ( 26 ) also projects from the housing exterior surface. The detent pin ( 26 ) is also employed in positioning the spray deflector as will be explained. An actuator lock ( 28 ) is provided on the top of the housing exterior surface. The actuator lock ( 28 ) is employed in holding the manual actuator in predetermined positions relative to the housing that are explained later. A bayonet connector ( 30 ) is provided on the housing front piece ( 12 ) and is employed in connecting the housing to a separate container of a liquid to be dispensed from the sprayer nozzle ( 10 ). The housing has a pair of elongated slots ( 32 ) on opposite sides of the housing that extend through a portion of the housing front piece ( 12 ) adjacent its rearward end. The slots ( 32 ) extend into the housing interior bore ( 16 ) and the lengths of the slots are parallel with the bore center axis ( 18 ). A pair of rectangular shaped openings ( 34 ) are provided in the housing front piece ( 12 ) on opposite sides of the housing interior bore ( 16 ) and adjacent to the rearward end of the front piece.
The housing front piece ( 12 ) has a cylindrical interior surface ( 35 ) that surrounds the portion of the nozzle interior bore ( 16 ) in the housing front piece. The interior surface ( 35 ) of the front piece is concentric with the nozzle center axis ( 18 ). A cylindrical tube ( 36 ) is centered in the housing front piece portion of the interior bore ( 16 ). The tube ( 36 ) has a cylindrical interior surface ( 38 ) that surrounds a center bore of the tube. An upstream end ( 40 ) of the tube functions as a circular valve seat, which will be explained later. The opposite downstream end ( 42 ) of the tube supports the product port control valve to be described later. A product port ( 44 ) extends through the tube intermediate its upstream end ( 40 ) and downstream end ( 42 ). The product port ( 44 ) communicates the interior bore of the tube ( 36 ) with the bayonet connector ( 30 ) on the exterior of the housing front piece ( 12 ). As seen in FIGS. 3 through 5, a hollow column ( 46 ) extends from the exterior surface of the housing front piece ( 12 ) and surrounds the product port ( 44 ). The dip tube ( 46 ) is inserted into the hollow column ( 46 ) and communicates the product port ( 44 ) with the interior of a separate container of product to be dispensed by the sprayer nozzle when the container is attached to the bayonet connector ( 30 ).
The housing back piece ( 14 ) has a hollow interior surrounded by a cylindrical interior surface ( 50 ) that also defines a portion of the housing interior bore ( 16 ). The cylindrical interior surface ( 50 ) of the back piece is concentric with the center axis ( 18 ). A pair of abutments ( 52 ) project from opposite sides of the exterior surface of the housing back piece ( 14 ) at the forward end of the back piece. A pair of attachment tabs ( 54 ) also project from opposite sides of the exterior surface of the housing back piece ( 14 ). As best seen in FIG. 2, the attachment tabs ( 54 ) are positioned circumferentially between the housing back piece abutments ( 52 ). An annular collar ( 56 ) projects from the exterior surface of the housing back piece ( 14 ) and extends completely around the housing back piece ( 14 ) at its rearward end.
In assembling the housing front piece ( 12 ) to the housing back piece ( 14 ), the housing back piece ( 14 ) is inserted into the interior bore ( 16 ) of the housing front piece ( 12 ) from the rear of the housing front piece. The housing back piece ( 14 ) is inserted into the front piece interior bore until the pair of attachment tabs ( 54 ) are aligned with and engage in the pair or rectangular openings ( 34 ) at the rearward end of the housing front piece. This snap-fits or snap connects the housing front piece ( 12 ) with the housing back piece ( 14 ) and defines the interior bore ( 16 ) that extends completely through the assembled housing from the inlet end ( 20 ) to the outlet end ( 22 ). However, before the housing front piece ( 12 ) and back piece ( 14 ) are assembled together in forming the housing, the control valve assembly is first assembled and positioned in the portion of the housing interior bore in the housing front piece ( 12 ) and the manual actuator assembly is assembled over the exterior surface of the housing front piece.
The control valve assembly is comprised of a control valve ( 60 ), a back flow valve ( 62 ) and a back flow valve seat ( 64 ) that are assembled together in constructing the control valve assembly. The control valve ( 60 ) is generally cylindrical and has a hollow interior bore ( 66 ) that forms a portion of the flow path through the sprayer nozzle ( 10 ). The control valve interior bore ( 66 ) is concentric with the housing center axis ( 18 ) and extends through the control valve from an inlet end ( 68 ) to an outlet end ( 70 ) of a control valve. As seen in FIGS. 3 through 5, a portion of the control valve exterior surface ( 72 ) adjacent the valve outlet end ( 70 ) engages in a sliding, sealing engagement with the interior surface ( 35 ) of the portion of the housing interior bore ( 16 ) in the housing front piece ( 12 ) and a portion of the control valve exterior surface ( 72 ) adjacent the valve inlet end ( 68 ) engages in a sliding, sealing engagement with the interior surface ( 50 ) of the portion of the interior bore ( 16 ) in the housing back piece ( 14 ). A pair of cam follower posts ( 74 ) project from the control valve exterior surface ( 72 ) on opposite sides of the control valve. When the control valve ( 60 ) is assembled to the housing, the posts ( 74 ) are inserted into the pair of slots ( 32 ) in the housing front piece ( 12 ) and permit axial reciprocating movement of the control valve ( 60 ) through the interior bore of the housing front piece ( 12 ), but prevent rotation of the control valve ( 60 ) in the interior bore.
The control valve interior surface ( 76 ) surrounds the control valve interior bore ( 66 ). A tubular valve support ( 78 ) is held in a centered position in the control valve interior bore ( 66 ) by a plurality of circumferentially spaced spokes or arms ( 80 ) that extend between the tubular valve support ( 78 ) and the interior surface ( 76 ) of the control valve. The fluid flow path through the interior bore of the sprayer housing passes through the spacings between the plurality of spokes ( 80 ). The tubular valve support ( 78 ) extends in a downstream direction or along the flow path through the housing to a circular valve element ( 82 ) at the forward end of the tubular support. The circular valve element ( 82 ) is dimensioned to seat inside the circular valve seat at the upstream or rearward end ( 40 ) of the cylindrical tube ( 36 ) in the housing front piece ( 12 ), as will later be explained. A second valve element in the form of a cylindrical sleeve valve ( 84 ) projects further downstream from the first, circular valve element ( 82 ). The sleeve valve ( 84 ) has a cylindrical exterior surface ( 86 ) and a hollow interior bore ( 88 ) that forms a portion of the flow path through the sprayer housing. An opening ( 90 ) is provided through the sleeve valve ( 84 ) adjacent its connection to the first valve element ( 82 ). The opening ( 90 ) communicates the fluid flow path passing through the control valve interior bore ( 66 ) and the spacings between the valve support arms ( 80 ) with the sleeve valve interior bore ( 88 ). Thus, the sleeve valve interior bore ( 88 ) forms a portion of the fluid flow path through the sprayer nozzle.
The back flow valve seat ( 64 ) has a circular outer perimeter ring ( 94 ) and a cylindrical center hub ( 96 ) that are connected together by a plurality of arms ( 98 ). The plurality of arms ( 98 ) extend radially between the center hub ( 96 ) and the outer ring ( 94 ) and are spatially arranged around the center hub ( 96 ) leaving spacings between adjacent arms ( 98 ). The fluid flow path of the nozzle passes through the spacings between the adjacent arms ( 98 ).
The back flow valve ( 62 ) is a flexible disc valve having an annular flange portion ( 102 ) and a circular collar ( 104 ) at the center of the flange portion. The valve circular collar ( 104 ) is assembled over the center hub ( 96 ) of the back flow valve seat ( 64 ) with the annular flange portion ( 102 ) of the valve covering over the arms ( 98 ) and the spacings between the arms of the valve seat ( 64 ). The outer perimeter of the valve flange portion ( 102 ) lays against the perimeter ring ( 94 ) of the valve seat ( 64 ). The valve seat ( 64 ) is assembled to the control valve ( 60 ) by inserting the valve seat hub ( 96 ) in the hollow interior of the tubular valve support ( 78 ) of a control valve. This positions the outer perimeter ring ( 94 ) of the back flow valve seat ( 64 ) against the interior surface ( 76 ) of the control valve. Thus, the fluid flow path through the control valve interior bore ( 66 ) passes through the spacings between the back flow valve seat arms ( 98 ) displacing the back flow valve annular flange ( 102 ) from the arms and the seat outer perimeter ring ( 94 ), and then continues through the control valve interior bore ( 66 ) to the outlet end ( 70 ) of a control valve. A reverse flow of liquid through the control valve interior bore ( 66 ) from the valve outlet end ( 70 ) to the valve inlet end ( 68 ) is prevented by the back flow valve flange ( 102 ) laying over the back flow valve seat arms ( 98 ) and perimeter ring ( 96 ) and the spacings between the arms.
The two piece manual actuator is comprised of an actuator front piece ( 110 ) and an actuator back piece ( 112 ). The actuator front piece ( 110 ) has a cylindrical interior surface ( 114 ) and a cylindrical exterior surface ( 116 ) and axially opposite forward ( 118 ) and rearward ( 120 ) edges. The exterior surface ( 116 ) has a plurality of axially extending raised ribs ( 122 ) that assist in manually gripping the actuator. A plurality of notches, specifically three notches ( 124 ) are provided in the forward edge ( 118 ) of the actuator front piece. The front piece interior surface ( 114 ) has a pair of cam surfaces ( 126 ) that spiral or extend axially as they extend circumferentially around portions of the interior surface ( 114 ) of the actuator front piece.
The manual actuator back piece ( 112 ) is generally cylindrical and has an annular flange ( 128 ) at the rearward edge of the back piece and a pair of arcuate panels ( 130 ) that project axially from the annular flange. The arcuate panels ( 130 ) have cylindrical interior surface portions ( 132 ) and cylindrical exterior surface portions ( 134 ) that give the actuator back piece ( 112 ) its general cylindrical configuration. The panels ( 130 ) extend axially from the annular flange ( 128 ) to forward edges ( 136 ) of the arcuate panels. A pair of cam surfaces ( 138 ) are formed in the forward edges ( 136 ). The pair of cam surfaces ( 138 ) of the actuator back piece ( 112 ) are complementary to the pair of cam surfaces ( 126 ) in the interior of the manual actuator front piece ( 110 ). Together, the two pairs of cam surfaces ( 126 , 138 ) form a cam slot that spirals around the interior of the manual actuator front piece ( 110 ). One of the cam slots ( 140 ) is shown in dashed lines in FIG. 3 .
In assembling the control valve assembly and the manual actuator to the sprayer nozzle housing, the actuator front piece ( 110 ) is first assembled over the rearward end of the housing front piece ( 12 ). The control valve assembly, with the back flow valve seat ( 64 ) and back flow valve ( 62 ) assembled into the interior of the control valve ( 66 ), is then inserted into the portion of the interior bore ( 16 ) in the housing front piece ( 12 ) with the control valve posts ( 74 ) in sliding engagement with the pair of slots ( 32 ) in the housing front piece. The manual actuator back piece ( 112 ) is then assembled into the actuator front piece ( 110 ) with the posts ( 74 ) of the control valve ( 60 ) positioned in the spiraling slots ( 140 ) formed by the actuator front piece cam surfaces ( 126 ) and the actuator back piece cam surfaces ( 138 ). The housing back piece ( 14 ) is then assembled into the housing front piece ( 12 ) with the attachment tabs ( 54 ) on the housing back piece snapping into engagement in the rectangular openings ( 34 ) of the housing front piece. This positions the abutments ( 52 ) on the housing back piece against the annular flange ( 128 ) of the manual actuator back piece, preventing the manual actuator from sliding off of the exterior surface of the assembled housing.
The two piece hose connector is comprised of a cylindrical cap ( 144 ) and a circular washer or gasket ( 146 ). The cylindrical cap ( 144 ) has an interior bore with internal screw threading ( 148 ) extending along a portion of the cap internal bore. The screw threading ( 148 ) is complementary to the conventional external screw threading of a garden hose. An annular shoulder ( 150 ) is also provided in the cap interior bore at one axial end of the cap. The shoulder ( 150 ) is dimensioned slightly larger than the annular collar ( 56 ) on the housing back piece ( 14 ) enabling the shoulder ( 150 ) to be snapped over the collar ( 56 ) to attach the cap for rotation on the housing inlet end ( 20 ). The washer ( 146 ) is inserted into the cap interior bore and seats against the housing inlet end ( 20 ).
The product port control valve ( 154 ) is a cylindrical valve having a center bore that extends between axially opposite input ( 156 ) and output ( 158 ) ends of the cylinder valve. The input end ( 156 ) of the valve has a tab ( 160 ) that projects radially outwardly from the input end. As seen in FIGS. 3 through 5, the input end tab ( 160 ) engages over the housing tube upstream end ( 40 ) and prevents axial movement of the product port control valve ( 154 ) in the tube while permitting rotational movement of the valve in the tube. A lever ( 162 ) projects from the exterior of the valve and is in sliding engagement with the opposite downstream end ( 42 ) of the housing tube. This positioning of the lever also prevents axial movement of the product port control valve while allowing rotational movement. The product port control valve ( 154 ) has a first valve opening ( 164 ) and second valve opening ( 166 ) that pass through the valve and communicate with the valve interior bore. In the preferred embodiment of the invention the first valve opening ( 164 ) is spaced 90 degrees from the second valve opening ( 166 ), and the second valve opening is larger or has a greater opening area than the first valve opening.
The spray deflector ( 170 ) is tubular and has a rectangular cross section defined by opposite top ( 172 ) and bottom ( 174 ) walls of the deflector and opposite side walls ( 176 ) of the deflector. The side walls ( 176 ) have coaxial pivot pin holes ( 178 ) that receive the pivot pins ( 24 ) on the housing front piece ( 12 ) in mounting the deflector to the housing. A tab ( 180 ) projects from one of the deflector side walls ( 176 ). The tab ( 180 ) has three detent holes ( 182 ) that are positioned on the tab ( 80 ) where they will align with the detent pin ( 26 ) on the side of the housing front piece ( 12 ) as the spray deflector ( 170 ) is pivoted about its connection to the pivot pins ( 24 ) of the housing front piece.
In operation of the adjustable sprayer nozzle ( 10 ), a garden hose is connected to the cap ( 144 ) at the inlet end ( 20 ) of the sprayer housing to supply a source of water to the nozzle. A separate container (not shown) of a product to be selectively mixed with and discharged with the flow of water directed through the nozzle is connected to the bayonet connector ( 30 ) of the housing. With the supply of water and the separate product connected to the sprayer nozzle ( 10 ), the manual actuator comprised of the two actuator pieces ( 110 , 112 ) can be selectively, manually rotated about the sprayer to vary the discharge from the sprayer.
Manual rotation of the manual actuator ( 110 , 112 ) in different directions around the sprayer housing moves the control valve ( 60 ) between three positions relative to the housing interior bore ( 16 ) and the liquid flow path through the housing interior bore. FIG. 3 shows the first position of the control valve ( 60 ) relative to the housing. In FIG. 3 the actuator lock ( 28 ) on the housing is engaged in one of the three notches ( 124 ) in the forward end of the actuator. In FIG. 3 the actuator lock ( 28 ) is positioned in the “off” notch of the manual actuator front piece ( 110 ). The control valve ( 60 ) is positioned in the housing interior bore with the first, circular valve element ( 82 ) engaged in the valve seat at the upstream end ( 40 ) of the tube ( 36 ) contained in the housing front piece ( 12 ), and with the second, sleeve valve element ( 84 ) covering over the aligned product port ( 44 ) and first valve opening ( 154 ) of the product port control valve. Thus, in the first position of the control valve ( 60 ) the fluid flow path through the sprayer nozzle is closed and communication of the dip tube ( 48 ) and product port ( 44 ) with the housing interior bore is closed.
FIG. 4 shows the two piece manual actuator ( 110 , 112 ) rotated relative to the housing causing the control valve ( 60 ) to move to its second position in the housing interior bore. To rotate the manual actuator, the actuator lock ( 28 ) is bent away from its engagement in one of the notches ( 124 ) of the actuator, allowing the actuator to be rotated. In FIG. 4 the actuator lock ( 28 ) is engaged in the second notch identified as the “water” notch on the exterior of the actuator. The movement of the actuator to the position shown in FIG. 4 rotates the cam slots ( 140 ) defined by the cam surfaces ( 126 , 138 ) around the sprayer housing. The engagement of the control valve posts ( 74 ) in the cam slots pushes the control valve axially through housing interior bore toward the inlet end ( 20 ) of the housing. In the position of the control valve ( 60 ) relative to the housing shown in FIG. 4, the first valve element ( 82 ) has been disengaged from the valve seat at the upstream end ( 40 ) of the tube contained in the first housing piece ( 12 ). This allows the fluid flow path to flow through the interior bore ( 16 ) of the housing and the interior bore ( 66 ) of the control valve to the opening ( 90 ) in the side of the second, sleeve valve element ( 84 ). The flow of fluid continues through the interior of the second, sleeve valve element ( 84 ) and the interior of the tube ( 36 ) contained in the housing front piece ( 12 ) to the spray deflector ( 170 ) where the flow of fluid is discharged from the sprayer nozzle. However, the second, sleeve valve element ( 84 ) remains over the valve opening ( 164 ) of the product port control valve ( 154 ) preventing communication of the product port ( 44 ) with the flow path through the sprayer housing. Thus, only water is discharged from the sprayer housing with the control valve positioned as shown in FIG. 4 .
FIG. 5 shows the two piece manual actuator ( 110 , 112 ) rotated to its third position which causes the control valve ( 60 ) to move to its third position relative to the sprayer housing. Again the actuator lock ( 28 ) is disengaged from the “water” notch ( 124 ) in the actuator front piece ( 110 ) and the actuator is rotated until the lock engages in the “product” notch. This movement of the actuator causes the control valve ( 60 ) to move axially through the interior bore ( 16 ) of the sprayer and moves the second sleeve valve element ( 84 ) from its position covering over the first valve opening ( 164 ) of the product port control valve ( 154 ). This communicates the product port ( 44 ) with the flow path of water through the housing interior. The flow of water over the first valve opening ( 164 ) and the product port ( 44 ) creates a venturi effect that draws product contained in a separate container attached to the bayonet connector ( 30 ) up through the dip tube ( 48 ), the product port ( 44 ) and the first valve opening ( 164 ), mixing the product with the flow of water passing through the sprayer nozzle. Thus, in FIG. 5, a mixture of water and product is dispensed from the sprayer nozzle.
The concentration of the product mixed with the water flowing through the sprayer nozzle can be adjusted by adjustably positioning the product port control valve ( 154 ) between its two positions relative to the sprayer housing. In FIG. 5 the product port control valve ( 154 ) is positioned so that its first valve opening ( 164 ) is aligned with the product port ( 44 ). The first valve opening ( 164 ) has a smaller opening area than the second valve opening ( 166 ), and therefore a smaller concentration of the product will be mixed with the water flowing along the sprayer nozzle flow path. Rotating the product port control valve ( 154 ) so that the second valve opening ( 166 ) is aligned with the product port ( 44 ) will increase the concentration of product mixed with the water flowing along the fluid flow path through the sprayer nozzle.
FIG. 3 shows the first position of the sprayer deflector ( 170 ) relative to the sprayer housing. In the first position of the spray deflector ( 170 ) the liquid discharged from the downstream end ( 42 ) of the tube ( 36 ) of the housing front piece ( 12 ) is discharged as a stream that passes through the deflector ( 170 ) without impacting with the top wall ( 172 ), the bottom wall ( 174 ) or the side walls ( 176 ) of the deflector. FIGS. 5 and 6 show the deflector ( 170 ) moved to its upwardly pivoted position. The deflector is moved by manually bending the deflector tab ( 180 ) outwardly from the housing front piece ( 12 ) disengaging the center tab detent hole ( 182 ) from the detent pin ( 26 ) on the side of the housing front piece. This enables the tab to be pivoted about the pair of pivot pins ( 24 ) on the housing front piece to the position shown in FIG. 5 where the detent pin ( 26 ) aligns with the upper tab detent hole ( 182 ). Engagement of the detent pin ( 26 ) in the upper detent hole ( 182 ) of the tab holds the deflector ( 170 ) in its upward orientation shown in FIGS. 5 and 6. A stream of liquid discharged from the downstream end ( 42 ) of the housing front piece tube ( 36 ) will impact against the spray deflector bottom wall ( 174 ) and will be discharged in an upwardly directed fanned out spray pattern.
In a like manner, the deflector ( 170 ) can be directed downwardly as shown in FIG. 7 . Again, the tab ( 180 ) is pulled outwardly from the detent pin ( 26 ) on the side of the housing front piece ( 12 ) enabling the pivoting movement of the deflector. The deflector is pivoted downwardly until the detent pin ( 26 ) on the housing front piece ( 12 ) is aligned with the bottom tab detent hole ( 182 ). Releasing the tab ( 180 ) and engaging the detent pin ( 26 ) in the bottom detent hole ( 182 ) holds the deflector ( 170 ) in its downwardly oriented position shown in FIG. 7. A stream of liquid discharge from the downstream end ( 42 ) of the tube ( 36 ) in the housing front piece ( 12 ) will impact against the deflector top wall ( 132 ) and will be discharged in a downwardly directed fanned out spray pattern.
The twelve component parts of the sprayer nozzle of the invention described above provide the nozzle with a simplified, reduced cost construction. In addition, they provide the nozzle with several desirable features, i.e., the ability to stop liquid flow through the nozzle, to open liquid flow through the nozzle without mixing with the separate product, and to open liquid flow through the nozzle while mixing with the separate liquid product. In addition, the concentration of the separate product mixed with the liquid passing through the nozzle can be adjusted. Still further, the liquid discharge from the nozzle can be directed as a stream from the nozzle or can be deflected in a fan pattern downwardly and upwardly. By providing valves that are operated by manual rotation of valve actuators about the center axis of the nozzle housing, the different options available to alter the discharge of liquid from the nozzle are easily controlled. | An adjustable nozzle is attachable to the end of a garden hose and is also attachable to a separate product container, for example, a bottle containing a garden fertilizer or a bottle containing a cleaning soap concentrate. The adjustable nozzle receives a flow of water from the garden hose and dispenses a product from the container attached to the nozzle. The nozzle has a simplified construction with a reduced number of component parts and the operation of the nozzle is simplified yet enables a user to selectively discharge a flow of water or a mixture of water and product from the nozzle, to control the ratio of water to product when the nozzle is employed in dispensing the mixture of water and product, and to direct the discharge as a stream or disperse the discharge in an upwardly or downwardly directed fanned spray pattern. | 1 |
FIELD OF THE INVENTION
The present invention relates to a method of producing a support belt for an elevator installation, to a corresponding device for producing a support belt, to a support belt and to an elevator installation with such a support belt.
BACKGROUND OF THE INVENTION
An elevator installation usually includes at least one elevator car or platform for transporting persons and/or goods, a drive system with at least one drive motor for moving the at least one elevator car or platform along a travel path and at least one support means for supporting the at least one elevator car or platform and transmitting the forces from the at least one drive motor to the at least one elevator car or platform. Cable-like support means (wire cables), chain-like support means and, increasingly in recent times, also belt-like support means (support belts) currently come into question as support means for mechanical drives.
In the case of belt-like support means there are also known, inter alia, double-layer support means comprising a first belt layer and a second belt layer connected therewith. Several tensile carriers, particularly cable-like tensile carriers, are then usually embedded in the molded body of the support belt.
A method producing a double-layer support belt of that kind is disclosed in, for example, DE 102 22 015 A1. In this known method, initially a part-belt forming the first belt layer and then a finished support belt with molded-on second belt layer are produced in two production stations integrally connected one behind the other. Several cable-like tensile carriers, which are embedded to the extent of up to half in the first belt layer, are simultaneously fed to the first production station. First and second belt layers of the support belt are each formed by means of an extrusion process.
In addition, WO 2007/032763 A1 describes a production method for a double-layer support belt in which the first belt layer and the second belt layer are formed in a production station and at the same time the tensile carriers are embedded in the second belt layer.
Finally, WO 2007/033721 A1 shows a two-stage production method for a single-layer support belt. The molded body of the support belt is formed by an extrusion process in the first production station and at the same time several tensile carriers are embedded therein. One outer side of the support belt body is then provided in the second production station, which directly adjoins thereat, with a profile in the form of wedge ribs extending in longitudinal direction.
SUMMARY OF THE INVENTION
It is a first object of the present invention to create an improved production method for a support belt for an elevator installation.
It is a second object of the present invention to create an improved production device for a support belt for an elevator installation.
It is a further object of the present invention to create an improved support belt for an elevator installation.
The method for production of a support belt for an elevator installation includes the steps of placing at least one cable-like tensile carrier; embedding the at least one cable-like tensile carrier in a first belt layer of a first plasticizable material in such a manner that a part-belt with a first outer surface and a surface forming a connecting plane arises, in which the at least one tensile carrier protrudes partly out of the connecting plane of the part-belt and the protruding section of the at least one tensile carrier is covered at least in part with the first plasticizable material; and molding on a second belt layer of a second plasticizable material at the connecting plane of the part-belt and the protruding sections of the at least one tensile carrier in such a manner that a support means with the first surface on the side of the first belt layer and a second outer surface on the side of the second belt layer arises.
The tensile carriers are in this method embedded as fully as possible in the first plasticizable material of the first belt layer so that the second plasticizable material for the second belt layer does not come into contact with the tensile carriers. Since the tensile carriers protrude from the connecting plane between the two belt layers the connecting surface formed in the embedding step from the first plasticizable material of the first belt layer has a larger area so that a good connection between the first and second belt layers can be achieved.
In one embodiment of the invention the area of the at least one tensile carrier in the embedding step is covered to at least 80%, preferably at least 90%, particularly preferably at least 95%, with the first plasticizable material. In that case, preferably also the free spaces within the at least one tensile carrier are filled in the embedding step at least partly with the first plasticizable material.
The same materials, the same materials with different characteristics or different materials can be selectably used for the first belt layer and the second belt layer. By the term “same materials” there are to be understood materials of the same synthetic material category (for example, PUR, EPDM). “Same materials with different characteristics” are thus materials of the same synthetic material category which, in consequence of different production parameters or of different additives (for example, graphite, wax), have different characteristics.
In a further embodiment of the invention the surface of the part-belt forming the connecting plane is provided at least in part with a surface structure prior to the molding-on step of the second belt layer, whereby the area of the connecting plane is increased and thus a better connection with the second belt layer, which is to be molded on later, is produced. The surface structure at the connecting surface is in that case preferably constructed during the embedding step.
In a further embodiment of the invention the first outer surface and/or the second outer surface is or are constructed with at least one rib extending in longitudinal direction of the support means. The construction of the ribs also preferably takes place during the embedding step or during the molding-on step.
In yet another embodiment of the invention the embedding step is performed as an extrusion process with extrusion of the first plasticizable material and the molding-on step is performed as an extrusion process with extrusion of the second plasticizable material.
In a further embodiment of the invention the first belt layer and the second belt layer are formed by the same or different process parameters (for example temperature, pressure, rotational speed of the molding wheel, etc.), which are each optimally matched to the first or second plasticizable material.
In another embodiment of the invention the at least one tensile carrier is placed under bias during the embedding step.
For better connection of the tensile carrier with the first belt layer the at least one tensile carrier is preferably heated during the embedding step and for better connection of the first belt layer with the second belt layer the connecting surface of the part-belt is preferably heated during the molding-on step.
The device for producing a support belt for an elevator installation comprises a first production station for forming a part-belt with a first outer surface and a surface forming a connecting plane and a second production station for forming the support belt with the outer surface and a second outer surface. The first production station comprises a first molding wheel, a first guide looping around a part-circumference of the first molding wheel, equipment for feeding at least one cable-like tensile carrier to the first molding wheel and a first extruder for feeding a first plasticizable material into a mold cavity formed between the first molding wheel and the first guide. The second production station comprises a second molding wheel, a second guide looping around a part-circumference of the second molding wheel, equipment for feeding the part-belt, which is produced in the first production station, to the second molding wheel and a second extruder for feeding a second plasticizable material into a mold cavity formed between the second molding wheel and the second guide. According to the invention the circumferential surface of the first molding wheel of the first production station is constructed with at least one longitudinal groove, which extends in circumferential direction of the first molding wheel and into which the at least one fed tensile carrier is guided, the longitudinal groove being so dimensioned that in the part-belt produced in the first production station the at least one tensile carrier protrudes partly out of the connecting plane and the protruding section of the at least one tensile carrier is at least partly covered with the first plasticizable material.
The same effects and advantages as with the above-described production method can be achieved with this device.
In one embodiment of the invention a width of the longitudinal grooves of the circumferential section of the first molding wheel is selected to be smaller than a diameter of the tensile carrier, wherein the width of the longitudinal grooves preferably lies in a range of approximately 70% to 95%, particularly preferably in a range of approximately 75% to 90%, of the diameter of the tensile carrier. In addition, a depth of the longitudinal grooves of the circumferential surface of the first molding wheel preferably lies in a range of approximately 25% to 50%, particularly preferably in a range of approximately 30% to 40% of the diameter of the tensile carrier.
In a further embodiment of the invention the first production station further comprises a device for feeding the at least one tensile carrier to the first molding wheel under bias and a first heating device for heating the at least one tensile carrier prior to the feed thereof to the first molding wheel.
In yet another embodiment of the invention the first guide of the first production station is so formed at its side facing the first molding wheel that it gives to the first outer surface of the part-belt or of the support belt a profile having, for example, the form of wedge ribs.
In yet another embodiment of the invention the first molding wheel is provided at its circumferential surface in the region between the longitudinal grooves with a structure so as to give a surface structure to the surface of the part-belt forming the connecting plane. This surface structure produces an enlargement of the area of the said connecting plane, whereby a better connection between the first and the second belt layers of the support belt is achieved.
In a further embodiment of the invention the second production station further comprises a second heating device for heating the part-belt prior to the feed thereof to the second molding wheel and the second guide of the second production station is so formed at its side facing the second molding wheel that it gives to the first outer surface of the part-belt or of the support belt a profile having, for example, the form of wedge ribs.
By the term “belt-like support means” there is to be understood all kinds of flexible tensile means, which do not have a circular cross-section, are sufficiently flexible in order to be able to be guided over driving or deflecting pulleys and in that case can transmit forces between components of an elevator installation.
The belt-like support means for an elevator installation (subsequently frequently denoted simply by “support belt”) comprises a first belt layer of a first plasticizable material with a first outer surface and a surface forming a connecting plane, at least one cable-like tensile carrier which is so embedded in the first belt layer that it protrudes partly out of the connecting plane of the first belt layer and the protruding section of the at least one tensile carrier is covered at least in part with the first plasticizable material, and a second belt layer of a second plasticizable material, which is molded on at the connecting plane of the first belt layer and the protruding sections of the at least one tensile carrier and which forms a second outer surface of the support belt.
The same effects and advantages can be achieved with the thus-constructed support belt as have been cited above in connection with the production method.
In one embodiment of the invention the area of the at least one tensile carrier is covered with the first plasticizable material to at least 80%, preferably at least 90%, particularly preferably at least 95%, and the free spaces within the at least one tensile carrier are filled at least partly with the first plasticizable material.
The first belt layer and the second belt layer of the support belt can selectably be formed from the same material, the same material with different characteristics or from different materials.
In one embodiment of the invention the first outer surface of the first belt layer is constructed with at least one rib, which extends in longitudinal direction of the support means and is preferably constructed in the form of a wedge rib and which has a flank angle between 60° and 120°, preferably between 80° and 100° and/or is constructed with a flattened tip.
In a further embodiment of the invention the second outer surface of the second belt layer is constructed with at least one rib, which extends in longitudinal direction of the support means and is preferably constructed in the form of a wedge rib and which has a flank angle between 60° and 100°, preferably between 80° and 100° and/or is constructed with a flattened tip.
In yet a further embodiment of the invention the ratio of the total height of the support belt to the total width of the support belt is greater than 1. Alternatively, this ratio can, however, be approximately 1 or less than 1.
The elevator installation of the invention has at least one elevator car or platform for transporting persons and/or goods, a drive system with at least one drive motor for moving the at least one elevator car or platform along a travel path and at least one support means for supporting the at least one elevator car or platform and for transmitting the forces from the at least one drive motor to the at least one elevator car or platform.
The at least one support means is preferably a belt-like support means according to the present invention or a belt-like support means produced in accordance with the production method of the invention.
The elevator installation comprises a drive system, preferably in the form of a driving pulley drive or a drum drive.
DESCRIPTION OF THE DRAWINGS
The above as well as further features and advantages of the invention are better understandable from the following description of preferred, non-restrictive exemplifying embodiments with reference to the accompanying drawings, in which:
FIG. 1 shows a schematic illustration of the construction of an elevator installation according to the invention, with a drum drive;
FIGS. 2A and 2B show schematic illustrations of the construction of an elevator installation according to the invention with a driving pulley drive, wherein an elevator car is disposed in a lower end position or in an upper end position in an elevator shaft;
FIG. 3 shows a schematic perspective view of a basic construction of a support belt according to the present invention;
FIGS. 4A and 4B show schematic illustrations of the construction and mode of function of a first station for production of the support belt illustrated in FIG. 3 ;
FIG. 5 shows a schematic illustration for explanation of the mode of function of the first station illustrated in FIGS. 4A and 4B ;
FIG. 6 shows a schematic illustration of a part-belt, which is produced in the first station of FIGS. 4A and 4B , according to a special form of embodiment;
FIGS. 7A and 7B show schematic illustrations of the construction and mode of function of a second station for producing the support belt illustrated in FIG. 3 ;
FIG. 8 shows a schematic sectional view of a support belt according to a first exemplifying embodiment of the invention, which is produced in accordance with the method of the invention;
FIG. 9 shows a schematic sectional view of a support belt according to a second exemplifying embodiment of the invention, which is produced according to the method of the invention;
FIG. 10 shows a schematic sectional view of a support belt according to a third exemplifying embodiment of the invention, which is produced according to the method of the invention; and
FIGS. 11A and 11B show schematic sectional views of two variants of a support belt, which is produced in accordance with the method according to the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
1. Elevator Installation
An elevator installation according to the present invention can be constructed as a passenger elevator for the transport of persons and optionally also goods or as a goods elevator for exclusive transport of goods. The following description of the individual elevator components is undertaken in each instance on the basis of a design as a passenger elevator; however, the teaching according to the invention is basically also transferrable to goods elevators.
The elevator installation according to the invention comprises at least one elevator car or alternatively one or more movable platforms which are movable in vertical direction between fixed access points (particularly between floors of a building) and guided at least in sections along their travel paths. The elevator car is movable with the help of a drive system, wherein the drive system comprises one or more drive motors optionally operable independently of one another. The elevator car is optionally constructed to also be movable in horizontal direction or along an arcuate curved track with the help of the drive system.
With respect to drive systems distinction can basically be made between a mechanical drive system with use of a driving pulley or a drum, a hydraulic system and a so-called rack drive. The present invention relates particularly to elevator installations with a driving pulley drive or drum drives as drive system.
The construction of the drive system according to the invention in practice is described in detail further below.
1.1 Elevator Car
The elevator car represents one of the main subassemblies of the elevator system according to the invention and serves for the reception of persons and goods. Elevator cars are in general produced with a rectangular or square plan, but other car shapes are also possible, for example with a round plan or the like. At least one access to the elevator car is provided. In most cases the access to the elevator car is closable by a car door, without the present invention being restricted to this design of an elevator car.
At least one support means, which in an exemplifying embodiment is fastened indirectly or directly to the elevator car, serves for supporting and driving the elevator car. In modified exemplifying embodiments the support means is guided over deflecting pulleys mounted below or above the elevator car.
1.2 Counterweight
Particularly in the case of elevator installations with a driving pulley drive use is preferably made of a counterweight, which is guided at counterweight guide rails, for reducing the drive energy required. The counterweight in that case also serves the purpose of tightening the support means so as to enable transmission of a traction force between a driving pulley and the support means.
The weight of the counterweight is usually at most equal to the sum of the weight of the elevator car and half the maximum rated load of the elevator installation. Full compensation, in which the drive energy is supplied principally to overcome the frictional resistances in the system, is thus present in the case of loading the elevator car with half the rated load.
1.3 Elevator Shaft
According to the invention the car is arranged in an elevator shaft of a building, wherein it will be obvious that the presently described elevator system is also usable in larger mobile units such as ships or in mines.
The elevator shaft is a space which is bounded at several sides by vertical walls and in which the travel path of the elevator car is disposed. In preferred manner, the travel path of the counterweight is also disposed in the elevator shaft near the travel path of the elevator car.
A shaft head in the upper end region and a shaft pit in the lower end region of the elevator shaft also belong to the elevator shaft. Arranged in the shaft pit can be, for example, buffers for the elevator car and the counterweight.
1.4 Guide Rails
According to the invention guide rails for the elevator car and the counterweight, which securely and precisely guide the elevator car and the counterweight along the travel paths thereof in the elevator shaft, are arranged at the side walls of the elevator shaft. The guide rails at the same time serve as elements at which safety brake devices of the elevator car and/or the counterweight engage in the case of a safety braking process.
The elevator car is preferably equipped on two opposite sides respectively at the top and the bottom with a guide, for example in the form of guiding slide shoes and/or roller guide shoes, by which it is guided at the guide rails in the elevator shaft.
1.5 Safety Brake Device
One of the most important and oldest requirements for operation of elevator installations (particularly walk-in passenger elevators) is safety of the elevator car against falling down.
In general, currently two forms of safety brake devices are in use: the blocking safety brake device and the braking safety brake device. The blocking safety brake device is permitted only up to a specific operating speed, whilst the braking safety brake device is suitable for elevator installations with higher operating speeds.
Both kinds of safety brake device are fixedly connected with the elevator car or the counterweight. They usually consist of two safety brake housings with the safety brake elements (and, in particular, a respective safety brake housing for each of the two opposite guide rails), the transmission elements and the connecting elements for triggering the safety brake device. The two kinds of safety brake device are triggered by a speed limiter/regulator when a predetermined trigger speed is exceeded. As speed limiter distinction can be made between two forms of construction: pendulum regulators and centrifugal force regulators.
The basic function of both kinds is often the same: in the case of a safety braking process, wedges, rollers or the like are moved upwardly into the upwardly tapering wedge chambers of the safety brake housing. The elevator car is thereby firmly clamped to the guide rails of the elevator shaft or braked to a standstill.
At the same time, a safety brake switch is opened for interrupting the control and thus for shutting down the drive system.
1.6 Travel Shaft Doors and the Safety Devices Thereof
The travel shaft doors can be constructed in accordance with the respective kind and intended purpose of an elevator installation. The different forms of embodiment of travel shaft doors can be subdivided into panel doors (or single-panel and double-panel rotary doors), folding panel doors, horizontally moved sliding doors, vertically moved sliding doors and special constructions.
Door closures as important safety devices of elevator installations can be divided on the one hand according to the type of doors to be locked and on the other hand according to the type of locking means employed. Door closures with push locks or with flap door locks are, for example, known for rotary doors, and for horizontally moved sliding doors and for vertically moved sliding doors there are, for example, door closures with push locks or with hook locks.
The travel shaft doors and the door closures thereof are in that case usually coupled with the elevator car or the car doors thereof. For example, departure of the elevator car is to be possible only after closing of both doors and after complete locking of the respective travel shaft door.
1.7 Buffers
Particularly in the case of elevator installations with high operating speeds several buffers are provided in the region of the shaft pit in order to, for example, prevent an overly hard settling of the elevator car or, in a given case, of the counterweight on the floor of the shaft pit in the event of failure of the brake of the drive system or in the event of overrunning of the operational end settings of the elevator car.
The buffers can be constructed either as springs (energy-storing buffers) or to be hydraulically acting (energy-absorbing buffers).
2. Drive System
The construction of the already above-mentioned drive system will now explained in more detail.
2.1 Drum Drive
With reference to FIG. 1 , initially the construction of an elevator installation with a drum drive is described more precisely.
The elevator installation comprises an elevator car 10 movable upwardly and downwardly in an elevator shaft 12 . In that case the elevator car 10 is guided along vertical guide rails (not illustrated), for example at the walls of the elevator shaft 12 . In order to move the elevator car 10 a drive 14 is provided which comprises, in particular, a drum 18 driven by a motor 16 , wherein motor and drum are preferably constructed as an integral unit. A drive control (not illustrated) forming part of the elevator control controls the actions of the drum drive and thus the movement of the elevator car.
In order to support the elevator car 10 and transmit the forces from the drum 18 of the drive 14 to the elevator car 10 at least one support means 20 is present. In general, several parallelly extending support means 20 are present, as indicated in FIG. 1 . One end of the or each support means 20 is fastened to the elevator car 10 and the other end of the or each support means 20 is fixed on the drum 18 of the drive 14 . Movement of the elevator car 10 takes place by winding up the or each support means 20 on the drum 18 of the drive 14 or by unwinding the or each support means 20 from the drum, which is produced by rotation of this drum 18 .
Whereas no counterweight is provided in the form of embodiment according to FIG. 1 , such can also exist in the case of a drum drive. A counterweight is then coupled by way of a second support means with the drum 18 of the drive 14 in order to reduce the required driving forces of the motor 16 .
The drive 14 is arranged in FIG. 1 in a machine room 22 above the elevator shaft 12 , wherein the machine room 22 is separated from the elevator shaft 12 by a shaft ceiling 24 , a crossbeam, a bridge or the like. However, elevator installations without a machine room are equally possible and the drive 14 can alternatively also be arranged near the elevator shaft 12 . The drive 14 can, for example, also be fastened on the guide rails for the elevator car 10 and/or the counterweight.
2.2 Driving Pulley Drive
The construction of an elevator installation with a driving pulley drive is explained in more detail in the following with reference to FIGS. 2A and 2B . In that case, components which are present with the same action in the driving pulley drive as in the afore-described drum drive are denoted by the same reference numerals.
The elevator installation comprises an elevator car 10 which is movable upwardly and downwardly in an elevator shaft 12 . In that case the elevator car 10 is guided along vertical guide rails (not illustrated), for example, at the walls of the elevator shaft 12 . Provided for movement of the elevator car 10 is a drive 14 which comprises, in particular, a driving pulley 26 driven by a motor 16 . Provided for supporting the elevator car 10 and for transmission of the driving forces from the drive 14 to the elevator car 10 is at least one support means 20 , the two free ends of which are fastened to fastening points 28 a and 28 b in or at the elevator shaft 12 . A drive control (not illustrated) forming part of the elevator control controls the actions of the driving pulley drive and thus the movement of the elevator car.
From the first fastening point 28 a (on the left in FIGS. 2A and 2B ) the support means 20 runs initially downwardly along the elevator shaft 12 , loops around a counterweight support pulley 30 at which a counterweight 32 hangs, and runs upwardly again in direction towards the drive pulley 26 of the drive 14 . After looping around the drive pulley 26 the support means 20 extends downwardly again and loops under the elevator car 10 , which for this purpose has at its underside two car support pulleys 34 a and 34 b which are each looped around by the support means 20 by approximately 90°. The support means 20 subsequently runs along the elevator shaft 12 upwardly again to the second fastening point 28 b.
The driving pulley 26 transmits the forces, which are produced by the motor 16 , to the support means 20 , which is coupled not only with the elevator car 10 , but also with the counterweight 32 . In that case, on rotation of the drive pulley 26 the elevator car 10 and the counterweight 32 move upwardly and downwardly by the support means 20 in opposite sense in the elevator shaft 12 . FIG. 2A shows the elevator car 10 in its lower operating end setting (i.e. the counterweight 32 in its upper position) and FIG. 2B shows the elevator car 10 in its upper operating end setting (i.e. the counterweight 32 in its lower position).
A significant advantage of the driving pulley drive is the possibility, by virtue of the provided counterweight 32 , to manage with comparatively low motor torques of the drive 14 . Although not illustrated, the counterweight 32 is also usually guided along vertical guide rails, for example at the walls of the elevator shaft 12 .
Buffers 38 for the elevator car 10 and buffers 40 for the counterweight 32 are usually arranged in the shaft pit 36 of the elevator shaft 12 .
The construction of an elevator installation with driving pulley drive was explained by way of example in the foregoing with reference to FIGS. 2A and 2B ; however, numerous variants are conceivable.
For example, it is also possible to mount the two car support pulleys 34 a , 34 b at the upper side of the elevator car 10 (analogously to the counterweight support pulley 30 in FIGS. 2A and 2B ). In analogous manner the counterweight support pulley 30 can be mounted, instead of at the upper side of the counterweight 32 also below that so that the support means 20 loops under the counterweight 32 . Moreover, the numbers of supporting pulleys are obviously not restricted only to the one counterweight support pulley 30 and the two car support pulleys 34 a , 34 b.
Whereas in each of FIGS. 2A and 2B only one support means 20 is illustrated, it is usual, particularly for safety reasons to provide several identical support means 20 which run parallel to one another in the above-described sense.
A 1:2 suspension of the elevator car 10 by the support means 20 is illustrated in FIGS. 2A and 2B . However, other support means arrangements such as, for example, a 1:4 suspension, a 1:8 suspension, etc., are also possible, in which the region, which is driven by the drive 14 , of the support means 20 moves four, eight, etc., times as quickly as the elevator car 10 . An elevator installation with a 1:4 suspension is described in detail in, for example, WO 2006/005215 A2 of the applicant, to which document reference is accordingly made in terms of the whole content with respect to the construction and the mode of function of a 1:4 suspension.
The drive 14 is, in FIGS. 2A and 2B , arranged in a machine room 22 above the elevator shaft 12 , wherein the machine room 22 is separated from the elevator shaft 12 by a shaft ceiling 24 , a crossbeam, a bridge or the like. However, elevator installations without a machine room are equally known and the drive 14 can alternatively also be arranged below the elevator shaft 12 or near this. For example, the drive 14 can also be fastened on the guide rails for the elevator car 10 and/or the counterweight 32 .
In elevator installations with higher operating speeds use is generally made, apart from the above-described support means 20 , also of so-called under-cables. They are tensioned around a deflecting roller, which is located in the shaft pit 36 , between a car floor and an underside of the counterweight 32 . In this manner they shall compensate for the weights of the upper support means 20 and prevent ‘jumping’ of the elevator car 10 or the counterweight 32 when the counterweight 32 or the elevator car 10 is set down or subjected to safety braking.
3. Drive
In the case of drive 14 of mechanical drives the expert distinguishes between transmissionless drives and drives with transmissions. The significant components of the drives are in that case a motor 16 , a brake, a driving pulley 26 or a drum 17 and optionally a transmission. The motor, the brake and in a given case the transmission are in that case preferably constructed, for the purpose of precise alignment and low-noise operation, as an integral subassembly on, for example, a common base plate.
3.1 Motor
The motor 16 of the drive 14 for the elevator installation is usually an electric motor which is matched to the desired parameters, such as acceleration values, travel speeds, sizes of the rated loads, noise conditions, switching frequencies and switch-on duration. Moreover, the motors have to be very robust and capable of overload with respect to their electrical and mechanical part.
The motors used in elevator installations are most frequently three-phase alternating current motors operable at one or more fixed rotational speeds. In the case of higher travel speeds or special demands on stopping accuracy use is preferably made of three-phase alternating current motors, which are regulated in rotational speed by means of frequency converters, or permanent magnet motors.
3.2 Brake
The brake of a drive 14 for an elevator installation is preferably constructed as a mechanically acting friction brake and can serve as a holding brake and/or as a deceleration brake. As a holding brake it has to fix the elevator car 10 at the desired stopping position; as deceleration brake it has the task of safely and precisely bringing the elevator car to a stop at the desired stopping position. Decelerations can also be produced by pole changing in the case of appropriate three-phase alternating current motors or by reduction in the frequency of the motor current in the case of three-phase alternating current or permanent magnet motors.
3.3 Driving Pulley
The driving pulley 26 is a significant component of the drive 14 with driving pulley drive. In that case the driving pulley 26 has to be optimally matched in each instance to the kind of support means 20 used for the elevator installation. Thus, the forces generated by the motor 16 of the drive 14 are, for example, transmitted by way of traction effect from the driving pulley 26 to the support means 20 in the case of a cable-like or belt-like support means 20 , whereagainst in the case of a chain-like support means 20 the driving pulley 26 is constructed with a toothed rim.
The traction effect achieved depends very strongly on the exact construction of the cable-like or belt-like support means 20 and the associated driving pulley 26 . For example, driving pulley and belt-like support means can have circumferential ribs and circumferential grooves with traction surfaces which are arranged in wedge shape and by way of which they are in contact with one another. Analogously to the action of a wedge belt, it is possible in the case of such a form of embodiment to influence the traction force transmissible from the driving pulley to the support means by selection of the angle between the flanks of the ribs and grooves. Moreover, co-operating ribs and grooves of the driving pulley and the support means serve for lateral guidance of the support means on the driving pulley or on correspondingly constructed deflecting rollers.
The drive 14 in general comprises several parallel driving pulleys 26 or one driving pulley 26 with several parallel force transmission sections, the number of which corresponds with those of the parallelly extending support means 20 of the elevator installation.
The construction and mode of function of the driving pulley 26 according to the invention are described in detail further below in connection with the support means 20 according to the invention.
3.4 Drum
Whereas in the case of a driving pulley drive the support means 20 runs over the driving pulley 26 and is entrained by, for example, traction depending on the respective kind of support means, in the case of a drum drive the support means 20 , the length of which has to be matched to the length of the conveying height of the elevator installation, is wound on a drum 18 . In most currently known elevator installations with a drum drive the drive 14 with the drum 18 is arranged, by contrast to the simplified illustration of FIG. 1 , at the bottom.
4. Support Means
4.1 Construction of the Support Means
Currently, cable-like support means (wire cables), chain-like support means and, increasingly in recent times, also belt-like support means (support belts) come into question as support means for mechanical drives in elevator installations. The present invention in that case relates to improvement of belt-like support means, for which reason at this point there will be no detailed discussion of cable-like and chain-like support means.
The construction, mode of function and production method for a belt-like support means for an elevator installation according to the present invention are described in more detail in the following with reference to FIGS. 3 to 11 .
FIG. 3 schematically shows, initially, the outset, the basic construction of a belt-like support means 20 for an elevator installation.
In the case of the support belt illustrated by FIG. 3 several tensile carriers, in particular several cable-like tensile carriers 42 , are embedded in a belt-like molded body (belt body) 44 . Usable as cable-like tensile carriers 42 within the scope of the present invention are, in particular, cables, strands, cords or braidings of metal wires, steel, synthetic material fibers, mineral fibers, glass fibers, carbon fiber and/or ceramic fibers. The cable-like tensile carriers can each be formed from one or more single elements or from one or more stranded elements.
In one embodiment of the invention each tensile carrier 42 comprises a double-layer core strand with a core wire (for example 0.19 millimeters diameter) and two wire layers (for example 0.17 millimeters diameter) wrapped around this as well as single-layer outer strands, which are arranged around core strand, with a core wire (for example 0.17 millimeters diameter) and a wire layer (for example 0.155 millimeters diameter) wrapped around these. Such a tensile carrier construction which, for example, can have a core strand with 1+6+12 steel wires and eight outer strands with 1+6 steel wires, has proved in tests to be advantageous with respect to strength, manufacturability and capability of bending. Advantageously, in that case the two wire layers of the core strand have the same angle of wrap, whilst the one wire layer of the outer strands is wrapped against the wrap direction of the core strand and the outer strands are wrapped around the core strand against the wrap direction of their own wire layer. However, the present invention is obviously not restricted to tensile carriers 42 with this special tensile carrier construction.
The use of cable-like tensile carriers 42 (also termed cords) with small diameters or thicknesses transversely to the length direction of the support belt 20 makes it possible to use driving pulleys 26 and support pulleys 30 , 34 a , 34 b with small diameters. The diameter of the tensile carrier 42 preferably lies in the range of 1.5 to 4 millimeters. Belt-like support means with such tensile carriers can co-operate with driving pulleys or deflecting pulleys having an outer diameter or effective diameter of less than 100 millimeters, preferably even less than 80 millimeters.
As illustrated in FIG. 3 , the belt body 44 of the support belt 20 is constructed from a first belt layer 46 of a first plasticizable material and a second belt layer 48 of a second plasticizable material and has a first outer surface 50 of the first belt layer 46 , a connecting plane 52 between the first and the second belt layers 46 , 48 and a second outer surface 54 of the second belt layer 48 . The plurality of tensile carriers 42 is embedded in the double-layer belt body 44 in the region of the connecting plane 52 .
The first outer surface 50 of the first belt layer 46 of the belt body 44 is disposed in engagement with, for example, the traction surface of the driving pulley 26 , whilst the second outer surface of the second belt layer 48 is disposed in engagement with the running surfaces of the counterweight support pulley 30 and the two car support pulleys 34 a , 34 b . However, the support belt 20 of the invention is obviously usable in inverted manner in an elevator installation with driving pulley drive, as is illustrated in FIGS. 2A and 2B , i.e. the first outer surface 50 of the first belt layer 46 of the belt body 44 can equally be disposed in engagement with the traction surface of the driving pulley 26 , whilst the second outer surface 54 of the second belt layer 48 is in engagement with the running surfaces of the counterweight support pulley 30 and the two car support pulleys 34 a , 34 b.
The first material for the first belt layer 46 and the second material for the second belt layer 48 are preferably produced from an elastomer, for example from polyurethane (PUR), ethylene-propylene-diene-rubber (EPDM), acrylnitrile-butadiene-rubber (NBR), polychloroprene (CR) or natural rubber. However, other synthetic materials, such as polyamide (PA), polyethylene (PE), polyethersulfone (PES), polyphenylsulfide (PPS), polytetrafluorethylene (PTFE), polyvinylchloride (PVC) and the like can also be used for the belt layers 46 , 48 for forming the molded body 44 of the support belt. However, the invention is not to be restricted to the stated materials. In addition, special adhesion agents can be added to the materials for the first and second belt layers 46 , 48 in order to increase the strength of the connection between the belt layers 46 , 48 and between the first belt layer 46 and the tensile carriers 42 . In addition, the intercalation of further fabrics, fabric fibers or other fillers is also possible.
As explained further below in more detail, the first and second belt layers are each formed in an extrusion process. Thermoplastic elastomers are preferably used as materials for that purpose. In principle, it is also possible to use vulcanizable elastomers or rubber material, wherein the final vulcanization can be carried out only after the extrusion process so as to have a flowable material for the extrusion process.
According to the invention it is possible to use for the first belt layer 46 and the second belt layer 48 in each instance the same material with the same characteristics, in each instance the same material with different characteristics, or different materials. Important characteristics of the material or materials for the molded body 44 are, in particular, the elasticity, the coefficient of friction, the wear resistance, the flowability during extrusion, the capability of bonding with the cable-like tensile carriers 42 , the color, the light resistance and the like.
In special embodiments of the invention at least one of the belt layers 46 , 48 can be formed from a transparent material so as to facilitate checking of the support belt 20 for damage, particularly for broken tensile carriers 42 . Moreover, the first and/or the second belt layer can be constructed with an antistatic quality, i.e. from a material which is not electrostatically chargeable. In a further embodiment, for example, the second belt layer can be of luminescent construction so as to render the rotation of the driving pulley or the drum recognizable or to produce defined optical effects.
The embedding of the cable-like tensile carriers 42 in the first belt layer 46 produces a lubrication of its individual wires in the case of mutual movement thereof in use in an elevator installation. Moreover, the tensile carriers 42 are thus additionally protected against corrosion and held precisely in their desired positions.
In order to increase the pressing pressure of the support means 20 against a driving pulley 26 it is advantageous, with respect to an increase in the traction capability or drive capability, to construct those contact surfaces of the belt body 44 which co-operate with the driving pulley 26 , i.e. the first or the second outer surface 50 , 54 , with so-called (wedge) ribs (not illustrated in FIG. 3 ). The ribs extend as longitudinal elevations in the direction of the length of the support belt 20 and preferably come into engagement with correspondingly shaped grooves on the running surface of the driving pulley 26 . At the same time, the wedge ribs guarantee, by their engagement in the grooves at the driving pulley 26 , a lateral guidance of the support belt 20 on the driving pulley 26 .
Moreover, the two outer surfaces 50 , 54 of the support belt 20 of the invention can be provided over the entire length thereof or only in corresponding part-sections, in which they come into contact with the driving pulley 26 and the various supporting and deflecting pulleys of the elevator installation, with a special surface property which, in particular, influences the slide characteristics of the support belt 20 . For example, the outer surface 50 , 54 , which mates with the traction surface of the driving pulley 26 , of the support belt can be provided with a traction-reducing coating, surface structure or the like. Alternatively, the support belt 20 can also be sheathed at one or both of the outer surfaces 50 , 54 with a fabric or the like so as to influence the characteristics of the support belt surface.
It is, in principle, possible to provide several differently constructed support belts 20 of the described kind in one elevator installation.
4.2 Production of the Support Belt
The production method of the support belt 20 of the invention and the corresponding device for producing the support belt are now explained in detail with reference to FIGS. 4 to 7 .
The method for producing the support belt 20 with a first belt layer 46 and a second belt layer 48 and cable-like tensile carriers 42 embedded therein is a two-stage method. The first production station of this two-stage production method is illustrated in FIG. 4A and the second production station is illustrated in FIG. 4B . It is to be noted that the first and second production stations are directly connected one behind the other as separate production stations or within an integral production process.
As illustrated in FIG. 4A , the first production station for the support belt 20 of the invention comprises a first rotating molding wheel 56 and a first guide 58 looping around a circumferential section of this first molding wheel 56 . This first guide 58 can be formed from, for example, an endless molding belt which is guided over several rollers and which together with the circumferential surface of the first molding wheel 56 and two guide ribs 61 protruding therefrom forms a mold cavity such as disclosed in, for example, DE 102 22 015 A1 cited in the introduction. Alternatively, the first guide 58 can be a stationary outer wall of the said mold cavity, which forms it together with the circumferential surface of the first molding wheel 56 and the two guide ribs 61 protruding therefrom. In this case, the side of the first guide 58 facing the molding wheel is advantageously provided with a slide element, for example a slide covering of PTFE, so as to facilitate relative movement between the first guide 58 , which forms the stationary outer wall of the mold cavity, and the extruded molded body, which circulates together with the molding wheel 56 , of the resulting part-belt 66 .
The circumferential surface 98 as shown in FIG. 5 of the first molding wheel 56 is constructed with several longitudinal grooves 60 , which extend along the circumferential direction of the molding wheel as illustrated in FIG. 4B . The width of the circumferential surface of the molding wheel 56 , which is preferably bounded by suitable lateral guide elements 61 (see FIG. 5 ), corresponds with the desired width of the support belt 20 and the number of longitudinal grooves 60 in the circumferential surface of the first molding wheel 56 corresponds with the desired number of the cable-like tensile carriers 42 in the support belt 20 .
As illustrated in FIG. 4B , the width b of the guide grooves 60 is selected to be smaller than the diameter d of the tensile carriers 42 . For example, the width b of the groove 60 lies in a range of approximately 70% to 95% of the diameter d of the tensile carriers 42 , particularly preferably in a range of approximately 75% to 90%. Moreover, the depth t of the longitudinal grooves 60 lies in a range of approximately 25% to 50%, preferably in a range of approximately 30% to 40%, of the diameter d of the tensile carriers 42 .
In the first production station of FIG. 4A the cable-like tensile carriers 42 are now fed from a storage roll 62 to the first molding wheel 56 , wherein they are guided into the longitudinal grooves 60 of the circumferential surface of the first molding wheel 56 and preferably held under bias. By virtue of the above-described dimensioning of the width b and the depth t of the guide grooves 60 in relation to the diameter d of the tensile carriers 42 the tensile carriers 42 are received only partly in the longitudinal grooves 60 . The tensile carriers 42 contact the first molding wheel 56 only along the rim edges 90 of the longitudinal grooves 60 thereby forming contact points 92 , so that free spaces 94 or cavities are present between the tensile carriers and the first molding wheel 56 in the regions of the longitudinal grooves 60 as shown in FIG. 5 . A portion of the at least one tensile carrier 42 protrudes partly out of the connecting plane 52 , thereby forming a protruding portion 96 .
A flowable flow of the first material is dispensed from a first extruder 64 substantially without pressure into the mold cavity formed between the first molding wheel 56 and the first guide 58 , wherein the at least one tensile carrier 42 rests on the circumferential surface of the first molding wheel 56 before the flow of the first material enters the mold cavity. The material flow from the first extruder 64 is pressed by the first guide 58 against the tensile carriers 42 and the first molding wheel 56 and thus obtains its final shape so as to ultimately form the part-belt 66 with the first belt layer 46 and the tensile carriers 42 embedded therein. The first outer surface 50 of the part-belt 66 or of the support belt 20 in that case faces the guide 58 and the surface of the part-belt 66 forming the connecting plane 52 faces the first molding wheel 56 .
As illustrated in FIG. 5 , in this embedding process the flowable first material also flows into the cavities within the cable-like tensile carriers 42 and through these cavities as well as through the free spaces 94 to substantially cover an external surface of the protruding portion 96 , which are formed by virtue of the twisting of the tensile carriers 42 , between the tensile carriers 42 and the first molding wheel 56 (see flow lines 67 indicated in FIG. 5 by arrows) also into the free spaces 94 or cavities, defined as areas which are formed between the tensile carriers 42 and the corresponding grooves 60 and between the contact points 92 , of the mold cavity. The penetration of the first material into these free spaces 94 or cavities is facilitated in that the tensile carriers contact the first molding wheel 56 only at the contact points 92 , that is, only along the rim edges 90 of the longitudinal grooves 60 , so that the tensile carriers 42 by their twisted outer strand wires hardly obstruct inflow of the material into the cavities between the tensile carriers and the first molding wheel 56 . In this manner, on the one hand the cavities within the cable-like tensile carriers 42 are at least partly filled with the first material, whereby a very good connection between the tensile carriers 42 and the first belt layer 46 of the first material results. On the other hand, the tensile carriers 42 are embedded as fully as possible in the first belt layer 46 , so that no direct contact exists between the embedded tensile carriers 42 and the second belt layer 48 subsequently molded on at the connecting surface 52 .
The characteristics of the first plasticizable material (particularly its viscosity) and the process parameters of the first production station (particularly temperature and pressure) are in that case to be selected in such a manner that the first material during the embedding step can penetrate into the cavities within the cable-like tensile carriers 42 and the cavities between the tensile carriers 42 in the first molding wheel 56 , as explained above with reference to FIG. 5 .
In the exemplifying embodiment illustrated in FIGS. 4 and 5 the at least one tensile carrier 42 of the support belt 20 after the first production step in the first production station protrudes by approximately 5% to 20% (the protruding portion 96 ) of its diameter relative to the connecting surface 52 of the part-belt 66 . In that case, more than 80%, preferably more than 90%, particularly preferably more than 95%, of the surface of the at least one tensile carrier 42 is covered by the first plasticizable material of the first belt layer 46 .
In order to further improve the connection between the first plasticizable material for the first belt layer 46 and the tensile carriers 42 to be embedded it is of advantage if the tensile carriers 42 are heated during the embedding process. For this purpose, for example, a first heating device 68 for heating the tensile carriers 42 to be fed to the first molding wheel 56 is so arranged that the tensile carriers are heated before they run onto the molding wheel 56 .
Although not illustrated in FIGS. 4 and 5 , the first guide 58 can be profiled at its inner side facing the first molding wheel 56 so as to impart a profile to the first outer surface 50 of the part-belt 66 or of the finished support belt 20 . In particular, it is possible to provide the first outer surface 50 of the support belt 20 with ribs or wedge ribs extending in longitudinal direction, as is later discussed in connection with special forms of embodiment of the support belt 20 with reference to FIGS. 8 to 10 . Alternatively or additionally, further surface structures can also be introduced into this outer surface 50 . The profiling or structuring of the first outer surface 50 of the support belt 20 in that case is carried out in advantageous manner during the embedding step of the at least one tensile carrier 42 in the first belt layer 46 .
According to a preferred alternative method, in the said embedding step the part-belt 66 is extruded with an unprofiled plane forming the first outer surface 50 of the support belt 20 . After the subsequently described second production step the support belt 20 is so re-processed in a separate, further production step that it has the afore-mentioned ribs extending in longitudinal direction of the support belt. Advantageously, this re-processing of the support belt is carried out by grinding with profiled grinding discs, which are particularly suitable for grinding elastomeric materials. The removed material is in that case sucked away and recycled.
In an advantageous development of the invention the first molding wheel 56 or its circumferential surface is constructed in such a manner that the connecting surface 52 of the part-belt 66 is provided with a surface structure during the embedding step. As indicated in FIG. 6 , preferably at least the sections of the connecting surface 52 between the tensile carriers 42 are constructed with a surface structure 70 , for example in the form of a grid-shaped or irregular roughening, knurling or rippling. In addition, however, the regions of the tensile carriers 42 in the connecting surface 52 can also be constructed with a surface structure 70 . Such a surface structure 70 increases the area of the connecting surface 52 and thus improves the later connection with the second belt layer 48 .
After production of the part-belt 66 in the first production station according to FIGS. 4A and 4B production of the support belt 20 in a second production station, which is shown by way of example in FIGS. 7A and 7B , is carried out.
As is illustrated in FIG. 7A , the second production station comprises, similarly to the first production station for the support belt 20 , a second molding wheel 72 rotating in anticlockwise sense and a second guide 74 looping around a circumferential section of this second molding wheel 72 . This second guide 74 can be formed, for example, like the first guide 58 of the first molding wheel 56 from an endless molding belt which is guided over a plurality of rollers and which together with the circumferential surface of the second molding wheel 72 and two guide ribs, which are not illustrated here and which protrude from the circumferential surface, forms a mold cavity. Alternatively, the second guide 74 can be a stationary outer wall of the mold cavity, which forms it together with the circumferential surface of the second molding wheel 72 and two guide ribs protruding therefrom. In this case, the side of the second guide 74 facing the molding wheel 72 is advantageously provided with a slide element in order to facilitate relative movement between the second guide 74 , which forms the stationary outer wall of the mold cavity, and the extruded molded body, which circulates with the molding wheel 72 , of the resulting second belt layer 48 .
By contrast to the first production station of FIGS. 4A and 4B the second molding wheel 72 of the second production station is constructed with a circumferential surface corresponding with the profile of the first outer surface 50 of the first belt layer 46 or of the part-belt 66 . In the exemplifying embodiment shown in FIG. 7B a flat circumferential surface is provided for the second molding wheel 72 for the case that the first outer surface 50 of the support belt 20 is not to have a profile, i.e. is to have a flat surface structure, or for the case that the outer surface 50 is profiled only by re-processing. The width of the circumferential surface of the second molding wheel 72 , which is preferably bounded by suitable lateral guide elements (not illustrated), corresponds with the desired width of the support belt 20 .
In the second production station according to FIG. 7A the part-belt 66 produced in the above-described first production station is so fed to the second molding wheel 72 that the first outer surface 50 of the part-belt 66 stands in contact with the circumferential surface of the second molding wheel 72 . A flowable flow of the second plasticizable material is dispensed from a second extruder 76 substantially without pressure into the mold cavity formed between the second molding wheel 72 and the second guide 74 . The material flow from the second extruder 76 is pressed by the second guide 74 against the connecting surface of the part-belt 66 and is molded thereat as the second belt layer 48 . In that case the second belt layer 48 receives its final form and ultimately forms together with the first belt layer 46 and the tensile carriers 42 embedded between the two belt layers the support belt 20 . The second outer surface 54 , which is formed by the second belt layer 48 , of the support belt 20 in that case faces the guide 74 .
As illustrated in FIG. 7B , in this molding-on process the flowable second material flows against the entire surface of the part-belt 66 forming the connecting plane 52 . In the case of a surface structuring 70 of this connecting surface 52 as explained above, the connection between the first and second belt layers 46 , 48 is particularly good. Since the tensile carriers 42 were, in the first production station, embedded as fully as possible in the first belt layer 46 , the second belt layer 48 hardly comes into contact or does not even come into contact with the tensile carriers 42 .
In order to further improve the connection between the second plasticizable material for the second belt layer 48 and the previously produced part-belt 66 it is of advantage if the part-belt 66 is heated during the described molding-on process. For this purpose, for example, a second heating device 78 for heating the part-belt 66 to be fed to the second molding wheel 72 is so arranged that the part-belt is heated before it runs onto the second molding wheel 72 .
Although not illustrated in FIGS. 7A and 7B , the second guide 74 can also be profiled at its inner side facing the second molding wheel 72 so as to impart a profile to the second outer surface 54 of the finished support belt 20 . In particular, it is possible to also provide the second outer surface of the support belt 20 with ribs or wedge ribs running in longitudinal direction, as is discussed later in connection with special forms of embodiment of the support belt 20 with reference to FIGS. 8 to 10 . Alternatively or additionally, further surface structures can also be introduced into this second outer surface 54 . This profiling or structuring of the second outer surface 54 of the support belt 20 in that case is carried out in advantageous manner during the molding-on process in the second production station.
According to a preferred alternative method, in the course of the said molding-on process the second belt layer 48 is extruded with an unprofiled plane forming the second outer surface 54 of the support belt 20 . After the subsequently described second production process the support belt 20 is so re-processed in a separate, further production step that it has the afore-mentioned ribs extending in the longitudinal direction of the support belt. Advantageously, this re-processing of the support belt is carried out by grinding with profiled grinding discs, which are specifically suitable for the grinding of elastomeric materials. The removed material is in that case sucked away and recycled.
As already mentioned above, the same or different materials with the same or different characteristics can be selectably used for the first and second belt layers 46 , 48 . By virtue of the two-stage production method it is of advantage if the second material has a lower flow temperature or melt temperature than the first material so that if need be the material flow fed by the second extruder 76 in the second production station softens the surface of the first belt layer 46 at the connecting surface 50 so as to achieve a better connection between the two materials, but does not soften the entire part-belt 66 . It can thus be ensured that the shape of the entire part-belt 66 with the tensile carriers 42 enclosed by the first material remains virtually unchanged.
In a preferred exemplifying embodiment a softer material is selected for the second belt layer 48 of the support belt 20 than for the first belt layer 46 of the support belt 20 . For example, the first material for the first belt layer 46 has a Shore hardness of approximately 85 at room temperature, whilst a second material with a Shore hardness of approximately 80 at room temperature is used for the second belt layer 48 .
In the above exemplifying embodiment of the production method it was described that the first and the second outer surfaces 50 , 54 in the first and second production stations can be selectably constructed with planar surfaces or with a profile. Moreover, it is possible to provide one or both of the outer surfaces 50 , 54 by an additional coating, vapor deposition, flock-coating or the like (not illustrated) so as to selectively change the surface characteristics, particularly the friction characteristics, of the surfaces of the support belt 20 . This surface processing can be used selectably on the complete outer surfaces 50 , 54 or only a part of the outer surfaces, such as, for example, the flanks of wedge ribs forming these outer surfaces. A coefficient of friction of μ≦0.3, for example, is preferred for the second belt layer 48 , which comes into contact with the deflecting pulleys.
4.3 Special Forms of Embodiment of the Support Belt
Various preferred forms of embodiment of a support belt 20 , which are producible by the above-described production method according to the invention, are now described with reference to FIGS. 8 to 10 .
In the first exemplifying embodiment according to FIG. 8 the support belt 20 comprises a molded body 44 , which is formed from a first belt layer 46 and a second belt layer 48 and in which a tensile carrier arrangement with a total of four cable-like tensile carriers 42 is arranged. The first outer surface 50 of the first belt layer 46 is provided for contact with the driving pulley 26 . It has for this purpose two drive ribs in the form of wedge ribs 80 , which engage in associated grooves of the driving pulley 26 and are laterally guided by this, wherein the pressing-on forces and thus the traction capability of the drive increase as a consequence of the wedge action.
The second outer surface 54 of the second belt layer 48 is provided for contact with the car support pulleys 34 a , 34 b and has for this purpose a guide rib in the form of a wedge rib 82 , which engages in an associated roller of the deflecting pulleys 34 a , 34 b and is laterally guided by these.
In the exemplifying embodiment of FIG. 8 the total height of the support belt 20 is dimensioned to be greater than its total width. The stiffness in bending of the support belt 20 about its transverse axis is thereby increased and thus jamming in the grooves of the driving pulley 26 and the support pulleys 30 , 34 a , 34 b is counteracted. In the illustrated example the ratio of total width to total height is approximate 0.90.
The flank angle α of the drive ribs 80 of the first belt layer 46 is defined as an inner angle between the two flanks of a drive rib 80 and in the exemplifying embodiment is approximately 90° (in general between 60° and 120°). The correspondingly defined flank angle β of the guide rib 82 of the second belt layer 48 is in this example approximately 80° (in general between 60° and 100°).
As apparent in FIG. 8 , the flank height of the guide rib 82 is greater than the flank height of the two drive ribs 80 . The guide rib 82 can thereby dip deeper into a corresponding groove of the deflecting pulleys 30 , 34 a , 34 b than is the case with the drive ribs 80 and the associated grooves of the driving pulley 26 . Equally, it is apparent in FIG. 8 that the flank width of the guide rib 82 is also larger than that of the two drive ribs 80 . Through this larger flank width of the guide rib 82 the support belt 20 is guided on its second outer side 54 over a wider region in transverse direction, whereby the risk of jumping of the support belt out of its guide groove in the deflecting pulley is reduced.
As indicated in FIG. 8 , the wedge ribs 80 , 82 each have a flattened tip with a width which is at least as large as the minimum spacing of the corresponding counter-flanks of the grooves of the pulleys 26 , 30 , 34 a , 34 b . It is thereby avoided that the tips of the wedge ribs contact the base of the corresponding wedge grooves in the stated pulleys and thus are protected against a corresponding concentration of stress.
The first outer surface 50 can have a coating with a PA film or the like at least in those regions of the wedge ribs 80 which enter into frictional couple with the flanks of the driving pulley 26 . Moreover, the possibility exists of providing a wedge rib 80 with a coating reducing the coefficient of friction and/or noise.
A support belt 20 , as has been described above with reference to FIG. 8 , is explained in detail, for example, in EP 06127168.0 of the applicant, which is not yet published and to which reference is accordingly made in terms of the complete content with respect to the construction and shape of the support belt 20 .
The second exemplifying embodiment of a support belt 20 illustrated in FIG. 9 differs from the above-described example in that, instead of the two wedge ribs 80 on the side of the first belt layer 46 , only one wedge rib 80 is constructed. This one wedge rib 80 also has a flank angle α of approximately 90° (in general between 60° and 120°) and a flattened tip. Overall, in the case of this support belt 20 a V-shaped profile results not only at the first, but also at the second outer surface 50 , 54 . The support belt disclosed by FIG. 9 has overall a cross-section geometrically corresponding with a kite quadrilateral (deltoid). If the flank angles α and β are of the same size, then the overall cross-section of the support belt corresponds with a lozenge (rhombus). Such a support belt has the advantage that it can be guided by its two sides around driving and deflecting pulleys which are provided with identically shaped wedge grooves.
FIG. 10 shows a third exemplifying embodiment of the support belt 20 . This differs from the support belt 20 illustrated in FIG. 9 in that the wedge rib 80 of the first belt layer 46 is constructed to be rounded overall.
It is obvious that the exemplifying embodiments of FIGS. 8 to 10 are only by way of example and the invention is not to be restricted to these special shapes of the support belt 20 . The expert will readily recognize further variants of the support belt which can be made by the above-described production method of the invention.
Although in the exemplifying embodiments of FIGS. 8 to 10 in each instance the total height of the support belt 20 was dimensioned to be greater than its total width, the invention is obviously not restricted thereto. As indicated in FIGS. 11A and 11B , the present invention embraces not only support belts 20 in which the height is greater than the width ( FIG. 11A ), but also support belts 20 in which the width is greater than the height ( FIG. 11B ). Beyond that, not only rectangular, but also square cross-sectional shapes are conceivable for the support belt 20 . The ratio of the total width to the total height of the support belt 20 preferably lies in the range between 0.8 and 1.2, particularly preferably in the range between 0.9 and 1.1.
In the above exemplifying embodiment the production of a support belt 20 with a specific width and a specific number of embedded tensile carriers 42 and wedge ribs 80 , 82 was described. However, particularly in the case of narrow support belts 20 (i.e. height/width >1), as shown by way of example in FIGS. 8 to 10 , it is also possible within the scope of the invention to allow several such support belts 20 to run at the same time adjacent to one another through respectively correspondingly conceived first and second production stations.
According to a variant of such a parallel production initially a wide belt of the width of several support belts 20 with a large number of tensile carriers 42 is produced and is subsequently divided up into several individual support belts 20 . Various mechanical methods such as cutting, sawing, etc., are conceivable for that purpose. For simplification of the dividing process frangible locations can also be provided in the wide belt to extend in its longitudinal direction. For dividing up such a wide belt with frangible locations into individual support belts 20 a driving pulley 26 can be provided in which increased spacings between two adjacent grooves are present in the region of desired separating points, whereby when the elevator installation is placed in operation the wide belt is spread apart at these locations and thereby separated, so that ultimately several individual support belts 20 are in use in the elevator installation.
For simpler handling during transport and assembly several support belts 20 with a support band or assembly band, for example of synthetic material or the like, can be connected together. The support band or the assembly band is preferably removed from the support belt 20 after mounting of the support belt in an elevator installation. This method is explained in more detail in, for example, EP 06118824.9 of the applicant, which is not yet published and to which reference in terms of the full content is accordingly made with respect thereto.
4.4 End Fastening Means (for Fastening the Free Ends of the Support Belt)
For secure fastening of the free ends 28 a , 28 b of the cable-like or belt-like support means 20 different end fastening means can be provided. The free ends of wire cables can be fixed by, for example, wedge locks, encapsulating, splicing or other methods; those of support belts are usually fastened by wedge locks, wherein the components, which co-operate with the ribbed sides of the support belt, of the wedge locks are preferably provided with corresponding grooves.
In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. | A process for producing a support belt for an elevator system includes steps of: placing at least one cable-shaped tension support in position; embedding the tension support in a first belt layer made from a first plasticizable material to produce a partial belt having a first outer surface and a surface which forms a connecting plane, wherein parts of the tension support project out of the connecting plane and at least parts of the projecting portion of the tension support are covered by the first plasticizable material; and integrally forming a second belt layer made from a second plasticizable material on the connecting surface of the partial belt and the projecting portions of the tension support so as to produce a support belt having the first outer surface on the side of the first belt layer and a second outer surface on the side of the second belt layer. | 3 |
RELATED APPLICATION
This application is a divisional of U.S. patent application Ser. No. 12/114,856 filed May 5, 2008, and claims the benefit of U.S. Provisional Application Ser. No. 60/939,718 filed May 23, 2007, the entirety of which applications are incorporated by reference.
BACKGROUND OF THE INVENTION
This invention relates to a method and an apparatus for hydrolysis treatment of cellulosic fiber material.
In conventional systems, wood chips (or other cellulosic or fiber material) undergo hydrolysis in a first reactor vessel prior to introduction to a second vessel, e.g., a digester. One such conventional system is described in U.S. Pat. No. 4,174,997 ('997 patent). In the first reactor vessel, hydrolysis of the slurry of wood chips passing through that vessel occurs under acidic conditions. In the first reactor vessel, hydrolysate, e.g., sugars such pentose and hexose, is extracted from wood chips and the hydrolysate is recovered. Fiber material is discharged from the bottom of the first reactor vessel and transferred via the transfer line to the top of the second reactor vessel, e.g., digester, for cooking treatment of the cellulosic material.
In conventional systems, such as described in the '997 patent, hydrolysis occurs throughout the first reactor vessel. A chip slurry is introduced into the top of the first reactor vessel and is discharged from the bottom of the vessel. Heat is added to the vessel by introducing hot water, e.g., 150° C. degrees Celsius (° C.), to the bottom of the vessel and steam at the top of the vessel. In addition, acidic solutions were added to promote hydrolysis, especially where the material was at temperatures below 150° C. The hot water flows upward in the vessel, which is counter to the downward flow of fiber material. The hot water and steam provide sufficient heat to the material to maintain hydrolysis through the vessel.
In some conventional systems, cooking chemical such as white liquor is introduced to the bottom of the first reactor vessel and into a transfer pipe for transporting the chip slurry from the first reactor vessel to the second reactor vessel. The injection of cooking chemicals to the bottom of the first reactor vessel starts the impregnation of the fibers of the cellulosic material in the bottom of the first reactor vessel while the hydrolysis reaction is still underway. It is undesirable to introduce cooking chemicals to the cellulosic material while hydrolysis is ongoing.
BRIEF DESCRIPTION OF THE INVENTION
A novel hydrolysis system has been developed for a pulping system. Cellulosic material, e.g., wood chips, undergoes hydrolysis in an upper region of a first vessel (hydrolysis reactor). Hydrolysis is preferably conducted where the material in the vessel is at a temperature of between 150° C. and 175° C., more between 160° C. to 170° C. Hydrolysis is preferably conducted where the material in the vessel is preferably at a pH of 1 to 6, and more preferably at a pH 3 to 4. Hydrolysate and liquids are removed from the hydrolysis reactor through an extraction screen.
Below the extraction screen, cool wash liquid flows upward through a wash zone in the hydrolysis reactor and to the extraction screen. The cool wash liquid suppresses hydrolysis reactions in the cellulosic material below the extraction screen. Substantially all of the hydrolysis is preferably performed above the extraction screen in the hydrolysis reactor. The cool wash liquid preferably has a temperature of 10° C. to 70° C. cooler than the hydrolysis temperature, more preferably 20° C. to 50° C. cooler, and most preferably 25° C. to 35° C. cooler than the hydrolysis temperature. The cool wash liquid preferably has a pH of 3 to 7, and most preferably a pH of 4 to 5. Further the cool wash liquid preferably includes mostly water and may include an added chemical in an amount of 0.01 percent (%) to 5 percent of the amount of cellulosic material, e.g. wood, in the slurry flowing through the vessel. The amount of added chemical is most preferably 0.1 percent to 1 percent of the amount of cellulosic material in the slurry. The chemical added to the cool wash water may be either or both sodium hydroxide (NaOH) or essentially sulfur free white liquor to produce a cool wash liquid.
A reactor vessel system has been developed comprising: a first reactor vessel having a material input receiving cellulosic material and a material discharge for the cellulosic material, wherein the cellulosic material flows through the first reactor vessel from the material input to the material discharge; a hydrolysate and liquid extraction screen in the first reactor vessel; a first region of the first reactor vessel between the material input and the liquid extraction screen, wherein the first region is maintained at conditions promoting a hydrolysis reaction in the cellulosic material; a heat energy inlet port for introducing a heated fluid added to the cellulosic material in or above the first region; a second region of the first reactor vessel between the liquid extraction screen and the material discharge in which the hydrolysis is substantially suppressed; a wash liquid inlet port for introducing a wash liquid below the extraction screen and flowing through the second region to the extraction screen, wherein the wash liquid is introduced at a temperature below a hydrolysis temperature and the wash liquid suppresses the hydrolysis second region; a transport pipe having an inlet coupled to the material discharge of the first reactor vessel and an outlet coupled to a second reactor vessel, wherein the cellulosic material flows from the material discharge, through the transport pipe to the second reactor vessel, and the second reactor vessel applies a cooking liquor to the cellulosic material in the second reactor vessel, and the second reactor vessel includes a liquid discharge that extracts a portion of liquid from the second reactor vessel and directs the portion of liquid to at least one of a lower inlet of the first reactor vessel or to the transport pipe.
A flash tank may receive liquid extracted from the extraction screen(s) of the first reactor vessel and provide steam to the vessel at or above the first vessel region. The flash tank may also discharge hydrolysate to a hydrolysate recovery system.
A reactor vessel system has been developed comprising: first reactor vessel having an upper material input receiving cellulosic material and a bottom material discharge for the cellulosic material, wherein the cellulosic material flows through the first reactor vessel from the material input to the material discharge; a hydrolysate and liquid extraction screen in the first reactor vessel; an upper region of the first reactor vessel between the material input and the liquid extraction screen, wherein the upper region is maintained at or above a hydrolysis temperature at which a hydrolysis reaction occurs in the cellulosic material; a heat energy inlet port for introducing a heated fluid to the cellulosic material in the upper region of the first reactor vessel; a lower region of the first reactor vessel between the liquid extraction screen and the bottom material discharge in which the hydrolysis is substantially suppressed; a wash liquid inlet port at a lower region of the first reactor vessel for introducing sufficient wash liquid to the vessel such that the wash liquid flows up through the lower region to the extraction screen, wherein the wash liquid is introduced at a temperature below the hydrolysis temperature and the wash liquid cools and suppresses the hydrolysis reactions in the second region of the reactor vessel; a transport pipe having an inlet coupled to the material discharge of the first reactor vessel and an outlet coupled to a second reactor vessel, wherein the cellulosic material flows from the bottom material discharge, through the transport pipe to an upper inlet of the second reactor vessel, and the second reactor vessel applies a cooking liquor to the cellulosic material in the second reactor vessel, and the second reactor vessel includes a liquid discharge that extracts a portion of liquid from the second reactor vessel and directs the portion of liquid to at least one of a lower inlet of the first reactor vessel or to the transport pipe.
A processing system has been developed for converting cellulosic material to pulp, the system comprising: a first pressurized reactor vessel operating at a pressure above atmospheric pressure, the first reactor vessel including a material input receiving cellulosic material and a material discharge for the material, wherein the cellulosic material flows from the material input to the material discharge, a heat energy input port in an upper portion of the first reactor vessel, a first region of the first reactor vessel between the material input and a liquid extraction screen, wherein the first region is maintained at a hydrolysis temperature of at least 170 degrees Celsius in the cellulosic material, the extraction screen having an outlet for extracting hydrolysate and liquid from the first vessel, and a second region of the first reactor between the liquid extraction screen and the discharge in which a temperature is below the hydrolysis temperature and the hydrolysis reactor is substantially suppressed and a discharge of the first vessel below the second region; the processing system further comprises a transport pipe providing a flow conduit from the discharge to a continuous digesting vessel, and the continuous digesting vessel receives the cellulosic material discharged from the first reactor vessel.
A method has been developed to produce pulp from cellulosic material comprising: introducing cellulosic material to an upper inlet in a first reactor vessel; hydrolyzing the cellulosic material in upper region of the an upper region of the first reactor vessel by adding pressure and heat energy to the vessel; extracting hydrolysate from the cellulosic material through an extraction screen below the upper region and in the first reactor vessel; introducing a wash liquid to a lower region of the first reactor vessel where the wash liquid suppresses hydrolysis of the cellulosic material in the lower region and said wash liquid flows upward through the cellulosic material to the extraction screen; discharging the cellulosic material from a lower outlet of the first reactor vessel; introducing the discharged cellulosic material to a second reactor vessel, and introducing cooking liquor into the top of the second reactor vessel to digest the cellulosic material to produce pulp.
A method has been developed to suppress hydrolysis of cellulosic material comprising: introducing cellulosic material in an upper inlet of a first reactor vessel, wherein the material moves downwardly through the vessel; adding steam at above atmospheric pressure to the first reactor vessel; maintaining at above a hydrolysis temperature the cellulosic material in an upper region of the first reactor vessel; extracting hydrolysate from the cellulosic material through an extraction screen below the upper region in the first reactor vessel; cooling the cellulosic material below the extraction screen to a temperature below the hydrolysis temperature, and discharging the cellulosic material from a bottom outlet of the first reactor vessel.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic diagram of a continuous pulping system having a chip feed, hydrolysis reactor and a continuous digester reactor.
DETAILED DESCRIPTION OF THE INVENTION
In a two reactor vessel system, steam is introduced to the top of both vessels for heating and pressurizing purposes. Hydrolysis occurs above extraction screens in the top of the first reactor vessel. The extraction screens in the first reactor vessel remove hydrolysate as the wood chips or other cellulosic or fiber material (collectively referred to cellulosic material) introduced at the top of the first vessel progress through the vessel and to a lower extraction port of that vessel.
The cellulosic material is washed in the first reactor vessel below the extraction screens. Wash liquid is introduced at the bottom of the first reactor vessel and flows upwards to the extraction screens. The wash liquid may be water only or water mixed with one or more chemicals, such as sodium hydroxide (NaOH) and essentially sulfur free white liquor. The diameter of the first vessel may be uniform above and below the extraction screen. The cellulosic material discharged from the extraction port of the first reactor vessel is introduced to the top of the second reactor vessel, which may be a digester vessel. The cellulosic material is cooked in the second reactor vessel to generate pulp that is discharged from a lower extraction port of the second reactor vessel.
In the first reactor vessel, the cellulosic material is washed in a lower section of the vessel to remove hydrolysate from the material. The washing in the lower portion of the first vessel is performed with wash liquid at a temperature below the hydrolysis temperature. The wash liquid temperature is preferably 10° C. to 70° C. cooler than the hydrolysis temperature, more preferably 20° C. to 50° C. cooler, and most preferably 25° C. to 35° C. cooler than the hydrolysis temperature. The wash liquid cools the cellulosic material to a temperature normal hydrolysis temperatures. The cool wash liquid flushes out remaining hydrolysate from the cellulosic material, lowers the temperature of the cellulosic material to below the hydrolysis temperature, and adjusts the pH of the cellulosic material to near or slightly above neutral (7 pH) in the first reactor vessel and prior to cooking of the material in the second reactor vessel.
The cool wash liquid preferably has a pH of 3 to 7, and more preferably a pH of 4 to 5. Keeping the pH of the cool wash liquid in these ranges prevents or minimizes the precipitation of dissolved lignin in the cooking chemicals of the second reactor vessel. The wash liquid may include added chemicals, e.g., NaOH and essentially sulfur free white liquor, to increase the amount of hydrolysate extracted from the cellulosic material in the first vessel. Introducing wash liquid, rather than a large amount of white liquor to the bottom of the first reactor vessel, reduces lignin precipitation in the first vessel that might otherwise occur if larger amounts of white liquor were added to the bottom of the first reactor vessel.
The second reactor vessel may be a continuous digester vessel, such as a vapor or steam phase digester. The use of a vapor or steam phase digester should avoid operating problems in the top of the second reactor vessel, caused by gas formation during the hydrolysis. The first and second reactor vessels may be substantially vertical, have a height of at least 100 feet, an inlet in an upper section of the vessel, and a discharge proximate a bottom of the vessel. Heat energy added to the reactor vessels may be pressurized steam at above atmospheric pressure.
FIG. 1 is a schematic diagram of an exemplary chip feed and pulp processing system having a first reactor vessel 10 (hydrolysis reactor) and a second reactor vessel 12 , e.g., a continuous pulp digester. The first reactor vessel includes an inverted top separator 14 that receives a slurry of cellulosic material and liquid from a conventional chip feed assembly 15 via chip feed line 33 .
The chip feed assembly 15 may include a wood chip bin 16 , such as the Diamondback® Chip Bin sold by Andritz Inc., connected to a double screw chip meter 18 and a chip chute 20 . Hot water 24 is added via pipe 26 to the chips or other cellulosic material in the chip chute 20 to form a slurry of cellulosic material. A liquid surge tank 22 supplies the water to the chip tube. Water may also be supplied directly to the chip tube through pipe 23 .
Separated liquid discharged from the top separator 14 and extracted to pipe 27 may be mixed (see valve 25 ) with hot water. The mixture flows through pipe 26 to the surge tank 22 and, via pipe 23 , to the chip tube 20 . The mixture of liquid discharged from the top separator 14 and hot water 24 is controlled, using valve 25 , to be at a temperature lower than the normal hydrolysis temperature, e.g., preferably 170° C., of the cellulosic material. The temperature of the water and liquid discharged from the top separator is preferably in a range of 100° Celsius (C) to 120° C. By temporarily storing the mixture of water and liquor from the top separator, the surge tank 22 may be used to provide temperature control of the mixture of water and liquid used to form the slurry of cellulosic material. For example, temperature control may be provided by adjusting the relative amounts in the surge tank of liquid flowing via pipe 27 from the top separator to the surge tank and hot water 24 .
To feed chips to the first reactor vessel, the slurry of cellulosic material is pumped via one or more pumps 32 (such as the TurboFeed® System as sold by Andritz Inc., and pumps described in U.S. Pat. Nos. 5,752,075; 6,106,668; 6,325,890; 6,551,462; 6,336,993 and 6,841,042) to the top separator 14 of the first reactor vessel. Other slurry feed systems, such as those using a high-pressure feeders, may also be suitable.
The first reactor vessel 10 may be controlled based on either or both the pressure and temperature in the vessel. Pressure control may be by use of a controlled flow of steam via steam pipe 74 or in addition an inert gas added to the first reactor vessel. A gaseous upper region 45 in the first reactor vessel is above an upper level 44 of the chip column.
The pressure from the gaseous phases assists in forcing the cellulosic fiber material down and out of the vessel at the bottom 56 discharge of the first vessel. The latent pressure plus hydrostatic head should be higher in the first reactor vessel 10 than in the second reactor vessel 12 to assist in transporting the cellulosic material discharged from the first reactor vessel to the second reactor vessel. If the latent pressure and hydrostatic head is greater in the second reactor vessel, a chip pump may be used between the two vessels to pump material from the first vessel to the second vessel.
Steam 72 is supplied at a temperature above the normal hydrolysis temperature, e.g., 170° C., to enable hydrolysis to occur in the cellulosic slurry in the first reactor vessel. The steam is added in a controlled manner that, at least in part, promotes hydrolysis in the first reactor vessel. The steam is added via lines 74 and 68 at or near the top of the first reactor vessel, such as to the vapor phase 45 of the vessel. The steam introduced to the first reactor vessel elevates the temperature of the cellulosic slurry to at or above the normal hydrolysis temperature, e.g., above 150° C.
The cellulosic material slurry fed to the inverted top separator 14 in the first reactor vessel may have excessive amounts of liquid to facilitate flow through the transport pipe 33 . Once in the vessel, the excess liquid is removed as the slurry passes through the top separator 14 . The excess liquid removed from the separator is returned via pipe 27 to the chip feed system, e.g., to the chip tube 20 , and reintroduced to the slurry to transport the cellulosic material to the top of the first vessel. Hot liquid may be added at or near the top separator 14 and gas phase 45 of the first reactor vessel. The added liquid may be hot water 24 (piping not shown) or hot liquid extracted from the extraction screen 48 in the first reactor vessel and flowing through pipe 31 to the top of the first reactor vessel.
The top separator 14 discharges chips or other solid cellulosic material to a liquid phase (below upper chip column 44 ) of the first reactor vessel. The top separator pushes, e.g., by a rotating vertical screw, the material from the top of the inverted separator 14 and into the gas phase. The pushed out material may fall through a gas phase 45 in the vessel and to the upper chip column 44 of cellulosic material and liquid contained in the first reactor vessel. The temperature in the gas phase (if there is such a phase) and in upper region of the first reactor vessel 10 is at or above the normal hydrolysis temperature, e.g., at or above 170° C. The slurry of cellulosic material gradually flows down through the first reactor vessel. As the material progresses through the vessel, new cellulosic material and liquid are added to the upper surface from the top separator.
Hydrolysis occurs in the upper region 46 of the first reactor vessel 10 , where the temperature is maintained at or above the normal hydrolysis temperature. The hydrolysis will occur at lower temperature, e.g., below 150° C., by the addition of acid, but preferably hydrolysis occurs at high temperatures, above 150° C. to 170° C., using only water and recirculated liquid from the top separator of the first reactor vessel. Hydrolysis should occur substantially only in the upper region 46 above an extraction screen 48 or above a set of multiple elevations of extraction screens 48 .
To stop hydrolysis as the cellulosic material moves downward through the vessel 10 past the extraction screen 48 , the temperature of the material is reduced to below the hydrolysis temperature or acid in the cellulosic material is removed from the first reaction vessel through the extraction screens 48 . Reducing the temperature and removing acids from the cellulosic material may be used together or separately to suppress and preferably stop hydrolysis.
Hydrolysate is a product of hydrolysis. The hydrolysate is removed with wash liquid and some other liquids through the extraction screens 48 and fed to pipe 29 and flows to the flash tank 30 . The hydrolysate, wash liquid and other extracted liquids may be recovered or recirculated to the chip feed system. The liquid in pipe 29 extracted from the first reactor vessel 10 and directed to a flash tank 30 includes hydrolysate extracted from the first reactor vessel. The flash tank 30 separates the hydrolysate laden liquid from steam. The liquid from the flash tank is preferably at a temperature below a hydrolysis temperature and more preferably below 110° C. The liquid with hydrolysate flows from the flash tank to pipe 28 and the steam may be returned via pipe 68 to an upper gaseous phase of the first reactor vessel 10 . A portion of the hydrolysate is recovered by a conventional hydrolysate recovery system 70 .
The steam 68 may be introduced to the vessel, especially if the pressure in the vessel is lower than in the flash tank. If the pressure of the vessel is not lower than the flash tank, the steam may be directed to a chip bin, a heater for water and/or white liquor to be used in the process. Similar circulations of steam and/or extracted liquids are described in U.S. Pat. No. 7,105,106 and US Patent Publication 2007-0000626.
The liquids from the flash tank 30 , including a portion of the hydrolysate flows through pipes 28 , 71 to the chip slurry in the chip tube 20 and, via pipe 73 , to the liquid surge tank 22 . The amount of liquids with hydrolysate added to the chip slurry in the chip chute 20 may be controlled to avoid excessive changes to the pH of the chip slurry, e.g., to avoid making the slurry excessively alkaline or excessively acidic. The addition of liquid to the cellulosic material in the chip tube 20 assists in conveying the chip slurry material through the chip pumps 32 and through the chip slurry pipes 33 extending between the chip chute 20 and the top separator 14 of the first reactor vessel 10 .
A counter-current wash zone 54 is in the vessel 10 below the extraction screens 48 . The wash zone 54 is a lower region of the vessel 10 below the extraction screen 48 and above the vessel bottom 56 . The wash liquid 50 flowing through the wash zone cools the cellulosic material flowing through the wash zone to eliminate or at least minimize continuing hydrolysis of the downwardly moving chip stream in the wash zone 54 . The wash liquid is preferably 10° C. to 70° C. cooler than the hydrolysis temperature, more preferably 20° C. to 50° C. cooler, and most preferably 25° C. to 35° C. cooler.
The wash liquid 50 flows in a counter flow direction, e.g., an upward flow, to the downward flow of cellulosic material in the first reactor vessel. The cool wash liquid 50 is pumped to the bottom of wash zone from pipe 52 which connects to the bottom of the first reactor vessel 10 . The wash liquid pressure in pipe 52 is sufficient to cause the wash liquid to flow upward (see arrow designed 50 ) through the first reactor vessel 10 in a counter-flow to the direction of cellulosic material flowing downward through the vessel. The wash liquid is removed at the extraction screen 48 .
Chemicals 82 , such as NaOH or essentially sulfur free white liquor, may be added via pipe 84 to the cool wash water flowing through pipe 52 prior to introduction to the bottom of the vessel 10 . The amount of the added chemicals in the wash liquid may be an amount of 0.01 percent (%) to 5 percent of the amount of cellulosic material, e.g. wood, in the slurry flowing through the vessel. The amount of added chemicals is preferably 0.1 percent to 1 percent of the cellulosic material. The chemical(s) are added to the wash water to suppress hydrolysis and remove hydrolysate, and optionally to adjust the pH of the wash liquid. The addition of the chemicals to the wash water results in substantially more hydrolysate being extracted from the cellulosic material flowing through the wash zone, that would occur if the wash liquid was purely water.
As the wash liquid 50 interacts with the cellulosic material in the wash zone and at or just above the extraction screen 48 , the liquid cools the cellulosic material to below the hydrolysis temperature and washes some chemicals out of the material. Preferably, the cool wash liquid reduces the temperature of the cellulosic material near the extraction screens 48 and in the wash zone 54 to suppress and stop hydrolysis reactions in the material. In addition, as the hydrolyzed cellulosic material moves below the extraction screens 48 , it is preferred that the material be at a pH level at which lignin does not dissolve. The amount of wash liquid and the chemicals in the wash liquid may be adjusted to cause the pH level of the cellulosic material in the wash zone 54 to be within a predetermined pH range.
The washed chips are discharged through the bottom 56 of the first reactor vessel and sent via chip transport pipe 62 to the top separator 57 , e.g., an inverted top separator, of the second reactor vessel 12 , such as a continuous digester. A pump 64 is optionally used to assist in the transport of the cellulosic material through pipe 62 from the first reactor vessel to the second reactor vessel. Water and other liquids remaining in the chips may be used to increase the liquid to chip ratio in the cellulosic material flowing through pipe 62 to assist in the transport of material through the pipe 62 and to the top separator 56 of the second reactor vessel.
Additional liquid, from pipe 58 , may be added to the cellulosic material slurry in the transport pipe 62 or to the bottom of the first reactor vessel through pipe 61 . The additional liquid may be extracted from the top separator 57 of the second reactor vessel 12 . The additional liquid may be recirculated by pumping (via pump 59 ) and via pipes 58 and 61 to the bottom 56 of the first vessel. The liquid in line 58 may be introduced directly into the discharged stream of cellulosic material in pipe 62 or via pipe 61 into the bottom 56 of the first reactor vessel as part of the liquid used to assist in the discharge of the chips form the first vessel. A valve 63 directs liquid flow from pump 59 and pipe 58 to pipe 61 or transport pipe 62 . The liquid recirculated from the top separator 57 of the second vessel should be relatively free of alkaline materials and the pH control may regulated to ensure that the recirculated liquid has an acceptable pH level before being introduced into bottom of the first reactor vessel 10 or transport pipe 62 .
Acid may be added to the circulation pipe 62 to assist in pH control of the cellulosic material being transported from the first reactor vessel to the second reactor vessel. If the pH of the cellulosic material in the chip transport pipe 62 is above a desired pH level, the addition of an acidic chemical into the pipe 62 or to the bottom 56 of the first reactor vessel may be used to decrease the pH in the cellulosic material.
A pH monitor 78 may be used to sense the pH level of the cellulosic material flowing from the first reactor vessel to the second reactor vessel. If the monitor 78 detects a pH level in the cellulosic material above a desired pH range, a controller may cause an acidic chemical to be added to the cellulosic material in bottom 56 of the first vessel 10 or in the transport pipe 62 . Additionally, if the monitor 78 detects a pH level above the desired pH range, the controller may cause additional wash water to be introduced into the bottom 56 of the first vessel or to the pipe 62 .
Steam from the flash tanks 30 , 66 may be may be conveyed may be used, via pipe 68 , to add heat to any of the chip feed system 16 , the first reactor vessel and a heat recovery system 90 . For example, the steam extracted from the first reactor vessel 10 may be added to the chip bin 16 to assist in the production of the slurry of cellulosic material and for controlling the liquid to wood ratio in the slurry. Before adding the steam to the chip feed system, the steam may be checked to confirm that it is substantially free of sulfur. Preferably, no sulfur containing chemical is added to the cellulosic material or to any other material or liquid introduced into the first reactor vessel 10 . Sulfur in the first reactor vessel 10 could undesirably result in sulfur compounds in the vessels 10 , 12 and in liquids extracted from the extraction screen 48 .
Additional steam 72 may be added via pipe 74 to the tops of the first reactor vessel 10 and to the top of the second reactor vessel 12 . The additional steam may provide heat energy for the reactor vessels.
Cooking chemicals, e.g., white liquor 76 , are added to the top, e.g., to an inverted top separator 57 of the second reactor vessel 12 . A portion of these cooking chemicals may be introduced to the circulation line 58 extracting liquor from the top separator 57 and adding liquor to the bottom of the first reactor vessel or to the chip transport line 62 . White liquor 76 is added to the top separator of the second reactor vessel 12 to promote mixing of liquor with the cellulosic material in the separator and before the mixture of material and liquor is discharged from the separator to the second reactor vessel.
Monitoring of circulation line 58 may be useful, including a pH monitor, to confirm that cooking chemicals do not flow from the second reactor vessel 12 to the first reactor vessel 10 or to the transport pipe 62 . The pH in the circulation line 58 should remain in the range of 4 pH to 10 pH, preferably in a range of 6 pH to 10 pH, and more preferably a range of 6 pH to 8 pH. If the pH in the circulation line 58 is high, additional cool wash water 50 may be added to the bottom 56 of the first reactor vessel or to the transport line 62 . The wash water 50 may be added to the bottom of the first reactor vessel or the transport line 62 to assist in pushing the slurry cellulosic material from the first vessel to the top of the second reactor vessel.
The second reactor vessel 12 may be a pressurized gas phase continuous digester vessel. The liquid level in the second reactor vessel is below the gas phase in the vessel and is sufficient to entirely submerge the solids, e.g., chips, of the cellulosic material. The liquid level in the second reactor vessel may be as high as the upper rim of the top separator 57 . This high liquid level may be helpful to provide a quick and thorough penetration of cooking chemicals into the chips. Cooking in the second vessel is co-current.
The second reactor vessel 12 , e.g., a cooking or digesting vessel, may be a single vessel system with multiple stages where the cellulosic material passing through the first stage (upper elevation) is at a lower temperature than the cellulosic material at other stages (lower elevations). An optional cooking or digester operation employs cooking the cellulosic material as soon as the chips are introduced into the cooking liquor. Yet another optional cooking or digester operation is cooking the cellulosic material as it is introduced to the cooking liquor and cooking the material at different temperatures as the cooking process proceeds through the second reactor vessel. For example, the second reactor vessel may have multiple cooking zones at different elevations and each zone is maintained at a different cooking temperature.
Heat recovery systems 90 and methods are conventional and well know in pulping plants. For example heat from the circulation streams, such as from the flash tanks 66 , may be recovered in heat exchangers or other such heat recovery systems 90 . The recovered heat from the flash tanks may also be applied to pre-heat liquid, such as wash filtrate 80 and white liquor 76 , introduced to the top of the second reactor vessel. This pre-heating of liquids may be accomplished by using heat exchangers to extract heat from the flash tanks and transfer the heat to the liquids.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | A reactor vessel system including: a first reactor vessel having a hydrolysate and liquid extraction screen, a first region above the extraction screen that is maintained at conditions promoting a hydrolysis reaction in the cellulosic material, a second region below the extraction screen in which the hydrolysis is substantially suppressed and a wash liquid inlet below the extraction screen providing wash liquid at a temperature below a hydrolysis temperature; a transport pipe having an inlet coupled to the first reactor vessel and an outlet coupled to a second reactor vessel, and the second reactor vessel includes a liquid discharge that extracts a portion of liquid from the second reactor vessel and directs the portion of liquid to the first reactor vessel or to the transport pipe. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to an article of clothing, a hood device, to a method for making a hood and to a kit for making a hood.
Articles of clothing that have hoods have typically had either attached hoods, integral with a garment such as a jacket or a coat or a cape or detachable hoods, typically detachable from a coat. Attached hoods, in some embodiments, have had a dramatic, theatrical, aesthetic effect, when worn. In other embodiments, however, hoods are a nuisance when not needed for protection from inclement weather and are unattractive.
Detachable hoods typically have functionality but no desirable aesthetics. Typically, detachable hoods are attached to a garment by button attachment mechanisms or zippers. Button attachment mechanisms define holes between the buttons. These holes are a source of drafts that chill the neck of an individual wearing a garment with a detachable hood.
Zipper attachment mechanisms tend to have openings on either side of a wearer's head. These openings also permit drafts to contact a wearer and to chill the wearer in cold or wet weather.
U.S. Pat. No. 5,845,340, which issued Dec. 8, 1998, describes a face and head protector garment for use against inclement weather. The garment includes a hood that covers the head and back area of the neck and a mask that fits over the head of the wearer. The mask defines openings for eyes, nose and mouth. The mask and hood function as a single unit.
SUMMARY OF THE INVENTION
In its product aspect, the present invention comprises an article of clothing. The article of clothing comprises a flexible main body. The flexible main body comprises a hood portion and a shoulder portion. The hood portion is attached to the shoulder portion. The shoulder portion comprises a pair of shoulder elements, attachable to each other and a back portion. The back portion is attached to each of the shoulder elements.
Another product aspect of the present invention comprises a kit for making a hood device. The kit comprises a template for a hood portion, a template for a first shoulder segment and a template for a second shoulder segment. The template for the second shoulder segment is a mirror image of the template for the first shoulder segment. The kit further comprises a template for a back segment.
A method aspect of the present invention comprises a method for making a hood device. The method comprises providing fabric and cutting the fabric to make hood segments. The fabric is also cut to make shoulder segments. The shoulder segments are mirror images of each other. The fabric is cut to make a back segment. The hood segments are attached to each other to make a hood portion. The back segment is attached to the hood portion. The shoulder segments are attached to the hood portion and the back segment.
DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a perspective view of one embodiment of the hood device of the present invention.
FIG. 2 illustrates a top plan view of one embodiment of the hood device of the present invention.
FIG. 3 illustrates a top plan view of a backside of the hood device of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In its product aspect, one embodiment of the hood device of the present invention, illustrated generally at 10 in FIG. 1, comprises a main body 12 that includes a hood portion 14 and collar portion 16 attached to the hood portion 14 . The collar portion 16 is of a shape that rests upon the shoulders of a user as shown in FIG. 1 . The collar portion comprises an underlying end 18 and overlying end 20 that are attached to each other with an attachment mechanism, which is shown in FIG. 1 . The attachment mechanism is a device such as a VELCRO® brand strip of hook and loop fasteners, or snaps, or buttons. The attachment mechanism is not shown in FIG. 1 .
In one embodiment, illustrated at 10 in FIG. 1 the hood portion 14 comprises panels 22 , 24 , and 26 . Panels 22 and 26 are substantially mirror images of each other. Panel 24 is a generally rectangular panel size to fit about the head of a user. In one embodiment, the fit is a loose fit wherein the hood portion 14 extends past the head of the user when in a used position as shown in FIG. 1 .
In one embodiment, the hood device 10 is made with a double ply fabric arrangement, as shown in FIG. 1 at 28 and 30 . With the double ply configuration, the hood device 10 may comprise an outer water repellant, wind repellant fabric and an inner, softer fabric. The double ply arrangement can also be used to impart the aesthetically best “lay” of the hood. By “lay” is meant that the hood acquires a desirable symmetry when covering the head of the wearer. In another embodiment, illustrated in FIG. 2, the hood device is made of only a single layer of fabric. This layer of fabric may be wind resistant and water repellant. The fabric may also be a soft, warm fabric such as wool or cashmere.
In one embodiment, the hood device 10 includes a tie 40 for positioning the hood closer to the head of the wearer. The tie 40 is positioned within a channel 42 .
As illustrated in FIG. 2, the hood device 10 further comprises a back shoulder panel 32 . The back shoulder panel is attached to the collar portions 18 and 20 at 34 and 36 , respectively. The back shoulder panel 32 attachment is by a mechanism such as thread stitching. The back shoulder panel 32 is attached to the hood portion at 38 . The back shoulder panel 32 not only stabilizes the hood device 10 when worn by a wearer but also protects the neck of the wearer against drafts, and rain, snow or sleet. The back shoulder portion 32 also keeps the wearer warm.
The back shoulder panel 32 , shown in FIG. 3, is tapered so that the hood device 10 is securely held when positioned under a coat or jacket. The back shoulder panel 32 tapered shape also aids in reducing drafts. textile material such as a polyamide or an olefin blend, a viscose fiber, cotton, wool, silk or satin, polyethylene microfiber, polyethylene blend, polypropylene, velvet, nylon, velveteen, a polyethylene rayon blend, or other material. As discussed, the hood device 10 of the present invention may comprise a single fabric layer or may comprise a double fabric layer.
The hood device is made by separately cutting the components 18 , 20 , 32 , 22 , 24 , and 25 from cloth. The cloth may be one ply. For some embodiments, the cloth comprises at least two-ply of the same type of cloth or different types of cloth. The components 22 , 24 and 25 are sewn together as shown in FIGS. 1, 2 and 3 to make the hood portion. The back section 32 is sewn to the hood portion as shown in FIGS. 2 and 3. The shoulder segments 18 and 20 are sewn to the hood portion and the back portion 32 as is shown in FIGS. 2 and 3.
The components 18 , 20 , 32 , 22 , 24 and 25 are, in one embodiment, cut from pattern elements in a kit. Each pattern element provides a template for shaping each of the components. Each kit includes elements sized for particular types of wearers such as children and adults. Some kit embodiments include fabric.
Since the invention disclosed herein may be embodied in other specific forms without departing from the spirit or general characteristics thereof, some of which forms have been indicated, the embodiments described herein are to be considered in all respects illustrative and not restrictive. The scope of the invention is to be indicated by the appended claims, rather than by the foregoing description, and all changes, which come within the meaning and range of equivalency of the claims, are intended to be embraced therein. | The present invention includes a article of clothing. The article of clothing comprises a flexible main body, comprising a hood portion and a shoulder portion. The hood portion is attached to the shoulder portion. The shoulder portion comprises a pair of shoulder segments and a back segment. The shoulder segments are attachable to each other. The back segment is attached to each segment of the shoulder portion. | 0 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to the field of portable tables, and more specifically to portable expandable project tables.
[0002] There are numerous applications requiring a versatile portable project table. For example, workers in the construction industry commonly require an on-site table to support blueprints, plans, specifications, technical drawings and other information. Routine working conditions demand a table that is suitable for outdoor use. These conditions include wind, rain, and other adverse weather conditions, uneven terrain, and frequent on-site relocation. Portability, including convenient vehicle transportability, is essential for tables. Despite the need for portability, project tables must be sturdy and adaptable to numerous applications. The ability to expand the table surface is also needed in many applications.
BRIEF DESCRIPTION OF THE PRIOR ART
[0003] Prior art drafting tables are unsuited for applications as described above in that they are commonly constructed exclusively for indoor use with limited mobility. As such, they have limited adjustability, are not constructed to withstand outdoor weather conditions, and are not readily transportable. Portable tables are commonly constructed to be lightweight rather than hardy. A folding portable drafting table representative of the prior art is described in U.S. Pat. No. 5,315,935 to Weisenfels. The table is constructed of light-weight wood, and will necessarily be unsuitable for use in typical outdoor conditions including wind or moisture. It is not height adjustable, nor can it be adjusted for uneven surface conditions. While portable, the basic table requires that three separate pieces be carried separately, it is not expandable, and it is not readily apparent that it can be moved without disassembly and reassembly. U.S. Pat. Nos. 4,372,631 to Leon and 4,099,469 to Sahli also describe foldable drafting tables. Both tables are designed to fold only for ease of storage in a small space and they cannot be easily transported from one job site to another. The table described by Leon has wheels to facilitate movement only from room to room within a single building. Neither table is adjustable by height to accomodate various user requirements. Also, neither table is expandable or adjustable to accomodate any site condition other than a flat floor. U.S. Pat. No. 5,598,789 to Jonker describes a vertically adjustable table, the use of which would be limited to a relatively flat floor. It is not intended, and would not be suitable, for outdoor use or for convenient vehicle transportability.
[0004] Accordingly, there is a need for a portable drafting table that is suitable for on-site construction site use or use in other locations where hardiness is important. Such a table will be sturdy enough to withstand heavy use and adverse weather conditions. It will also be adjustable to accomodate sitting and standing users as well as uneven terrain. It will ideally have rollers for easy movement and will be expandable to accomodate unusually large drawings. Finally, it will fold compactly for easy carrying and transport by vehicle.
SUMMARY OF THE INVENTION
[0005] The present invention is a portable drafting table that folds compactly for convenient transport by vehicle, but is of sturdy construction to permit on-site construction project use. The legs of the table are independently adjustable to accommodate both the table surface height requirements of individual users and also level positioning on uneven terrain. The table top opens to expose a storage space within the frame. The frame also includes a storage drawer and a carrying handle for transportability.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Other advantages of the invention will become apparent from a study of the following specification when viewed in light of the accompanying drawing, in which:
[0007] [0007]FIG. 1 is a perspective view of a preferred embodiment of the folding table;
[0008] [0008]FIG. 2 is a perspective view of the table frame and table top in an open position;
[0009] [0009]FIG. 3 is an elevation view of an inner adjustable table leg;
[0010] [0010]FIG. 4 is a detailed top cutaway view of a table leg, illustrating a locking pin securing an outer fixed table leg and an inner adjustable table leg;
[0011] [0011]FIG. 5 is a front elevation view of an optional table extension;
[0012] [0012]FIG. 6 is a front elevation view of an optional plan holder;
[0013] [0013]FIG. 7 is a detailed illustration of a table extension securing mechanism; and
[0014] [0014]FIG. 8 illustrates a snap-in shoe suitable for use with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] Referring to FIGS. 1 and 2, a preferred embodiment of a portable expandable project plan table 20 according to the invention has a flat-surfaced table top 22 supported by a table frame 24 . Table frame 24 has the general shape of a truncated right triangular prism having base, right and left side, front and back surfaces. Table top 22 is positioned atop the frame 24 to enclose the frame 24 when the table top 22 is in its closed position. Because frame 24 is deeper at the back than at the front, the table top 22 slopes downwardly from rear to front. The length and width of table top 22 is preferably somewhat greater than that of table frame 24 to create an overhang or lip to table top 22 along the front and both sides of frame 24 . In a preferred embodiment, the lip is about 1 inch, but it may be varied at the discretion of the fabricator. The table, including the legs to be described below, is preferably made from a light-weight, but durable and strong, material such as aluminum. The aluminum-to-aluminum connections for the table legs and accessory attachments described herein is preferably welded.
[0016] Table top 22 is preferably secured to table frame 24 along the upper back edge of frame 24 by a piano hinge 25 . Raising the front edge of table top 22 to its open position reveals a storage space 27 suitable for placing drawings, instruments or other items. Hydraulic arms 23 are affixed on each side to table top 22 and table frame 24 to hold table top 22 in a raised position and allow it to be controllably opened and closed without slamming. The hinge 25 is secured to the table top 22 and frame 24 by an aluminum weld. Alternatively, it may be secured by other devices such as rivets, bolts, or screws.
[0017] A leg bracket is rigidly fixed and extends downwardly at each corner from the base of table frame 24 . In the preferred embodiment illustrated in FIG. 1, right side leg brackets 26 are relatively shorter than left side leg brackets 28 as will be explained more fully below. It will be readily apparent, however, that the invention will work equally well if the right side leg brackets 26 are relatively longer than left side leg brackets 28 . Each table leg has an outer table leg segment and an inner table leg segment. Right side outer table leg segments 30 are pivotally secured to brackets 26 by a pivot pin such that table leg segments 30 may pivot in a 90 degree arc between vertical and horizontal underneath table frame 24 . A fixed side leg brace 34 secures the right side outer table leg segments 30 together and provides fore-and-aft support to them. Left side leg brackets 28 are similar to right side leg brackets 26 except that brackets 28 are relatively shorter. Left side outer table leg segments 36 are pivotally secured to brackets 28 by a pivot pin 32 such that table leg segments 36 may pivot in a 90 degree arc between vertical and horizontal underneath table frame 24 . A fixed side leg brace 34 secures the left side outer table leg segments 36 together and provides fore-and-aft support to them.
[0018] At both the front and rear of the table 20 , a right side folding leg brace 38 is pivotally connected to table frame 24 and the table leg segment 30 to both permit the right table legs to fold under frame 24 and to restrict the table legs from rotating beyond the vertical away from the table. A pivot pin 40 at the center of folding leg brace 38 permits the table legs to fold under table frame 24 . Any suitable device, a number of which are well-known in the prior art, may be used to lock the folding leg brace 38 in position when the table legs are extended for use. Similarly, at both the front and rear of the table 20 , a left side folding leg brace 40 is pivotally connected to table frame 24 and the table leg segment 36 to both permit the left table legs to fold under frame 24 and to restrict the table legs from rotating beyond the vertical away from the table. A pivot pin 40 at the center of folding leg brace 42 permits the table legs to fold under table frame 24 . It will be readily apparent to one skilled in the art that right folding leg brace 38 is longer than left folding leg brace 42 to accommodate the differences in length between right side leg bracket 26 and left side leg bracket 28 .
[0019] The left side table legs 36 fold compactly under the right side table legs 30 in an overlapping, or nesting, arrangement, due to the relatively longer length of right side brackets 26 as compared to left side brackets 28 . It will be readily apparent to one skilled in the art how to determine the precise lengths of the various components to obtain the desired compact arrangement.
[0020] Each of the outer table leg segments 30 , 36 is adapted to receive an adjustable inner table leg segment 44 in telescoping arrangement. As is illustrated more clearly in FIGS. 1 and 3, each adjustable inner table leg segment 44 has a plurality of evenly spaced holes 46 on a first surface thereof. Each of the fixed outer table leg segments 30 , 36 has a hole 48 of substantially identical diameter to holes 46 and positioned to successively align with each of the holes 46 as the adjustable inner table leg segment 44 is moved relative to the outer table leg segments 30 , 36 . A spring tension peg 50 mounted through hole 48 on each of the outer table leg segments 30 , 36 engages hole 46 when holes 46 and 48 are aligned to lock inner table leg segment 44 in place, as is illustrated in FIG. 4. Inner table leg segment 44 has a socket 52 affixed at its lower end to receive the stem of a swivel “snap-in” non-marring caster wheel 54 , as is well known in the prior art. The diameter and material of caster wheel 54 may be varied to maximize mobility on different surfaces such as finished or unfinished interior floors or uneven outside terrain. Alternatively, a snap-in aluminum shoe 55 , as illustrated in FIG. 8, fitted with a rubber base 37 may be substituted for caster wheel 54 when it is desired that the table be more securely positioned in a fixed location.
[0021] As illustrated in FIG. 2, two non-threaded receivers 56 are placed on the right side of table frame 24 for mounting optional table extensions. Two additional non-threaded receivers are similarly mounted on the left side of table frame 24 . A suitably sized aluminum spacer 59 is preferably inserted between frame 24 and a table extension. FIG. 5. illustrates a first optional table extension in the form of a table expansion 58 . Table 58 has a top surface 60 and a frame 62 having a shape such that top surface 60 and table top 22 are coplanar when table expansion 58 is positioned adjacent frame 24 . On one side of frame 62 are two threaded receivers 64 positioned to align with non-threaded receivers 56 when table expansion 58 is positioned adjacent table 20 . FIG. 7 illustrates a preferred securing mechanism for securing table expansion 58 to table frame 24 . A wing bolt 66 is passed through non-threaded receiver 56 of table frame 24 and threaded into the threaded receiver 64 of table expansion 58 . A leg table brace 68 secured between the bottom of table expansion 58 and side leg brace 34 provides additional support for the table expansion 58 .
[0022] [0022]FIG. 6 illustrates a second optional table extension in the form of a plan holder 70 . Plan holder 70 has a horizontal top surface 72 and a frame 74 . On one side of frame 74 are two threaded receivers 64 positioned to align with non-threaded receivers 56 when plan holder 70 is positioned alongside table 20 . FIG. 7 illustrates a preferred securing mechanism for securing plan holder 70 to table frame 24 . A wing bolt 66 is passed through non-threaded receiver 56 of table frame 24 and threaded into the threaded receiver 64 of plan holder 58 . A leg table brace 68 secured between the bottom of plan holder 70 and side leg brace 34 provides additional support for the plan holder 70 .
[0023] The versatility of the invention is substantially enhanced with the inclusion of a drawer 72 provided through the front surface of frame 24 . A handle 76 permits opening and closing of the drawer 72 , and a lock 74 permits drawer 72 to be locked for security and to prevent accidental opening when the table 20 is transported. Similarly, a lock 78 is provided to secure table top 22 to frame 24 . Lock 78 both prevents access to the storage space 77 within frame 24 and also prevents accidentally opening of table top 22 when the table 20 is being transported.
[0024] Locks 74 and 78 are preferably keyed, lockable cam locks. Alternatively, a non-locking clasp of which there are many suitable types well-known in the prior art may be substituted in place of locks 74 and 78 if physical security is not considered necessary or desirable. A handle 80 is secured near the mid-section of the front surface of frame 24 to facilitate transportability of the table 20 when it is folded.
[0025] While the preferred forms and embodiments of the invention have been illustrated and described, it will be apparent to those of ordinary skill in the art that various changes and modification may be made without deviating from the inventive concepts set forth above. | A portable expandable project plan table includes a table top that is pivotally connected to a frame having a generally truncated right triangular prism shape. The table top is hinged to permit access to storage for drafting tools and papers within the frame and may be locked to prevent movement when the table is transported. The legs of the table pivot between vertical for use and horizontal for transporting, and are designed to overlap in the folded position in a compact arrangement. Each leg is independently height adjustable to permit the table to be made level on uneven surfaces, and wheels on each leg facilitate movement of the table in the open-for-use position. The table is constructed of durable materials to permit use out of doors or in adverse conditions. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to imrovements in and relating to an apparatus for the evaluation of yarn qualities.
As commonly known among those skilled in the art, yarn qualities comprise mainly physical properties such as strength and elongation values, chemical properties such as dyeing characteristics and morphologic tendency such as slub-formation, regardless of the kind and nature of the yarn, as of natural, synthetic or regenerated fibers.
In present advanced manufacturing process or finishing modes of these fibers, and in each of various and numerous processing steps, such as those of spinning, stretching, false-twisting, threading and sizing, it is possible to manage and control these values roughly within respective specified ranges, while it may be unavoidable that these practical values are subjected to appreciable fluctuation caused by a certain or other reason. It is, therefore, just an ideal to make the yarn quality evaluation, depending upon the degree of fluctuation of these characteristic values.
According to the conventional technique, it has been impossible to make a yarn quality evaluation on line in the yarn manufacturing or processing stage, such as its spinning, stretching, false-twisting, threading, sizing or the like step and concurrently in a combined manner of several yarn qualities, thus the realization of a multi-functional evaluation mode as above, has been a dream of the person skilled in the art.
As is commonly known, the micro-structure of the fiber may be explained briefly as follows:
The man-made fiber comprises a chain of high molecules which are arranged in a highly complicated manner within the fiber which can be said after all as representing a mixture of crystalline regions with amorphous regions.
The mechanical characteristic of the fiber can be expressed by its strength and the degree of elongation, as a representative example and for a practical purpose. Thus, the crystalline region reflects the strength of the yarn, while the amorphous region reflects the degree of elongation thereof. Therefore, yarn strength and its degree of elongation, in combination, can be deemed as the overall characteristics both kinds regions.
When the yarn is subjected to a forced vibration, the amorphous region represents the viscous nature of the yarn, while the crystalline region represents the elastic behavior thereof, thereby the visco-elastic nature of the yarn is the combination of both kinds behaviors.
On the other hand, when the fiber is dyed with a dyestuff, the amorphous region will play an important role. At the amorphous region, the dyestuff is easily diffused therein, regardless of the characteristic of the dyestuff which may have its dyeing performance based substantially upon its chemical or physical behavior. Therefore, the probability of existence of the dyestuff in the amorphous region is substantially higher than in the crystalline region, thus the former region is substantially easier to dye than the latter region.
On the other hand, the crystalline region presents a considerable difficulty in the diffusional affinity to such dyestuff as predominating its physically acting dyeing performance, and thus, this region can be dyed only with difficulty due to the lower prevailing percentage of the above kind of dyestuff. However, such dyestuff as predominating its chemically acting dyeing performance has a high chemical affinity to the crystalline region and is likely to occupy the dyeing seats prevailing in the material crystalline region of the yarn. Thus, this region is more likely to be dyed on account of higher rate of existence of the dye particles.
In the case of dyeing a yarn which is believed to have these crystalline and amorphous regions arranged substantially in a cyclic order when considered theoretically and in an idealized model, by means of a predominantly acting in physical or chemical behavior, the former regions will show a rather apparent difference in the dyed color tone, while the latter regions may show a rather minor difference in the dyed effect and demonstrate no appreciable difference in the color tone.
It has been known for several decades to lead a yarn continuously through a sensing gap formed between and defined by a pair of capacitive electrodes of a sensor unit, to scrutinize yarn mass or denier variation or fluctuation in a precise and continuous way. Those skilled in the art have believed that the electrical outputs from such sensor unit correspond exclusively to the yarn mass or denier variation or fluctuation. However, according to our profound experimentation, it is now found that the electrical output information of the capacitive sensor represents not only the mass or denier variation, but there is also additional and overlapped information which has an intimate corelationship with the visco-elastic characteristic distribution of the yarn under test. The latter characteristics are substantially influenced by the microstructure of the fibers, or more specifically, the corelationship between crystalline and amorphous structures of the yarn molecules. These micro-structural characteristics will have a substantial effect upon the macro-structural behavior of the yarn.
As for the sensor unit commonly used for the above purpose, it has generally the following order of outline dimensions, 8 mm in its length and 5 mm in its height or width. The thickness of a condenser electrode plate is generally about 0.5 mm, while the condenser gap is approximately 0.8 mm. There is provided a stationary yarn guide in close proximity to each end of the gap.
The yarn is guided through the yarn guides and led to travel through the condenser gap at a speed of 100-4,000 meters per minute.
It is observed that the yarn vibrates between the yarn guides, the vibration depending substantially upon the visco-elastic characteristics of the running yarn. With higher visco-elasticity thereof, the vibration amplitude will become larger. According to our finding, the degree of amplitude and frequency components during the yarn vibration plays a significant role in the determination of the yarn characteristic or quality.
In the case of the synthetic fiber yarn, the visco-elasticity will become larger when the yarn largely comprises amorphous regions.
In the dyeing step of the yarn, as was referred to hereinbefore, the dyestuff will be more easily diffused in and among amorphous regions or components of the yarn which characterize the viscous property of the yarn.
On the contrary, the diffusion of dyestuff in and among crystalline regions or components which characterize the elasticity of the yarn, will be rather difficult.
As the physically predominantly acting dyestuffs which are liably dispersed and adsorbed in and by the yarn material, may be raised, among others, direct dyes, disperse dyes and non-ionic dyes as representatives. On the other hand, as the chemically predominantly acting dyestuffs, may be raised among others, cationic dyes, anionic dyes and reactive dyes as representatives.
It has thus been highly difficult to anticipatingly determine the dyeing characteristics of the yarn, especially in advance of the dyeing process and even in the manufacturing step of the yarn and in the manner of the on-line mode.
SUMMARY OF THE INVENTION
The main object of the present invention is to provide an apparatus for the advance and continuous detection of an on-line condition of a yarn, such as mechanical, dyeing and other characteristic distributions, so as to enable an overall and classified evaluation of these characteristics even during the manufacturing stage of the yarn.
According to the presently proposed technique, the output electrical signal from a capacitive sensor is processed in a specific manner. The thus treated electrical signal includes such information as representing the vibration mode of the yarn which appears during the visco-elastic vibration thereof during passage through the sensing condenser gap.
The information includes naturally those of yarn mass variation and its shape-variation.
According to the invention, therefore, the information of yarn vibration is derived and evaluated. In this way, therefore, the yarn characteristic to the chemically predominantly acting dye can be determined in advance of its appearance otherwise upon practical dyeing. Fine and specific coloring characteristics of the yarn, fluctuation of degree of elongation, yarn bulkiness and the like vital and various yarn characteristics can be estimated even in advance of their practical appearance.
These and further objects, features and advantages of the present invention will become more apparent from the following detailed description of the invention to be set forth with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 at A, B, C and D are four yarn denier variation curves shown in the form of electrical output signals delivered from a capacitive sensor after passage of respective continuous man-made yarns.
FIG. 2 at A, B, C, D and E shows similar yarn denier variation curves in somewhat enlarged manner when compared with those shown in FIG. 1 and the correspondng amplitude frequency distribution charts at A', B', C', D' and E' obtained upon processing of said denier variation curves according to the present invention.
FIG. 3 at F, G, H and I shows four yarn denier variation curves and the respective amplitude frequency distribution charts F', G', H' and I' obtained by the processing of the foregoing.
FIG. 4 is a chart showing four different strength-elongation curves.
FIG. 5 is a chart of yarn elongation dispersion plotted against amplitude dispersion and based upon the results shown in FIG. 4, as an example.
FIG. 6 at J, K, L and M shows several yarn denier variation curves, and the corresponding amplitude frequency distribution charts obtained by the processing thereof, adapted for the determination of the corresponding yarn bulkinesses.
FIG. 7 shows a yarn denier variation curve and a corresponding frequency component distribution chart of a yarn of good quality.
FIG. 8 shows a rather specific similar chart of a yarn of relatively inferior quality.
FIG. 9 is a yarn denier variation curve of an unacceptable quality yarn and its corresponding frequency component distribution chart prepared as those of FIG. 7.
FIG. 10 shows a corresponding frequency distribution chart.
FIG. 11 is a schematic outside view of an embodiment of an embodiment of the apparatus according to this invention.
FIG. 12 is a block diagram of the electronic circuit components of the apparatus of the invention.
FIG. 13 at (A), (B), (C), (D) and (E), represents several signal forms appearing in the electronic circuit.
FIG. 14 is a more specific representation of the electronic circuit included in the apparatus of the present invention.
FIG. 15 shows several signal forms appearing at several points of the electronic circuit adopted.
FIG. 16, at (P) - (Q), shows several signal forms appearing at several points of the electronic circuit adopted.
FIG. 17 is a perspective view of a capacitive sensor unit adopted as part of the inventive apparatus.
FIG. 18, at K", L" and M", shows several charts, showing how to determine the degree of bulkiness of a yarn according to the inventive technique.
FIG. 19 is a simplified circuit arrangement of the apparatus of the invention.
FIGS. 20 - 22 are illustrative of several charts as before.
DETAILED DESCRIPTION OF THE INVENTION
In the following, several data and embodiments of the invention will be described in detail with reference to the accompanying drawings.
In FIG. 1, at A, B, C, D and E, five series of yarn denier signals are representatively shown, as obtained each by passing a continuous yarn through a capacitive sensor which will be shown and described hereinafter.
The yarn was that of a multifilament, 150d/32f, of polyacrylonitrile, manufactured and sold by Asahi Kasei Kogyo Kabushiki Kaisha (Asahi Chemical Industry Co., Ltd.), Osaka, under the trade name of "Pewlon".
The source voltage applied to the sensor unit was so adjusted that the output from the latter will amount to 4 volts when a yarn of 150 deniers is passed through the sensor.
In these graphs, A-E, one vertical gradation was set to 0.1 volt, while one horizontal gradation or scale was selected to correspond to a yarn length of 3.3 meters. Amplifier gain was 400.
In FIG. 2, graphs A-E were taken in an enlarged mode from the foregoing one shown in FIG. 1. These yarn denier signals, A-E in FIG. 2, were treated by the device according to the invention, so as to represent respective yarn denier deviation frequency distribution curves or-charts A'-E', which may be called mathematically as "elementary probability charts". Corresponding standard deviations calculated from these charts, as well as the corresponding coloring performance classification adopted by the Asahi Chemical, are given in the following Table 1.
Table 1______________________________________ Yarn StandardGroup Sample Deviations Classes of Coloring Performance______________________________________ A 0.18 Class 1 to show no uneven coloring B 0.26 Class 2 to show least amount ofI uneven coloring C 0.30 Class 3 to show slight amount of uneven coloring______________________________________ D 0.42 Class 5 to show thick color stripesII E 0.33 Class 4 to show fine color stripes______________________________________
According to the conventional technique, the patterns A, B and C belonging to Group I could not be identified from each other, resulting in similar or one category of output signals.
Further, according to the prior technique, the patterns D and E belonging to Group II could not be specifically identified from each other. It was only possible conventionally to identify the Groups I and II from each other.
It has been demonstrated that according to our comparative experiments, the above yarn quality classification are substantially in coincidence with practical values.
In a further embodiment, we have treated polyester yarns of 100d/24f which were spun and stretched in similar spinning conditions as before. The experimental results are shown in FIG. 3. In this Figure, F, G, H and I show four series of denier variation values obtained as the respective signal outputs from the same sensor unit. In the case of F, the mean yarn denier showed a 1% increase relative to the standard yarn denier of 100d. In the cases of G, H and I, the yarn samples showed a 2, 3 and 4% increase in the mean over the standard denier value of 100 d, respectively.
In each of these tests, the measured length of the yarn amounted to 2 meters, and the number of samplings amounted to 2,000. Therefore, a sampling yarn length was 1.0 mm.
FIG. 3, at F', G', H' and I' show the respective yarn denier or amplitude-frequency deviation charts as obtained by the treatment of the respective signals F - I according to this invention. In the charts F' - I', several mean values were calculated from these charts. As seen from charts, when the fluctuation is large, the denier increase will be substantially correspondingly large, and vice versa.
In these experiments, each measured yarn length amounted to 1,800 meters. The number of samplings were 12,000. Thus, each sampling length amounted to 0.15 meter.
In FIG. 4, polyester yarn samples corresponding to F - I were measured on a load- or strength-elongation tester and treated according to the invention to obtain the corresponding frequency distribution charts of the load-elongation of the yarn, when seen in FIG. 4 in succession from left to right. The corresponding standard deviations were found as 2.39; 2.50; 2.74 and 3.17, as shown.
On the other hand, the corresponding standard deviations which were calculated from the charts F' - I' were 1.9; 2.2; 3.2 and 3.5, respectively.
FIG. 5 represents a chart showing the relative relationship of the thus calculated standard deviations. As seen from this Figure, the fluctuation or distribution of the strength-elongation values and that of the corresponding values as found from the distribution charts represents a substantial correspondence. Therefore, it can be definitely concluded that from the frequency distribution which constitutes the core idea of the present invention, possible fluctuation of strength-elongation can be reliably anticipated in advance and in an on-line bases.
In FIG. 6 at J, K, L and M, are several examples of the denier fluctuation of yarns spun and threaded from polyacrylonitrile short length fibers are shown, in the form of electrical output signals from the same capacitive sensor. J' - M' are corresponding amplitude-frequency distribution charts obtained therefrom. It has been determined by comparative experiments that the deviation of the mean value of amplitude frequency distribution is substantially in correspondence to that of the corresponding yarn number counts, being in this case, 1-4%.
In FIG. 7, at left hand portion, a yarn denier variation curve of a yarn made of polyester (trade name "pewlon"), is shown as output the signal from the capacitive sensor as before. The right hand curve is the same signal after having been passed through a 1 - Hz low pass filter. As seen, this yarn has a relatively good quality.
A corresponding frequency component distribution curve which has been obtained in the similar manner as before is shown in FIG. 8.
Another example similar to that shown in FIG. 7 is demonstrated in FIG. 9. This yarn has a rather inferior yarn quality, as may be well supposed from the drawing. In FIG. 8, the frequency components appear in a rather random manner, from which it can be definitely expected no substantial amount of uneven coloring to appear upon weaving and dyeing of this yarn.
On the other hand, in FIG. 10, frequency components are appearing in a highly localized manner, from which a substantial amount of uneven coloring could occur later and with definiteness.
Experimental results of a further polyester yarn, 50d/24f, is shown in FIG. 20, demonstrating its distribution of frequency components. At the lower part L of this drawing, these frequency components are distributed in a rather even manner which means that this yarn is of good quality, demonstrating only a neglegibly small amount of uneven coloring occuring later.
The yarn is conveyed at a speed of 900 meters per minute and the chart corresponds to a yarn length of 225 meters.
In the upper part K of this drawing, a similar distribution curve of frequency components is shown. In this chart, longer period components, less than 27 Hz if expressed in frequency, appear in a highly localized manner. This yarn could show highly inferior uneven coloring after weaving and dyeing later, possibly to a commercially unacceptable degree.
At the yarn part L shown at the bottom of this drawing, the distribution is rather uniform which will result later in the occurrence of small amount of uneven coloring.
In the similar chart shown in FIG. 21, yarn viscous characteristics are overlapped with the occurrence of fluff formation which appears at left zone of the upper curve. The measured polyester yarn length amounted to 225 meters and the number N was 7705. One sampling length amounted to 30 mm. From the results of the upper curve, it may be said that the yarn quality is poor and a fabric made therefrom will show an unacceptably dark dyed color tone, thus being highly defective. On the other hand, the yarn portion represented by the lower curve has such a superior yarn quality which is high enough to be accepted for a commercial purpose.
It is possible to reduce the yarn bulkiness evaluation indices from the foregoing charts J', K', L' and M' shown in FIG. 6.
For this purpose, now referring to FIG. 16, there are shown several processed charts from the foregoing. These charts have been prepared by center-to-center overlapping the chart J' upon the respective charts K', L' and M'. The thus produced excess area is shown in each case by being shaded, while the area of chart J' is left in blank. Then, the ratio of the shaded area to the blank area J' is provided which value amounts to 0.33; 0.5 and 0.7, respectively at K", L" and M". According to our experience, this ratio represents the degree of bulkiness of the fiber-spun yarn. According to our experiments with a seriplane tester, a good correspondency has been demonstrated.
The results are shown in the following Table 2.
Table 2__________________________________________________________________________"A" Blank "B" Shaded Ratio of Standard SeriplaneArea Area B"/A" Deviation Evalvation__________________________________________________________________________J' 0.6 0 0 0.17 Class 1K' 0.6 0.2 0.33 0.22 Class 2L' 0.6 0.3 0.5 0.27 Class 3M' 0.6 0.4 0.7 0.32 Unacceptable__________________________________________________________________________
Next, referring to FIG. 12, a preferred embodiment of the apparatus of the present invention will be described in detail.
In FIGS. 12 and 17, numeral 1 represents a capacitive sensor unit employed in the invention.
Symbol 1a represents a yarn passage opening defined by the gap of a pair of capacitor electrodes. Numeral 101 represents a yarn under test which is taken out continuously from a delivery reel 100 and passed through the condenser gap 1a. The tested yarn is continuously wound on a winding reel 102. Numeral 31 in FIG. 11, represents a signal processor which contains the components shown in FIG. 12.
Numeral 33 in FIG. 12, represents a calculating section which operates in the manner to be later described.
The electrical output signal delivered from the sensor 1 is fed to a filter 42 which may be a low pass, high pass or band pass filter, so as to adapt it to the desired kind of job to be executed, thereby removing unnecessary signals therefrom.
As an example, at the present stage, the job may be assumed to be amplitude component distribution. For this purpose, output signal from filter 42 is fed to a sampling and hold circuit 3 wherein the signal is converted into a sampling signal which is then brought to a comparator input I 1 of a comparator 4. The latter has a second input I 2 . A sampling synchro-signal generator 304 delivers a series of clock pulses which is fed to a memory adder 5 which is thus driven stepwise. A ramp voltage in relation to the number of addresses contained in the adder 5 is applied to the second input I 2 . For this purpose, a sampling counter 90 is provided and connected as shown, so as to count drive clock pulses applied to the adder 5, thus acting as a kind of memory address counter. The thus counted value is fed to a D-A converter 91 which serves for converting the digital value into a corresponding analog signal which is then supplied to I 2 of the comparator 4 as its comparative standard ramp input voltage. At the comparator 4, the first input through I 1 is compared through I 2 with the ramp voltage, so as to find out a coincidence point within the voltage width of the ramp. Upon attaining such a coincidence point, a coincidence signal is delivered from the output of the comparator 4. By application of the coincidence signal, a binary "1" will be added at the memory address in the memory adder 5.
At each arrival of a sampling signal of the above kind, the aforementioned operation will be repeated and in this way, an amplitude frequency distribution derived from the electric output signal from the sensor unit is accumulated in the memory 5. This distribution could naturally be taken out from the memory 5 by successive read-out operations.
Next, the adopted structure for deriving the frequency component frequency distribution from the sensor output signal will be described. In this case, the sensor output signal is passed through a filter 42 which may be a high pass or band pass type, adapted for removal of the d.c. components and unwanted components. The thus filtered signal is fed to a zerocross comparator 43 as its input. This comparator is so designed and arranged to make a comparison at zero point of the signal and based upon the polarity-reversed component of the signal, to convert the latter into a rectangular wave signal having a duration period corresponding to zero-to-zero time length of the signal. Of course, in place of the zero-to-zero interval, the peak-to-peak duration can be adopted.
The rectangular wave signal convertedly produced at zero-cross comparator 43 is fed to an integrator 44 for being integrated therein. The integration constant of this integrator is made variable, so as not to be saturated even with the application of a possible long frequency signal component. Leading and trailing points of each rectangular wave signal are fed from the comparator 43 for resetting the integrator 44. A reset pulse is generated at 122 and the signal from the integrator 44 is reset at each of the state-changing points of the rectangular wave signal from comparator 43 so as to allow a repeated integrating operation as desired. The output signal from the integrator 44 is converted into a sampling signal at the circuit 301 depending upon the constant frequency period generated at and delivered from the sampling frequency signal generator 304.
The sampling signal converted at and delivered from sample and-hold circuit 301 is fed to the first input of comparator 302. The output from D-A converter 91 is fed to the second input of comparator 302. Comparator 302 will perform a similar operation as the comparator 4. With feeding of a coincidence signal, the memory address of memory adder 303 is added with a binary "1".
The above mentioned operation will be repeated for each arrival of the sampling signal and thus, the similar accumulation job is performed at the memory of the adder 303; and so on.
The amplitude component frequency distribution accumulated at memory adder 4 and the frequency components frequency distribution accumulated at memory adder 303 are converted into their corresponding analog sampling signals at respective D-A converters 16 and 94 for later utilization for the purpose of respective wave pattern observation. For satisfying these functions, memory adders 5 and 303 may be united into an overlapped stack assembly of MOS-type shift registers.
It can be easily carried out to perform respective write-in and read-out functions to and from this memory by driving shift registers with clock signals made in synchronism with output signals from sampling synchro-signal generator at 304.
Digital data at memory adders 5 and 303 may be transferred as per se to an electronic computor CPU 18 which is fitted therein with an operation control unit adapted for performing operations under the instructions from a programmed signal generator 19, so as to perform a printing function by means of a digital type printer 20.
With the arrangement referred to hereinbefore, the amplitude component frequency distribution as the contents of memory adder 5 and the frequency component frequency distribution as the contents of memory adder 303 may be processed to find the current mean value x and the current standard deviation Υ.
Since these calculated values are based upon the measured values taken from the sample material for a certain time period, specific and reliable evaluation standard can naturally be provided.
FIG. 13, shows several wave forms of preferred output signals delivered from selected circuit components of the circuit arrangement shown in FIG. 12.
More specifically, (A) represents the output signal from the sensor unit 1. (B) and (C) represent representatively and by way of example, two output signal waves from filter 2. (D) represents the output from zero-cross comparator 10. (E) represents the output from the sample-and-hold circuit 13.
Next, referring to FIG. 14, an embodiment is shown of means adapted for extracting the frequency component frequency distribution.
An electric signal fed to a terminal 41, which is electrically connected to a sensor unit such as that shown at 1 in the foregoing, is passed through a high pass and low pass filter 42 for removal of unnecessary frequency components therefrom. This filtered signal is converted into a rectangular signal at a zero-cross comparator 43. The output from the comparator 43 is subjected to a level conversion at voltage level converter 123 and then conveyed to short pulse generators 121 and 122, so as to deliver a short pulse at each of the leading and trailing edges of the rectangular signal. By the use of this short pulse, the electrical charge at the condenser C1 of the integrator 44 is caused to discharge towards P-channel field effect transistor switch 120. The short pulse width is designed to have a duration less than 1/10 or still shorter than the input electrical signal and current content at the said field effect transistor switch 120.
With the above structure and arrangement of the various circuit components employed, the rectangular signal as an output from the zero-cross comparator 43 and in relation to the frequency component contained in the electrical signal at terminal 41 is converted at the integrator 44 into an integrated wave form in relation to the frequency component while being subjected to resetting at each of the leading and trailing edges of the rectangular signal. The thus integrated wave form is fed through amplifier 45 to sample-and-hold circuit 46 and converted thereat into a sampling signal in dependence to a sampling time specified by a frequency divider 66. The sample-and-hold signal at the circuit 46 will be fed to one input of comparator 48 through buffer amplifier 47. To another input of comparator 48, is supplied the output from address counter 90 which serves for counting the addresses of MOS-type shift register 86, and after converted into a corresponding analog value at D-A converter 91. Therefore, the shift register 86 is arranged to act as a memory, and a voltage in relation to the address is applied to the comparator 48 and as the comparing ramp voltage. By adopting this means, a comparison is made with the signal incoming through buffer amplifier 47 and when a coincidence point is brought about, a coincidence signal pulse will be generated at the coincidence-detecting and wave shaping circuit 49. This coincidence signal is supplied to AND-gate 50 and when the latter is at its opened state, it will apply an input the lower bit in the adder 84. By this operation, a binary "1" will be added at the address section of MOS-type shift register 86.
The embodiment of shift register 86 shown in FIG. 14 has 128 address bits multiplied by 12 memory bits. The memory section is so designed and arranged that signals are caused to circulate in parallel through the adder 84.
When start switch 110 is turned on, the entire circuit is brought into its reset position. A delay is brought about by the one shot multivibrator 61, so as to bring flip-flop 62 into its operative position. With the output Q of flip-flop 62 at the binary "1"-level, the signal generated at and delivered from clock generator 65 is subjected to frequency division by frequency division circuit 66 and selected at sampling selection switch 67 and further supplied to AND-gate 63 which is preset by the signal delivered from start pulse generator 305 which is designed and arranged to do so at its peak point which corresponds substantially to that of peak voltage signal from the integrator 44. With each start pulse delivered, flip-flop 306 will generate one mode gate signal. When a binary "1" has been supplied from flip-flop 62 and so far as the latter is caused to reset, the sampling time pulse selected by sampling time selection switch 67 is allowed to pass.
The signal is then converted through single pulse converter 64 into a short pulse and conveyed to P-terminal (for preset use) of the next stage flip-flop 72, and thereby the Q-terminal of flip-flop 72 is brought to the "1"-level. On the other hand, the clock pulse from clock generator 65 is supplied to the CP-input of flip-flop 72, and thereby the Q-terminal of flip-flop 72 is brought again to the "0"-level. A single pulse in relation to this clock pulse is used for sampling purposes of the sample-and-hold circuit 46. This pulse is applied to sample number counter 51.
Further, this pulse is used as an input clock pulse to flip-flop 76 and at the trailing edge of this pulse, the Q-terminal of flip-flop 76 is brought to the "1"-level. With realization of this state, AND-gate 77 is opened and thus, the clock pulse from clock generator 65 will begin to drive concurrently both MOS-type shift register 86 and address counter 90.
With the count of the address counter being zero, a signal will be delivered from zero-value detector circuit 78 and conveyed to 2"-bit-section of MOS-type shift register 86. Thus, the clock pulse is conveyed through buffer 88 for driving the MOS-register, the shift operation being carried out to the address 128. Upon entrance of 128 clock pulses, a single pulse is generated at the generator 82 and conveyed through buffer 87 and OR-gate 81. Then, address counter 90, hold section of sample-and-hold circuit 46 and flip-flops 72, 76 and 306 are reset.
By these operations, the related arrangement is brought again to the sampling state, and the above operation is repeated. Since the number of samplings has been counted at the counter 51 provided for this purpose, it is possible to stop any further increase in the sampling number in an automatic way when it attains the present value of 52. In this case, automatic stop switch 113 is turned off. Or alternatively, a provisional stop switch is turned on for provisionally stopping the sampling operation.
The further value stored in MOS-type shift register 86 after the above stoppage of sampling, may be taken out as an output in a digital form via buffer 93, or in an analog form via D-A converter 94, so as to be utilized for various operational or observational purposes as desired.
The shift operation at this time of MOS-shift register 86 is brought about by such operation that the clock pulse from the generator 65 is subjected to a frequency division at the divider 66 and the thus provided synchlorizing signal is selected at the switch 68 and conveyed through AND-gate 69 to the shift register 86.
The starting operation at this time may be initiated by the operation of flip-flop 201 controlled by a low speed start switch 112 such as a push button.
Several representative wave forms as appearing in the circuit arrangement shown in FIG. 14 are demonstrated.
The first signal Vi represents by way of example the output signal of the filter 42.
The second signal Vio is the output from the zero-cross comparator 43. The third one is the reset pulses which are delivered from reset pulse generator 121 or 122 and used for the foregoing signal V O .
The fourth signal V O represents the output from the integrator 44.
FIG. 16 represents a timing chart for the circuit arrangement shown in FIG. 14.
The first signal at (P) represents a start signal of start switch 110. The second signal at (Q) is an output signal from one shot multivibrator 61.
The third signal at (R) is an output from single pulse generator 71. The fourth signal at (S) is an output from flip-flop 62.
The fifth signal at (T) is an output from frequency divider 66 at its sampling selection switch side. The sixth signal at (U) is an output series of clock pulses from the generator 65.
The seventh signal at (V) represents an output from flip-flop 72 at Q. The eighth signal at (W) is an output from single pulse generator 64.
The ninth signal at (X) is an output from flip-flop 76 at Q. The tenth signal at (Y) represents an output from single pulse generator 82.
In FIG. 17, the sensor unit 1 is shown in its enlarged perspective view. This sensor 1 is connected with a terminal box 108 carrying a number of input and output terminals.
Symbol 1a represents the condenser gap adapted for passage of the yarn 101, specifically shown in FIG. 11. Condenser electrodes 105 and 106 define the yarn passage gap. 103 and 104 represent two stationary yarn guides positioned at both ends of the gap. Numeral 107 represents a conducting cable arranged for electrical connection between the sensor and terminal box. Numeral 109 is a screw adjuster by which the condenser gap may be adjudged in its width as desired. The sensor and its related several main components are schematically shown in FIG. 19 which may be self-explanatory.
From the foregoing disclosure, any reader can well understand the nature and effects of the apparatus of the present invention. | The invention resides in an improved apparatus for the evaluation of qualities of a running continuous yarn. The apparatus is provided with a capacitive sensor through which the yarn is passed continuously. The apparatus is also provided with a device for extracting from the sensor an output signal with amplitude or frequency components frequency distribution. It is further provided with an electronic calculating device which determines the mean and standard deviation from the foregoing distributory information. | 6 |
RELATED APPLICATION
[0001] This patent application is a continuation-in-part patent application of U.S. Ser. No. 11/102,169 filed on Apr. 8, 2005 and entitled HIGH SPEED BEAM STEERING/FIELD OF VIEW ADJUSTMENT, the entire contents of which are hereby incorporated by reference.
TECHNICAL FIELD
[0002] The present invention relates generally to optics and, more particularly, to an apparatus and method for steering a beam of light using a spatial light modulator.
BACKGROUND
[0003] Light beams are used in a wide variety of different applications, such as communications, imagery, and weaponry. In such applications it is frequently necessary to steer a beam of light. In some such applications, beam steering must be performed rapidly.
[0004] Beam steering is useful in optical communications, where a modulated light beam originating at a transmitter must be aimed toward a remote receiver. Beam steering is also useful in directed energy weaponry, where a light beam must be aimed toward a distant target. In such instances, it can be desirable to rapidly steer the beam from one receiver or target to another.
[0005] Mechanical systems for accomplishing beam steering are well known. Such mechanical systems include those that utilize movable optical components. For example, a mirror may be aimed so as to effect desired beam steering.
[0006] However, as those skilled in the art will appreciate, such mechanical components are subject to wear. Not only can wear contribute to premature failure, but it can also adversely affect the accuracy of a mechanical beam steering system prior to or in the absence of failure.
[0007] Further, such mechanical systems have strict speed limitations. These speed limitations are due, in part, to the inertia of the moving components. Drive motor capacities, current limitations, and structural constraints also contribute to such speed limitations.
[0008] Further, the mechanical components (mirrors, drive motors, gimbals, and linkages) of such systems have substantial weight and volume. The weight and volume of such mechanical systems makes them unsuitable for some applications. For example, launch vehicle payload weight and volume restrictions may limit the use of mechanical systems in space-based applications.
[0009] Non-mechanical beam steering systems are also known. However, contemporary non-mechanical systems require high voltages and/or expensive technology, thus making them unsuitable for many applications.
[0010] In view of the shortcomings of such contemporary systems, there is a need for lightweight, small, non-mechanical beam steering systems that respond rapidly and do not require high voltages for operation.
SUMMARY
[0011] The use of spatial light modulators, such as dual frequency liquid crystal spatial light modulators, to steer light beams is disclosed. Dual frequency liquid crystal spatial light modulators have rapid response times that make them suitable for use in many time critical applications, such as battlefield communications, real time imaging, and directed energy weaponry. Dual frequency liquid crystal spatial light modulators are substantially lighter in weight as compared to their mechanical counterparts, thus making them particularly desirable for use in space-based applications.
[0012] According to an embodiment, a method for steering a beam of light comprises using a blazed phase grating to varying a angle at which light incident upon the blazed phase grating is transmitted from the blazed phase grating.
[0013] According to an embodiment, a method for adjusting a field of view comprises using a blazed phase grating to determine the field of view incident upon an imager.
[0014] According to an embodiment, a method for adjusting a field of view comprises communicating light from a field of view to a spatial light modulator, controlling the spatial light modulator so as to communicate the light therefrom to an imaging device, and receiving the light by the imaging device.
[0015] According to an embodiment, a dual frequency liquid crystal spatial light modulator can be controlled so as to form a phase grating thereon that effects desire deflection of incident light. For example, a blazed phase grating can be formed on a dual frequency liquid crystal spatial light modulator. Blazed phase gratings are especially efficient at deflecting light.
[0016] According to an embodiment, the deflection of light can be used for beam steering. Thus, a dual frequency liquid crystal spatial light modulator can used be to direct a beam of light used for communications.
[0017] According to an embodiment, a dual frequency liquid crystal spatial light modulator can be electronically controlled so as to provide the desired deflection of light. Such electronic control is possible because dual frequency liquid crystal spatial light modulators are rapidly programmable and quickly responsive to such programming. That is, a blazed phase grating can be quickly defined and implemented so as to provide the desired degree of light deflection.
[0018] The scope of the invention is defined by the claims, which are incorporated into this section by reference. A more complete understanding of embodiments of the present invention will be afforded to those skilled in the art, as well as a realization of additional advantages thereof, by a consideration of the following detailed description of one or more embodiments. Reference will be made to the appended sheets of drawings that will first be described briefly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 shows a block diagram illustrating a beam steering system in accordance with an exemplary embodiment of the present invention;
[0020] FIG. 2 shows a block diagram illustrating a field of view adjustment system in accordance with an exemplary embodiment of the present invention.
[0021] FIG. 3 shows a block diagram of the blaze period and pitch control logic of FIG. 1 in further detail; and
[0022] FIG. 4 shows a block diagram of voltage commands from the multiplexed array commands circuit of FIG. 1 .
[0023] Embodiments of the present invention and their advantages are best understood by referring to the detailed description that follows. It should be appreciated that like reference numerals are used to identify like elements illustrated in one or more of the figures.
DETAILED DESCRIPTION
[0024] At least one embodiment of the present invention comprises a liquid crystal spatial light modulator, such as a dual frequency liquid crystal spatial light modulator, that is configured to facilitate beam steering. Such embodiments of the present invention may find application in optical communications and directed energy weaponry, for example. As those skilled in the art will appreciate, dual frequency liquid crystal spatial light modulators provide enhanced speed and controllability with respect to other types of spatial light modulators.
[0025] Thus, at least one embodiment of the present invention comprises a non-mechanical way to rapidly change the deflection angle of a light beam, so as to direct the light beam toward a desired target. More particularly, at least one embodiment of the present invention comprises a dual frequency liquid crystal spatial light modulator, electronic means to induce a blazed grating pattern on the dual frequency liquid crystal spatial light modulator, algorithms for varying the blaze period so as to effect beam steering, and algorithms to vary the blaze pitch.
[0026] Thus, a blazed phase grating can be created within a dual frequency liquid crystal spatial light modulator array. This can be accomplished by sending control signals, e.g., voltage signals of appropriate amplitude, frequency, and duty cycle, to the dual frequency liquid crystal spatial light modulator. The blazed grating deflects incident light by an amount dependent on the period of the grating. The beam deflection angle may be varied in time by varying the control signals. Thus, a beam of light, such as a laser beam, can be rapidly steered from one target to another.
[0027] The period and blaze angle can be controlled electronically, e.g., by blaze period and pitch control logic. Optionally, the beam can be monitored to determine the deflected beam angle and/or wavefront, so as to provide feedback that can be used to control the deflection angle.
[0028] FIG. 1 shows a beam steering system wherein a dual frequency liquid crystal spatial light modulator 10 receives incident light 11 and provides a steered beam 12 , according to one exemplary embodiment of the present invention. That is, incident light 11 is transmitted through dual frequency liquid crystal spatial light modulator 10 and is affected thereby so as to introduce a deflection angle θ into the steered beam 12 . Incident light 11 can come from a laser, such as a laser that is used to provide light which is modulated for communications or such as a laser that is suitable for use in a directed energy weapon.
[0029] More particularly, the deflection angle θ is defined by the period of an induced blazed phase grating formed within the dual frequency liquid crystal spatial light modulator 10 . The period of the blazed phase grating can be electronically controlled, so as to provide the desired deflection angle θ.
[0030] Blaze period and pitch control logic 14 defines the blaze period and pitch required to provide desired deflection angle θ. Blaze period and pitch control logic 14 receives a signal representative of a desired deflection angle and provides a control signal to multiplexed array commands circuit 13 , so as to effect the deflection of light by the desired angle. Multiplexed array commands circuit 13 controls dual frequency liquid crystal spatial light modulator 10 , so as to create the necessary blazed phase grating thereon and thus effect deflection of incident light 11 by the desired deflection angle θ.
[0031] At least one embodiment of the present invention comprises a dual frequency liquid crystal spatial light modulator configured to facilitate field of view adjustment. Such embodiments of the present invention may find application in imaging, such as in photography (either film or digital) and telescopy, for example. Thus, at least one embodiment of the present invention comprises a non-mechanical way to rapidly change the direction and field of view of a remote imaging system, so as to provide a multiplexed output of targeted scenes. In this manner, a plurality of different scene can be simultaneously viewed substantially in real time.
[0032] According to one embodiment of the present invention, a liquid crystal spatial light modulator, such as a dual frequency liquid crystal spatial light modulator, is incorporated into an optical system to effect changes in the direction and/or area of the field of view. In addition to the dual frequency liquid crystal spatial light modulator, the optical system can comprise static components, such as refractive and/or reflective elements, e.g., lenses and/or mirrors. The optical system may also comprise optical elements that affect the polarization or wavelength of light.
[0033] Commands are issued by a data processing and control system, which in turn are translated into voltage signals that are communicated to the elements of the dual frequency liquid crystal spatial light modulator, so as to effect desired control thereof. The control signals effect a varying refractive index across the dual frequency liquid crystal spatial light modulator. Thus, the dual frequency liquid crystal spatial light modulator can function substantially like a programmable lens, whose optical properties can be rapidly changed.
[0034] The dual frequency liquid crystal spatial light modulator is used to vary the tilt and focus of incoming light. It may also be used (in combination with other optical elements) to vary a zoom or magnification incoming light. In combination with the static elements of the optical system, these changes effect the direction and field of view of an imaging system.
[0035] The changes can be made synchronously with respect to the acquisition frame rate of the monitoring system. By this means, successive image frames can be dedicated to multiple scenes. The frames from each scene are segregated electronically, so that they can be displayed and/or recorded independently.
[0036] FIG. 2 shows a non-mechanical method and system for adjusting the field of view of a camera, according to one exemplary embodiment of the present invention. A dual frequency liquid crystal spatial light modulator 20 receives light 22 representing a field of view and provides light 21 processed thereby to an imaging system 27 , such as that of a camera.
[0037] Optionally, static optical elements 23 and/or 24 are interposed within the optical path. For example, input side static optical elements 24 can receive light 26 that defines a field of view and can provide light 22 to dual frequency liquid crystal spatial light modulator 20 . Input side static optical elements 24 can provide desired focus, zoom, polarization and/or filtering, for example.
[0038] Also, light 21 from dual frequency liquid crystal spatial light modulator 20 can be provided to output side static optical element 23 , which in turn provide light 25 to imaging system 27 . Output side static optical elements 23 can provide desired focus, zoom, polarization and/or filtering, for example.
[0039] Imaging system 27 can provide an electronic signal representative of an image of the field of view to a signal processing/control system 28 , which in turn provides a control signal to dual frequency liquid crystal spatial light modulator 20 , so as to effect viewing of the desired field of view. The control signal provided by signal processing/control system 28 can also determine the focus, zoom, or other desired optical parameters of the viewed image.
[0040] Commanded field of view circuit 29 provides a signal to signal processing/control system 28 that is representative of a desired field of view. That is, this control signal determines what field of view dual frequency liquid crystal spatial light modulator 20 is configured to provide. The desired field of field commanded by commanded field of view circuit 29 can be defined by either a human operator or an automated system.
[0041] Referring now to FIG. 3 , the blaze period and pitch control logic 14 is shown in further detail. The blaze period and pitch control logic 14 can comprise a pitch control 30 and a blaze control 31 .
[0042] The blaze period and pitch control logic 14 determines the exact geometry of the modulation characteristics. The equation that governs this geometry is:
sin(θ d )=(λ n/s )sin(θ i )
[0043] where θ d is the angle of diffraction (the steered angle after passing the dual frequency liquid crystal spatial light modulator 10 ); θ i is the angle of incidence coming into the dual frequency liquid crystal spatial light modulator 10 ; λ is the wavelength of light being used; n is the diffraction order; and s is the pitch (which is the separation between the peaks in the diffraction grating).
[0044] It is worthwhile to note that the diffraction or steering angle is only controlled by the separation in the peaks, not by their individual depth. Steering does not depend on the absolute value of the optical path length modulation. Rather, the steering angle depends on the physical distance, i.e., the pitch, over which the angle changes.
[0045] The blaze angle, which defines the depth of the modulation, controls how much light goes into each order (n). Generally, it is desirable for all of the light to go into the first order. That requires a well defined, deep, modulation.
[0046] As is well known, diffraction gratings rely on phase to make light diffract into orders. Cheap or quickly made gratings will have a phase pitch, so that that light will go into a series of orders. However, the amount of light that goes into each order, as well as the angular spread of the order itself, will depend upon the exact construction of the individual modulations.
[0047] Modulations that are regular in shape, that are deep (not necessarily physically, but which have a strong effect, such as due to the alignment of the liquid crystal) will be said to have a strong blaze angle. This term originates from classical gratings, which were actually cut into metal. The shape of the individual ridges needed to be made into strong well defined edges, so that the diffraction angles would be well defined and therefore not have much angular spread and not have much stray scattering into background signals.
[0048] Referring now to FIG. 4 , the multiplexed array commands circuit 13 can use voltage commands that are routed to pixels of the dual frequency liquid crystal spatial light modulator 10 so as to define a blazed phase grating that results in the desired steering angle.
[0049] More particularly, a voltage command can increase optical path length as shown in block 41 . A voltage command can decrease optical path length as shown in block 42 . A voltage command can maintain optical path length as shown in block 43 . A voltage command can reset liquid crystal position to the initial case as shown in block 44 .
[0050] A router can be used to determine which pixels of the dual frequency liquid crystal spatial light modulator 10 receive which commands as shown in block 45 . That is, the router can route the voltage commands (such as those used to increase optical path length, decrease optical path length, maintain optical path length and reset the liquid crystal position) to individual pixels of the dual frequency liquid crystal spatial light modulator 10 .
[0051] The array commands from multiplexed array commands circuit 13 are delivered to each pixel. Each of these commands can change the relative liquid crystal alignment. One important aspect of this is the optical path length change, which can modulated in the dual frequency liquid crystal spatial light modulator 10 . In this manner, control is provided regarding which pixel or group of pixels needs this requires changes in order to provide desired beam steering.
[0052] Although the description herein refers to a dual frequency liquid crystal spatial light modulator, those skilled in the art will appreciate the other types of devices, e.g., other types of spatial light modulators, are likewise suitable, at least for some applications. Thus, discussion of the present invention as comprising a dual frequency liquid crystal spatial light modulator is by way of example only, and not by way of limitation.
[0053] Further, although the use of a single dual frequency liquid crystal spatial light modulator is discussed herein, those skilled in the art will appreciate that a plurality of dual frequency liquid crystal spatial light modulators or the like may alternatively be used, such as in tandem so as to provide a lensing effect that facilitates both focus and zoom.
[0054] According to one embodiment of the present invention, beam steering and field of view adjustment systems can be dedicated to a single particular function. That is, a beam steering system can perform beam steering without performing field of view adjustment and vice-versa. However, according to another embodiment of the present invention, a single system can perform both beam steering and field of view adjustment. This may be accomplished using at least some common components for these two functions. For example, a single dual frequency liquid crystal spatial light modulator can be used for both beam steering and field of view adjustment.
[0055] Thus, according to at least one embodiment of the present invention, a method and system for rapidly steering a light beam, such as for use in communications or weaponry, is provided. According to at least one embodiment of the present invention, a method and system is provided for changing a camera's field of view according to a multiplexing strategy is provided. Further, one or more embodiments of the present invention provide lightweight, small, non-mechanical beam steering and/or field of view adjustment systems that respond rapidly and do not require high voltages for operation.
[0056] Embodiments described above illustrate but do not limit the invention. It should also be understood that numerous modifications and variations are possible in accordance with the principles of the present invention. Accordingly, the scope of the invention is defined only by the following claims. | The use of spatial light modulators to steer light beams is disclosed. A dual frequency liquid crystal spatial light modulator can be controlled so as to form a blazed phase grating thereon that effects desire deflection of incident light. | 6 |
This application claims the benefit of PCT Application No. PCT/DK01/00285 filed Apr. 27, 2001.
BACKGROUND OF THE INVENTION
The present invention relates to an eyeglass frame, a hinge for connecting a temple bar to an eyeglass frame, an eyeglass, and a method of manufacturing a hinge for linking a temple bar to an eyeglass frame. In particular the invention relates to eyeglass frames comprising hinges fitted with friction members.
As used herein the term eyeglass relates to the well known accessory which substantially comprises two lenses of glass or of other refractive or tinted, transparent material intended to be worn in front of the eyes of the user enabling him to obtain a corrected or a darkened view through the glasses, and a form of spectacle frame arranged to keep the lenses or glasses expediently fixed in the preferred position of use, where the user can look straight forward with both eyes and with parallel lines of sight through the respective lenses.
It is well known to provide such eyeglass frames with a frame front for holding the glasses and with a pair of temple bars for supporting the frame, which temple bars are connected to the frame front by means of hinges so as to allow the eyeglass to be folded up when not in use.
Even though a variety of eyeglasses are available, development is still taking place in order to find new solutions which might gain market shares, e.g. by offering particular features or cost benefits or through offering new aesthetic features.
U.S. Pat. No. Re 36 882 to Lindberg et al. discloses an eyeglass frame wherein the temple bar comprises a wire of which one end section has been wound into a coil for providing the exterior part of a hinge. The hinge pintle comprises a straight section of wire integral with the frame front. End sections of the pivot wire are angled laterally so as to provide double constraints for axial movement of the coil. This hinge design has proven successful, however, it is associated with some aestethical and functional limitations. Thus, in this hinge the laterally angled sections of pintle wire protrude beyond the coil which may be undesirable. Both hinge parts comprise metal and thus the hinge operation involves metal rubbing against metal, a combination which gives rise to wear. Thus, it is not practically possible to make this hinge with a predetermined level of friction.
Due to the pitch in the coil the turning of the hinge is bound to be linked with some axial displacement, thus giving rise to wear between the lateral end portions of the pintle wire and adjacent portions of the coil. This rubbing gives rise to friction, however, on reversing the direction of pivoting this frictions vanishes due to play between the lateral pintle wire sections followed by restablishment of some degree of friction against the opposite one of the lateral pintle wire sections. Most often friction to turning of the temples vanishes quickly leading to a not very attractive tactile feel of the parts tending to be loose.
WO 97/23803 discloses an eyeglass with hinge means comprising double concentric coils of wire. Thus, a wide coil basically integral with the frame provides a female thread engaged by the exterior of a narrower coil integral with temple bar. This solution relies on wire rubbing against wire and does not permit establishing and maintaining any predetermined level of friction in the hinge.
WO 00/29896 discloses a hinge comprising coils in respect of each of the temples and of the frame front, which coils have generally similar diameter and pitch in order that they may engage about a common pin with interengaging windings. In this solution metal rubs against metal on turning the pivot with the likely result that friction will vary over time.
WO 98/40778 discloses a hinge for an eyeglass with coils in respect of each of the temple bars and the frame front. The coils are mutually similar and engaged about a common pin, one coil on top of the other. The pin comprises an enlarged head to provide axial restraint. In this coil metal rubs on metal with the likely result that friction may vary over time. On turning of the temple bar, there is bound to be axial movement and separation among the parts according to the pitch of the coil. This implies that the head of the pin must allow axial play. This does not create an optimum tactile feel. Further, the head of the pin bears on the top most winding of one of the coils with the danger that the coil may work its way past the head by the screwing action.
WO 99/21046 discloses a hinge for an eyeglass comprising a strip of metal wrapped about pivot inserts of friction material. The resilient strap of metal applies a radially directed biasing force on the friction member so as to eliminate any play in the hinge and to establish a controlled level of friction. Only with respect to the axial constraint there is the danger of metal rubbing against metal, however, the axial forces are virtually nil due to the absence of coils or other factors that might create axial displacement. This hinge is not integrated with wire components.
SUMMARY OF THE INVENTION
There is a desire to provide eyeglass hinges with a superior tactile feel, i.e. without any play, with a predetermined friction resistance on turning the pivot, which friction resistance should be completely unchanged over time, i.e. not affected by wear, or reversal of the motion, etc. There is a desire for such hinge means in association with eyeglass frames comprising wires. There is a desire for small and simple hinge means that permit easy adjustment of the attitude of the hinge axis in order to permit adapting the eyeglass frame so as to have the temple bars folded nicely together.
The invention in a first aspect provides an eyeglass frame as recited in claim 1 .
This eyeglass frame offers pivoting of the temple bars with friction retention at all positions without localized wear of the hinge means by the biasing forces relied on for providing the friction. The biasing on the pivot eliminates any sense of play in the hinge means. The hinge ensures accurate guidance of the temple bar in all positions and thus creates a tactile feel of a high quality product. The hinge does not rely on protruding parts to axially constraint the motion and thus offers the designer all options of creating a design of his choice. The hinge may be implemented in a very small size and thus is unobtrusive in view.
The hinge body comprises a friction material, preferably one that cooperates well with the resilient wire.
The hinge body comprises a hollow member fitted about a hard core. This permits combining a comparatively soft exterior capable of adapting to the coil together with a sturdy core for structural quality.
The core comprises a strip of metal extending from the frame end while the coil comprises one or more windings of an end section of wire of the temple bar. This provides easy integration of the hinge components with the eyeglass frame and with temple bar and permits easy adjustment, e.g. for achieving proper hinge alignment.
According to a preferred embodiment an end face of the coil wire cooperates with an abutment to provide a constraint for turning of the pivot. This provides a positive definition of the end position while the coil serves to provide a controlled degree of resilience so as to soften the impact on the abutment and so as to provide a comfortable operation. Preferably the abutment restraints the outward motion of the temple bar. In the opposite direction, i.e. in folding the temple bar against the eyeglass frame rear side, no further abutment is required.
Preferably the threaded groove comprises at least one full revolution in order to allow a secure retention by the coil and in order to ensure equal distribution of the forces affecting the hinge body.
The invention in a second aspect provides a hinge as recited in claim 4 . This hinge is simple in manufacturing and easily combines with various types of eyeglass frames, in particular eyeglass frames with wire temple bars. This hinge also achieves the advantages enumerated above.
Advantageous embodiments appear from the claims dependent from claim 4 .
The invention in a third aspect provides an eyeglass as recited in claim 7 . This provides an eyeglass with a high quality hinge that creates a high quality tactile feel and operation and that is completely stable in operation over long time spans. This eyeglass achieves the advantages enumerated above. Advantageous embodiments appear from the claims dependent from claim 7 .
The invention in a fourth aspect provides a method of manufacturing a hinge according to claim 10 . This provides a simple method of manufacturing a high quality hinge that easily integrates with the eyeglass frame front and with the temple bars. This method permits easy adaptation of hinge qualities such as a hinge attitude and friction retention.
Preferred embodiments of this method appear from the dependent method claims.
When fitting a hollow member about a hard core, the components should be matched to achieve a positive retention with no possibility of mutual rotation. This may be achieved by various methods known in the art such as by including resiliently tensioned elements and by providing barbs and cooperating recesses or by other means.
Further features and advantages of the invention will appear in further detail from the description of advantageous embodiments given below with reference to the drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of part of an eyeglass as seen from the front,
FIG. 2 is an isometric view of part of an eyeglass as seen from the rear,
FIG. 3 is an enlargement of a detail from FIG. 1 ,
FIG. 4 is an isometric view of basic components of the hinge in assembled state,
FIG. 5 is an exploded view of the components from FIG. 4 ,
FIG. 6 is an axial section of the hinge components shown in FIG. 4 ,
FIG. 7 is an enlargement of a detail from FIG. 6 ,
FIG. 8 is a different axial section of the hinge components shown in FIG. 4 ,
FIG. 9 is a view similar to FIG. 6 but showing an alternative embodiment of the hinge,
FIG. 10 is an enlarged view of a detail from FIG. 8 , and
FIGS. 11 a - 11 g depicts a component of the hinge in a set of views from all sides as well as in sections.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
All figures are schematic and not necessarily to scale and show only details essential for enabling those skilled in the art to practice the invention, while other details are omitted for the sake of clarity. In all figures the same references are used about identical or similar items.
Reference is first made to FIG. 1 which shows part of an eyeglass 1 , said part basically comprising one glass 2 , one hinge 5 and part of the eyeglass frame front 4 as well as part of the temple bar 7 . The complete eyeglass 1 generally comprises frame 3 and glasses 2 , the frame being constituted by frame front 4 , temple bars 7 and hinges 5 . The complete eyeglass has not been illustrated as the completion of the details shown and explained so as to implement the eyeglass is considered to lie wholly within the capabilities of those skilled in the art.
As may be seen in FIGS. 1 , 2 and 3 , the hinge 5 basically comprises temple coil 8 , pivot core 13 and body or barrel 16 .
In the embodiment shown in Figures the temple bar 7 comprises a piece of wire, of which an end section is wound into a coil 8 . This coil interacts with the barrel 16 in order to permit swinging the temple bar from the open position ready to use as illustrated in the Figures and into the folded position where the temple bar is situated closely against the rear side of the eyeglass frame 3 as will be understood by those skilled in the art.
On swinging outward the temple bar 7 , one coil end face 9 strikes on abutment 15 which provides a positive stop for the movement.
The coil winding of a resilient wire may be integrated with one of the frame front or the temple bar. The body with a threaded groove may be integral with the other one of the frame front or the temple bar.
The barrel 16 is fitted about pivot core 13 which is integral with a structural member referred to as the hinge base 10 . Hinge base 10 is an elongated member connected to an extension 6 of the frame front 4 by any means as known to those skilled in the art, e.g. by gluing, casting, or press fitting.
Reference is now made to FIGS. 4 and 5 for an explanation of further details concerning the hinge and in particular concerning hinge base 10 .
As will be evident from FIGS. 4 and 5 , the hinge base 10 comprises a piece of material which as been cut and bent into the shape illustrated in FIGS. 4 and 5 . The hinge base 10 comprises a lug 11 adapted for being integrated into the frame front entension (refer also to FIG. 3 ). The hinge base 10 further comprises arm 12 with an extension bent in order to provide the pivot core 13 .
In order to assemble the parts, the barrel 16 is fitted about the pivot core 13 , and the temple coil 8 is fitted about the barrel 16 . As an alternative, the temple coil may be fitted about the barrel and the combination subsequently fitted about the pivot core. Fitting of the lug 11 into the frame front extension may be undertaken prior to the assembly of the hinge or subsequent to the assembly of the hinge as is considered convenient.
Reference is now made to FIG. 11 for a description of the barrel 16 . FIG. 11 shows a barrel according to a first embodiment in views from above, from below, from the front, from the side, in sections with the lines A—A and B—B and in isometric view. As will appear the barrel basically comprises a member with an axial opening 17 and with an exterior thread comprising groove 19 and ridge 20 . The groove 19 is rounded with a shape adapted to match the windings of the temple coil. The thread basically comprises about 2½ full revolutions. The thread defines axis 25 which is the hinge axis.
The axial opening 17 has a rectangular section. Adjacent the top the recess is widened to etablish ledges 21 . In the barrel lower portion there is a rounded recess 18 to one side.
In other embodiments the axial opening 17 may have a uniform cross section outwardly, i.e. without the ledge 21 .
Reference is now made to FIGS. 6 and 7 which illustrate a section through the hinge. Thus, these figures show barrel 16 fitted about pivot core 13 and supporting the temple coil 8 .
In the embodiment shown in FIGS. 6 and 7 , the pivot core 13 comprises barbs 14 . On fitting the barrel on the pivot core these barbs form indentations in the barrel opening and thus provide retention of the barrel.
Prior to assembly the temple coil is wound to a diameter somewhat smaller than that of the barrel exterior in order that the temple coil is resiliently expanded on fitting the coil about the barrel. Thus the temple coil serves to secure the barrel against the pivot core and the barbs.
The resilient tension of the temple coil serves to ensure a good grip with no play in the hinge, with accurate control of the temple attitude in all directions and with a stable degree of friction resistance in turning the pivot.
As may be seen in FIGS. 6 , 7 and 8 the pivot core 13 does not protrude above the barrel 16 . At the hinge lower portion, the bend connecting the arm 12 with the pivot core 13 is completely concealed in the recess 18 in order that the lower side of the arm 12 is flush with the lower side of the barrel 16 . Thus, the pivot components are virtually completely concealed by the temple coil.
In opening the temple bar 7 the temple coil end face 9 engages abutment 15 which basically is a face on the arm 12 (refer FIG. 3 ). Preferably these cooparating faces are both planar and oriented along the axis of the hinge. This provides the advantage that the temple coil end face rests solidly against the abutment with no bias tending to displace the temple coil end face from the abutment and thus no tendency to distort the components.
Preferably the temple wire comprises a titanium wire with round cross section. A titanium wire of a diameter of 1.1 mm has been found well suited. The hinge base 10 may comprise a piece of titanium that has been stamped and bent into the shape illustrated.
The barrel may comprise a hard polymer such as polyacetal with reinforcements of carbon fibres or glass fibres. Admixings of polytetraflour ethylene may be used for superior sliding properties. A polymer named RTP 881 TFE 10 DEL Acetal Homopolymer Carbon Fiber PTFE Lubricated from RTP Company, Winona, Minn. USA, has been found well suited. Other types of suitable materials are a polymere A3WC4 from BASF in germany or. RMKU 2-2511 from Bayer Corporation in Germany.
Reference is now made to FIGS. 9 and 10 for illustration of a barrel according to a second embodiment.
In the second embodiment the barrel 22 inside the axial opening 17 comprises an internal bead 23 adapted for cooperation with a neck 24 on the pivot core 13 so as to provide retention of the barrel on the pivot core. Other details are similar to those of the first embodiment.
Although specific embodiments have been explained above for the illucidation of the invention, these embodiments are in no way considered to limit the scope of the invention which may be varied in many ways by one skilled in the art within the scope of the appended claims. | An eyeglass frame comprises a frame front, a pair of temple bars and a hinge for each temple bar to provide a pivotal connection. The hinge comprises a coil winding of a resilient wire integral with the temple bar and a body with a threaded groove integral with the other one of the frame front or temple bar. The body comprises friction material and the coil is adapted for cooperating and pretensioned engagement with the body in order to provide a pivotal connection with a controlled friction resistance to turning of the pivot. The invention a so provides a hinge, an eyeglass and a method of manufacturing a hinge. | 8 |
BACKGROUND OF THE INVENTION
Field of the Invention
The invention pertains to a sliding door system with at least one automatically driven sliding sash guided on a traveling carriage.
These types of sliding door systems and their sliding leafs are opened and closed by an electric drive and a corresponding control unit. These types of sliding door systems are often used to produce a leak-proof seal for interior spaces and therefore must be provided with effective sealing measures in the area of their contact edges and at other points where leakage is likely to occur. In the case of fire, the escape of smoke must be effectively and reliably prevented. When such systems are used in escape and rescue routes, furthermore, the sliding leafs and possibly their side parts can be pivoted around a vertical axis of rotation and thus opened in the escape direction when a panic situation occurs.
A sliding door system of this type is known from DE 197 53 132 A1, where expanding fire protection material is used to seal off several intermediate spaces located between the sliding leafs and the surrounding periphery. The disadvantage here is that the fire protection material is not activated until the temperature has been raised sufficiently by the fire. The only way to prevent the leakage of smoke before that point is reached, however, is by the use of additional measures, involving the use of sealing devices which are activated when a sensor-measured threshold value is exceeded.
It is also known that, when in their closed position, the sliding leafs of door systems can be sealed against the floor by lowerable sealing strips. A sealing device of this type is described in, for example, DE 35 26 720 C2. The disadvantage here is that the release device projects from the main contact edge of the sliding leaf but is not protected in any way.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a sliding door system which guarantees a reliable and effective sealing function especially against smoke and fire, and which is also suitable for use in escape and rescue routes. A sliding door system of this type should also be usable anywhere, regardless of the type of structure in question.
The sliding door system of the present invention is a door system which is always sealed when in the closed state, because the sliding leafs always provide a complete seal regardless of the boundary conditions such as smoke or fire. When smoke or fire occurs, there is no need to activate any additional sealing devices of any kind, which means that there is no need for any sensor-activated devices to create a smoke-tight seal. As a result of the continuous sealing function, the sliding door system is also suitable for use in situations where good sound damping or thermal insulation is also required and also in situations where nearly dust-free areas are to be created. As an option, the sliding door system according to the present invention can also have stationary side parts which can be designed to swing open in case of need. The overall design of the system is such that the sliding doors can be used in any type of structure and adapted to the prevailing construction tolerances.
The actuation or automatic drive of the sliding leafs can be adapted to various closing forces, which vary as a function of the number and type of sealing measures required in the specific case. A smoke alarm system can also be provided, so that the sliding leafs can be closed by a motor when an alarm is given and then locked so that they can no longer be opened in the sliding direction. The locking function can make use of the standard locking mechanism of the sliding door system, which holds the traveling carriages of the sliding leafs in place.
A sealing strip is integrated invisibly into the transverse profile at the bottom of the sliding leaf and lowered automatically onto the floor to form a seal when the door system is closed. A release device for the spring-loaded sealing strip is actuated by a rotatably supported cam located in the longitudinal profile at the secondary contact edge of the sliding leaf. This cam is turned by a stationary ramp when the sliding leaf moves in the closing direction. That the components which control and release the sealing strip are located within the frame at the secondary contact edge means that they are shifted into a protected area. No parts of any kind project into the room, where they could possibly be damaged or manipulated by passers-by. Because of the way in which the ramp and the cam interact according to the invention to release the sealing strip, the actuating force increases continuously, which is advantageous especially with respect to control, because this prevents the door from being a slow-moving hazard.
Because the release device and the cam are mounted permanently in the frame of the sliding leaf and are thus aligned precisely with each other, they never need to be readjusted. The cam, the axle body of the cam, and a floor glide on the bottom form a compact assembly. The cam has a projecting lobe, which slides along the ramp. On the radially opposite side of the cam there is a slide block, which actuates the release device. At least one axially projecting stop at the bottom of the slide block prevents the cam from turning too far. It is advantageous to fabricate the cam out of aluminum, because this reduces wear, especially on the contact surfaces. The cam and the floor glide are accessible through openings in the longitudinal profile of the sliding leaf, so that they can be replaced or so that the height of the components can be adjusted.
When the door is opened, no additional force component is required to retract the sealing strip, because the sealing strip's own elastic restoring force fulfills this function. The release device also presses the cam back into the starting position. The cam is supported rotatably on the axle body; when the sliding leaf is swung open to open an escape route, the release device therefore travels by a rotational movement around the slide block of the cam, which remains in its position, with the result that the release device is automatically pulled back and the sealing strip rises from the floor. The friction and wear which occur during the pivoting of the sliding leaf are therefore reduced. It is advantageous for the sliding leaf to be swung into its closed position by a door closer, which is installed under cover at the top, inside the frame. Here again, the slide block of the cam actuates the release device to lower the sealing strip back onto the floor. It follows from this that the swinging of the sliding leaf does not interfere with the functions of the cam and the release device either during or after the swinging open or swinging closed of the sliding leaf.
The runway rail which guides the sliding leaf along the floor and the ramp which controls the cam are screwed permanently to the attachment of the side part to the floor, which guarantees their precise alignment with the cam and the reliable operation of the release function. As a result, the sliding leaf is also guided precisely across a vertical seal located on the side part. In an advantageous embodiment, the runway rail and a threshold, onto which the sealing strip is lowered, can be designed as a one-piece profile.
The functional area pertaining to the release of the bottom sealing strip is completely outside the vertical sealing plane. The vertical sealing at the secondary contact edge between the stationary side part and the sliding leaf is advantageously provided by an elastic sealing profile. The sealing profile has the shape of a lip to minimize the force required to actuate the seal and thus to minimize the load on the drive. That the motion occurs along a wedge-shaped vertical profile has the effect of reducing the load.
Sealing profiles with sealing lips are mounted on the main contact edge; even in the case of a door system with two leafs, these profiles and lips ensure a good seal after the sliding leafs have been swung shut. Here, too, the actuating force to be provided by the drive is minimized.
The door system is also sealed adequately along the top horizontal edges. An automatically actuated sealing strip between the drive housing and the support profile of the sliding leaf provides the seal. This sealing strip is designed basically in the same way as the bottom sealing strip and is integrated into the housing. Slots are provided so that its position with respect to the support profile can be adjusted. The sealing strip is operated by way of a force-reducing lever mechanism, which is actuated by an arm mounted on the support profile. The arm has a plastic end piece, which can be adjusted in several directions and which is designed so that it can be mounted on or under the arm, depending on the preset height of the sliding leaf.
The housing is sealed off horizontally with respect to the ceiling by an extendable ceiling cover profile and possibly also by silicone. Lining panels, which can be extended toward the wall, are also mounted on the edge areas of the vertical columns. These panels can also be sealed with silicone if desired. The leakage points at the corners and transition areas are sealed by brush seals or by molded plastic parts.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view in plan, of a sliding door system with side parts and sliding leafs in the closed state;
FIG. 2 is a partial longitudinal cross-sectional view of a sliding door system according to FIG. 1 ;
FIG. 2 a is an enlarged plan view of part of FIG. 2 , in which a sealing strip and a lever are in a first position;
FIG. 2 b is an enlarged plan view of part of FIG. 2 , in which a sealing strip and a lever are in a second position;
FIGS. 3–5 are enlarged partial cross-sectional views in plan of the sliding door system according to FIG. 1 in various stages of the closing operation;
FIG. 6 is a partial cross-sectional view of the sliding door system according to FIG. 5 with the sliding leaf in various stages of the outward swinging movement, starting from the closed position;
FIG. 7 is a partial cross-sectional view of the sliding door system according to FIG. 5 , where the sliding leaf has been swung outward from the closed position;
FIG. 8 is a partial longitudinal cross-sectional view through the sliding door system along axis VIII—VIII of FIG. 3 ;
FIG. 9 is a partial longitudinal cross-sectional view through the sliding door system along axis IX—IX of FIG. 5 ;
FIG. 10 a is an isometric view of a cam of the sliding door system;
FIG. 10 b is a bottom view of the cam of the sliding door system;
FIG. 10 c is a side view of the cam of the sliding door system;
FIG. 10 d is a plan view of the cam of the sliding door system;
FIG. 11 a is a side view of a ramp of the sliding door system; and
FIG. 11 b is a plan view of the ramp of the sliding door system.
Although the invention is explained and described in the following in the form of a sliding door system with a smoke protection function, it can also be put into service wherever a tightly-sealing door system is used.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIGS. 1 and 2 , the illustrated sliding door system 1 consists of two stationary side parts 2 and two sliding leafs 3 , which are guided so that they can slide back and forth between the side parts. Steel columns 50 (illustrated generically) are installed at the sides of an opening in a building. These columns extend between the floor and the ceiling, and a runway rail 4 and a housing 6 , which supports a drive 5 , are attached to them. The side parts 2 are attached laterally to the steel columns 50 and also, at the top, to the housing 6 . In FIGS. 8 and 9 , a door threshold 7 and rails 8 , which serve to guide the sliding leafs 3 along the floor, are permanently connected to the floor, and are preferably also connected to the frame 9 of the side parts 2 . Floor glides 10 on the sliding leafs 3 are attached in a form-locking manner to the rails 8 and are free to slide along them.
Referring to FIG. 2 , each sliding leaf 3 is attached pivotably to its own support profile 12 by an adjustable support arm 11 . The support profile 12 is connected in turn to a carriage 13 , which travels along the runway rail 4 . The sliding leaf 3 is kept in the normal position with respect to the support section 12 by interlocking profiles 14 . When a panic situation occurs, these profiles are disconnected from each other, and the sliding leafs 3 are swung out of their normal position in the escape direction. Door closers (not shown) are installed under cover in the upper horizontal transverse profile 15 of the sliding leafs 3 . These door closers have slide rail arms, which are connected to slide pieces in the support profile 12 above, which is open at the bottom. The closers make it possible for the leafs to swing back automatically into the normal position.
In FIGS. 3 and 8 , a spring-loaded sealing strip 17 is integrated invisibly into the transverse profile 16 at the bottom of each sliding leaf 3 ; when the door system 1 is closed, this strip is lowered automatically to the floor to form a seal. In FIGS. 2 , 2 a and 3 , a release device 18 for the sealing strip 17 is actuated by a rotatably supported cam 21 , which is located in a longitudinal profile 19 at the secondary sealing edge 20 of the sliding leaf 3 . When the sliding leaf 3 travels in the closing direction, this cam 21 is turned by a ramp 22 , which is attached permanently to the side part 2 . The ramp 22 is preferably fabricated as an injection-molded part and has an entrance bevel 23 .
Referring also to FIG. 10 a – 10 d , the cam 21 has a projecting lobe 24 . Opposite it, on the cam 21 , a radially ascending slide block 25 extends over a certain area. A stop 26 , which projects axially from the bottom of the slide block 25 , prevents the cam 21 from rotating too far.
The release device 18 and the cam 21 are positioned precisely with respect to each other, because the two components are premounted at the factory in permanent positions in the transverse profile 16 and in the longitudinal profile 19 , respectively, of the sliding leaf 3 . The cam 21 an axle body 27 of the cam, and the floor glide 10 attached to the bottom of the axle body form a compact assembly, the axle body 27 being supported with freedom to slide in a bearing block 28 mounted inside the longitudinal profile 19 . The assembly is accessible through openings 29 in the longitudinal profile 19 of the sliding leaf 3 , so that the components can be replaced or so that their height can be adjusted.
During a normal closing operation, the sliding leaf 3 is moved automatically by the drive 5 . This operation starts from the completely open position shown in FIG. 3 , in which the sealing strip 17 is completely retracted into the transverse profile 16 at the bottom of the leaf. During the closing operation, the lobe 24 of the cam 21 has a first phase of free travel before it starts to slide along the entrance bevel 23 of the ramp 22 . As a result, the cam 21 is forced to turn, and the slide block 25 comes into contact with the release device 18 of the sealing strip 17 (see FIG. 4 ). As the closing movement of the sliding leaf 3 continues, the cam 21 continues to be turned by the ramp 22 , so that the slide block 25 continues to press the release device 18 farther and farther inward (see FIG. 5 ), which has the effect of pushing the sealing strip 17 outward to a corresponding extent. By the time the leaf is completely closed, the sealing strip 17 is resting on the floor or on the threshold 7 to form a seal as shown in FIG. 8 . All the other seals have also assumed effective positions by the time the sliding leaf 3 is closed. An additional horizontal sealing strip 30 between the housing 6 and the support profile 12 is also moved automatically into position.
During the normal door opening operation, no additional force component is required to retract the sealing strip 17 , because the elastic restoring force of the sealing strip 17 fulfills this function. The release device 18 also presses the cam 21 back into its starting position.
FIG. 6 shows that when the sliding leaf 3 is swung open in a panic situation, the release device travels rotationally around the slide block 25 of the cam 21 , which is held in position against the ramp 22 . The radially descending design of the slide block 25 makes it possible here for the spring-loaded release device 18 to travel outward, which has the effect of lifting the sealing strip 17 from the floor. The door closer takes care of swinging the sliding leaf 3 shut; during this phase , the slide block 25 of the cam 21 controls the movement of the release device 18 , which now travels back in the opposite direction. It follows from this that there is no interference with the interaction between the cam 21 and the release device 18 either during or after the swinging-open or the swinging-closed of the sliding leaf 3 .
The vertical seal along the secondary contact edge 20 between the stationary side part 2 and the sliding leaf 3 is advantageously accomplished by an elastic sealing profile 31 , which is mounted on the sliding leaf 3 . The sealing profile 31 has the shape of a lip to minimize the load on the drive 5 . A load-reducing effect is obtained here in that the lip is supported by a wedge-shaped vertical profile (not shown in FIG. 3 ), which is mounted on the side part 2 . For the sake of protecting the fingers, a web is also provided to guarantee a safety gap with respect to the side part 2 .
As shown in FIG. 1 , sealing profiles 33 with sealing lips are mounted on the central edge 32 , i.e. axis, 32 of the sliding leafs 3 . These profiles perform the desired sealing function after the sliding leafs 3 have been swung shut even in the case of a dual-leaf door system 1 . Here again, the actuating force which the drive 5 must produce is minimized.
The door system 1 is also adequately sealed along the top horizontal edges. An automatically actuated sealing strip 30 shown in FIGS. 2 , 2 a , 2 b corresponds in its basic design to the sealing strip 17 at the bottom and is attached to the housing 6 . The sealing strip 30 moves from the housing 6 toward the support profile 12 of the sliding leaf 3 . An appropriate release device 18 a is operated by a force-reducing lever 34 , which is actuated by an arm 35 attached to the support profile 12 , the arm having an end piece 36 . The end piece 36 is designed so that it can be mounted on or under the arm 35 , depending on the height at which the sliding leaf 3 is mounted. The way in which the sealing strip 30 operates is similar to that of the sealing strip 17 at the bottom. During the closing and opening of the sliding leaf 3 , the movement of the sealing strip 30 is controlled by the arm 35 , which is mounted on the support profile 12 and actuates the lever 34 .
The horizontal sealing of the housing 5 against the ceiling is accomplished by extendable ceiling cover profiles (not shown) and possibly by silicone on the nonmoving parts. Extendable lining panels are also mounted on the edge areas of the vertical columns facing the wall, which panels are sealed with silicone if desired. The leakage points at the corners and transition areas are sealed by brush seals or molded plastic parts.
The preceding description of the exemplary embodiments according to the present invention serves only to illustrate the object of the invention, not to limit it. Within the scope of the invention, various changes and modifications can be made without abandoning the scope of either the invention itself or its equivalents.
LIST OF REFERENCE NUMBERS
1 sliding door system
2 side part
3 sliding leaf
4 runway rail
5 drive
6 housing
7 threshold
8 rail
9 frame
10 floor glide
11 support arm
12 support profile
13 carriage
14 profile
15 transverse profile
16 transverse profile
17 sealing strip
18 release device
19 longitudinal profile
20 secondary closing edge
21 cam
22 ramp
23 entrance bevel
24 lobe
25 slide block
26 stop
27 axle body
28 bearing block
29 opening
30 sealing strip
31 sealing profile
32 main closing edge
33 sealing profile
34 lever
35 arm
36 end piece | The invention pertains to a sliding door system with at least one automatically driven sliding leaf, which is guided on a traveling carriage and a support profile, where the drive and a runway rail are mounted in a housing above the sliding leaf, and where the sliding leaf can be swung open if necessary in the outward direction around a vertical axis. To create a sliding door system which ensures a reliable and effective sealing function, especially with respect to smoke and fire, which is suitable for use in escape and rescue routes, and which can be used anywhere, regardless of the structural conditions, the sliding leaf, when in the closed position, has sealing-devices, which are active at all times, on all horizontal and vertical edges. | 4 |
[0001] This application is a continuation of U.S. application Ser. No. 10/832,408, filed Apr. 26, 2004, which is a continuation of application Ser. No. 09/529,617, filed Jun. 7, 2000, now U.S. Pat. No. 6,736,957, which claims priority from PCT/US98/21815, filed on Oct. 16, 1998, which claims priority from U.S. application Ser. No. 60/061,982, filed Oct. 17, 1997, all of which are incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The invention is in the general field of electrodes for amperometric biosensors. More specifically, the invention is in the field of compounds for use as mediators for the recycling of cofactors used in these electrodes.
[0003] NAD- and NADP-dependent enzymes are of great interest insofar as many have substrates of clinical value, such as glucose, D-3-hydroxybutyrate, lactate, ethanol, and cholesterol. Amperometric electrodes for detection of these substrates and other analytes can be designed by incorporating this class of enzymes and establishing electrical communication with the electrode via the mediated oxidation of the reduced cofactors NADH and NADPH.
[0004] NAD- and NADP-dependent enzymes are generally intracellular oxidoreductases (EC 1.x.x.x). The oxidoreductases are further classified according to the identity of the donor group of a substrate upon which they act. For example, oxidoreductases acting on a CH—OH group within a substrate are classified as EC 1.1.x.x whereas those acting on an aldehyde or keto-group of a substrate are classified as EC 1.2.x.x. Some important analytes (e.g., glucose, D-3-hydroxybutyrate, lactate, ethanol, and cholesterol) are substrates of the EC 1.1.x.x enzymes.
[0005] The category of oxidoreductases is also broken down according to the type of acceptor utilized by the enzyme. The enzymes of relevance to the present invention have NAD + or NADP + as acceptors, and are classified as EC 1.x.1.x. These enzymes generally possess sulfydryl groups within their active sites and hence can be irreversibly inhibited by thiol-reactive reagents such as iodoacetate. An irreversible inhibitor forms a stable compound, often through the formation of a covalent bond with a particular amino acid residue (e.g., cysteine, or Cys) that is essential for enzymatic activity. For example, glyceraldehyde-3-P dehydrogenase (EC 1.2.1.9) is stoichiometrically alkylated by iodoacetate at Cys 149 with concomitant loss of catalytic activity. In addition, the enzymes glucose dehydrogenase, D-3-hydroxybutyrate dehydrogenase (HBDH), and lactate dehydrogenase are known to be irreversibly inhibited by thiol reagents. Thus, in seeking to develop stable biosensors containing NAD- or NADP-dependent dehydrogenases, avoidance of compounds that are reactive toward thiols is imperative, as they can act as enzyme inhibitors.
SUMMARY OF THE INVENTION
[0006] The present invention is based on the discovery of NAD + and NADP + mediator compounds that do not bind irreversibly to thiol groups in the active sites of intracellular dehydrogenase enzymes. Such mediator compounds avoid a common mode of enzyme inhibition. The mediators can therefore increase the stability and reliability of the electrical response in amperometric electrodes constructed from NAD- or NADP-dependent enzymes. In one embodiment, the invention features a test element for an amperometric biosensor. The element includes an electrode, which has test reagents distributed on it. The test reagents include a nicotinamide cofactor-dependent enzyme, a nicotinamide cofactor, and a mediator compound having one of the formulae:
[0000]
[0000] or a metal complex or chelate thereof, where X and Y can independently be oxygen, sulphur, CR 3 R 4 , NR 3 , or NR 3 R 4+ ; R 1 and R 2 can independently be a substituted or unsubstituted aromatic or heteroaromatic group; and R 3 and R 4 can independently be a hydrogen atom, a hydroxyl group or a substituted or unsubstituted alkyl, aryl, heteroaryl, amino, alkoxyl, or aryloxyl group. In some cases, either X or Y can be the functional group CZ 1 Z 2 , where Z 1 and Z 2 are electron withdrawing groups.
[0007] Any alkyl group, unless otherwise specified, may be linear or branched and may contain up to 12, preferably up to 6, and especially up to 4 carbon atoms. Preferred alkyl groups are methyl, ethyl, propyl and butyl. When an alkyl moiety forms part of another group, for example the alkyl moiety of an alkoxyl group, it is preferred that it contains up to 6, especially to 4, carbon atoms. Preferred alkyl moieties are methyl and ethyl.
[0008] An aromatic or aryl group may be any aromatic hydrocarbon group and may contain from 6 to 24, preferably 6 to 18, more preferably 6 to 16, and especially 6 to 14, carbon atoms. Preferred aryl groups include phenyl, naphthyl, anthryl, phenanthryl and pyryl groups especially a phenyl or naphthyl, and particularly a phenyl group. When an aryl moiety forms part of another group, for example, the aryl moiety of an aryloxyl group, it is preferred that it is a phenyl, naphthyl, anthryl, phenanthryl or pyryl, especially phenyl or naphthyl, and particularly a phenyl moeity.
[0009] A heteroaromatic or heteraryl group may be any aromatic monocyclic or polycyclic ring system, which contains at least one heteroatom. Preferably, a heteroaryl group is a 5 to 18-membered, particularly a 5 to 14-membered, and especially a 5 to 10-membered, aromatic ring system containing at least one heteroatom selected from oxygen, sulphur and nitrogen atoms. 5 and 6-membered heteroaryl groups, especially 6-membered groups, are particularly preferred. Heteroaryl groups containing at least one nitrogen atom are especially preferred. Preferred heteroaryl groups include pyridyl, pyrylium, thiopyrylium, pyrrolyl, furyl, thienyl, indolinyl, isoindolinyl, indolizinyl, imidazolyl, pyridonyl, pyronyl, pyrimidinyl, pyrazinyl, oxazolyl, thiazolyl, purinyl, quinolinyl, isoquinolinyl. quinoxalinyl, pyridazinyl, benzofuranyl, benzoxazolyl and acridinyl groups.
[0010] When any of the foregoing substituents are designated as being substituted, the substituent groups which may be present may be any one or more of those customarily employed in the development of compounds for use in electrochemical reactions and/or the modification of such compounds to influence their structure/activity, solubility, stability, mediating ability, formal potential (E°) or other property. Specific examples of such substituents include, for example, halogen atoms, oxo, nitro, cyano, hydroxyl, cycloalkyl, alkyl, haloalkyl, alkoxy, haloalkoxy, amino, alkylamino, dialkylamino, formyl, alkoxycarbonyl, carboxyl, alkanoyl, alkylthio, alkylsulphinyl, alkylsulphonyl, arylsulphinyl, arylsulphonyl, carbamoyl, alkylamido, aryl or aryloxy groups. When any of the foregoing substituents represents or contains an alkyl substituent group, this may be linear or branched and may contain up to 12, preferably up to 6, and especially up to 4, carbon atoms. A cycloalkyl group may contain from 3 to 8, preferably from 3 to 6, carbon atoms. An aryl group or moiety may contain from 6 to 10 carbon atoms, phenyl groups being especially preferred. A halogen atom may be a fluorine, chlorine, bromine or iodine atom and any group which contains a halo moiety, such as a haloalkyl group, may thus contain any one or more of these halogen atoms.
[0011] An electron withdrawing group may be any group, which forms a stable methylene group CZ 1 Z 2 . Such electron withdrawing groups may include halogen atoms, nitro, cyano, formyl, alkanoyl, carboxyl and sulphonic acid groups.
[0012] Preferably, X and Y are both oxygen atoms.
[0013] It is also preferred that R 1 and R 2 are independently selected from phenyl, naphtuyl, pyridyl and pyrrolyl groups with pyridyl groups being especially preferred. The term “pyridyl group” also includes the N-oxide thereof as well as pyridinium and N-substituted pyridinium groups.
[0014] Preferably, R 1 and R 2 are unsubstituted or substituted only by one or more, preferably one or two, alkyl groups, especially methyl groups. It is especially preferred that R 1 and R 2 are unsubstituted.
[0015] R 3 and R 4 , if present, are preferably independently selected from hydrogen atoms and alkyl groups.
[0016] Metal complex and chelates include complexes and chelates with transition metals, especially first-, second-, and third-row transition elements such as ruthenium, chromium, cobalt, iron, nickel and rhenium, with ruthenium being particularly preferred. Other groups such as 4-vinyl-4′-methyl-2,2′-bipridyl (v-by) and bipyridyl (bpy) groups may also be included in such complexes and chelates as parts of a complex metal ion. Typically, such complexes and chelates will form as a result of heteroatoms in R 1 and R 2 coordinating with a metal ion or metal ion complex.
[0017] The test reagents can be deposited on the electrode in one or more ink-based layers. The test reagents can be screen-printed onto the working electrode in a single layer.
[0018] The element can be an amperometric dry-strip sensor that includes an elongated, electrically insulating carrier having a pair of longitudinal, substantially parallel electrically conducting tracks thereupon, and a pair of electrodes. The electrodes can each be electrically connected to a different one of the tracks; one of the electrodes can be a reference/counter electrode, while another electrode can be a working electrode. The element can also include a dummy electrode. Further, the element can include a membrane positioned to filter samples prior to their introduction onto the electrodes.
[0019] The sensor can additionally include a supporting strip of electrically insulating carrier material (e.g., a synthetic polymer such as polyvinyl chloride, or a blend of synthetic polymers).
[0020] The mediator compound can be a quinone. Examples of suitable quinones include 1,10-phenanthroline quinone, 1,7-phenanthroline quinone, and 4,7-phenanthroline quinone.
[0021] In another embodiment, the invention features an electrode strip for an amperometric sensor having a readout. The strip includes a support adapted for releasable attachment to the readout, a first conductor extending along the support and comprising a conductive element for connection to the readout; a working electrode in contact with the first conductor and positioned to contact a sample mixture; a second conductor extending along the support and comprising a conductive element for connection to the readout; and a reference/counter electrode in contact with the second conductor and positioned to contact the sample and the second conductor. The active electrode of the strip includes a mediator compound having one of the formulae:
[0000]
[0000] wherein X, Y, R 1 , and R 2 are as previously defined.
[0022] Still another embodiment of the invention features a method for mediating electron transfer between an electrode and a nicotinamide cofactor. The method includes the steps of using a mediator compound in the presence of a nicotinamide cofactor-dependent enzyme, where the mediator compound is a quinoid compound that is incapable of binding irreversibly to the thiol groups. The mediator compound can, for example, have reactive unsaturated bonds in adjacent aromatic ring. Suitable mediator compounds include those having the formulae:
[0000]
[0000] wherein X, Y, R 1 , and R 2 are as previously defined.
[0023] For example, the mediator compound can be 1,10-phenanthroline quinone, 1,7- phenanthroline quinone, or 4,7-phenanthroline quinone.
[0024] In yet another embodiment, the invention features a printing ink. The ink includes a nicotinamide cofactor-dependent enzyme, a nicotinamide cofactor, and a mediator compound having one of the formulae:
[0000]
[0000] wherein X, Y, R 1 , and R 2 are as previously defined.
[0025] For example, the mediator compound can be 1,10-phenanthroline quinone, 1,7-phenanthroline quinone, or 4,7-phenanthroline quinone. The enzyme can be, for example, alcohol dehydrogenase, lactate dehydrogenase, 3-hydroxybutyrate dehydrogenase, glucose-6-phosphate dehydrogenase, glucose dehydrogenase, formaldehyde dehydrogenase, malate dehydrogenase, or 3-hydroxysteroid dehydrogenase.
[0026] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are described below. All publications, patent applications, patents, technical manuals, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present application, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.
[0027] An advantage of the new mediators is their non-reactivity with respect to active-site thiol groups in enzymes. This improves the stability and the shelf life of biosensor electrodes to an unexpected degree. Also as a result of this stability, the enzyme and mediator can be incorporated together in a printing ink or dosing solution to facilitate construction of the biosensors. The use of a mediator that is not an irreversible inhibitor of the enzyme will result in the retention of a large proportion of enzyme activity during the biosensor manufacture. NAD- and NADP-dependent dehydrogenase enzymes are generally expensive and labile and improvement of their stability is therefore highly desirable.
[0028] Advantageously, the compounds disclosed herein can also be used as mediators to the cofactors NADH and NADPH coupled with a wide range of NAD- or NADP-dependent enzymes; as labels for antigens or antibodies in immunochemical procedures; and in other applications in the field of electrochemistry and bioelectrochemistry. The mediators require low oxidation potentials for re-oxidation following the reaction with NADH or NADPH. This is of particular advantage when testing in whole blood, in which the potential for interference from exogenous electroactive species (e.g., ascorbic acid, uric acid) is particularly high. The low potential can be advantageous because it can obviate the need for a dummy electrode to remove electroactive species in the sample. Also, the oxidized native form of the mediator can decrease the background current that would be present with a reduced mediator.
[0029] Other features and advantages of the invention will be apparent from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is an exploded view of an electrode strip according to one embodiment of the invention.
[0031] FIG. 2 is a representation of an assembled electrode strip.
[0032] FIG. 3 is a graphical plot of current in μA against NADH concentration in mM for printed electrodes containing 1,10-phenanthroline quinone.
[0033] FIG. 4 is a graphical plot of current in μA against NADH concentration in mM for printed electrodes containing Meldola's Blue.
[0034] FIG. 5 is a bar chart displaying residual enzyme activity (i.e., as a percentage of the initial activity) after incubation of HBDH with various mediators.
[0035] FIG. 6 is a graphical plot of current in μA against D-3-hydroxybutyrate concentration in mM for printed electrodes containing 1,10-phenanthroline quinone, D-3-hydroxybutyrate dehydrogenase and NAD + tested after 4, 14, and 26 weeks.
[0036] FIG. 7 is a graphical plot of current in μA against D-3-hydroxybutyrate concentration in mM for printed electrodes containing Meldola's Blue, D-3-hydroxybutyrate dehydrogenase, and NAD + tested after 2 and 14 weeks, respectively.
[0037] FIG. 8 is a graphical plot of calibrated response to glucose in whole blood for printed electrodes containing 1,10-phenanthroline quinone, glucose dehydrogenase, and NAD + .
[0038] FIG. 9 is a graphical plot of current μA as a function of potential in mV for a working electrode formulated in accordance with the present invention.
[0039] FIG. 10 is a graphical plot of current in μA as a function of potential in mV for a working electrode formulated in accordance with Geng et al.
[0040] FIG. 11 is a graphical plot of integrated current in μC as a function of the concentration of glucose in mM.
[0041] FIG. 12 is a graphical plot of integrated current in μC as a function of the concentration of glucose in mM.
DETAILED DESCRIPTION OF THE INVENTION
[0042] A class of compounds, selected for their inability to combine irreversibly with thiols, is disclosed for use as NADH or NADPH mediators. The structural, electronic, and steric characteristics of these mediators render them nearly incapable of reacting with thiols. Because these mediators are virtually precluded from binding irreversibly to the active site sulphydryl groups of NAD- and NADP-dependent dehydrogenases, inactivation of the enzyme and consequent loss of biosensor stability is circumvented.
[0043] The NADH and NADPH mediators can be used in the manufacture of amperometric enzyme sensors for an analyte, where the analyte is a substrate of an NAD-or NADP-dependent enzyme present in the sensor, such as those of the kind described in EP 125867-A. Accordingly, amperometric enzyme sensors of use in assaying for the presence of an analyte in a sample, especially an aqueous sample, can be made. For example, the sample can be a complex biological sample such as a biological fluid (e.g., whole blood, plasma, or serum) and the analyte can be a naturally occurring metabolite (e.g., glucose, D-3-hydroxybutyrate, ethanol, lactate, or cholesterol) or an introduced substance such as a drug.
[0044] Of particular utility for the manufacture of amperometric enzyme sensors, the present invention further provides an ink that includes the NADH and NADPH mediators disclosed herein.
[0045] The present invention also includes any precursor, adduct, or reduced (leuco) form of the above mediators that can be converted in situ by oxidation or decomposition to the corresponding active mediators. Such precursors or adducts can include hemiacetals, hemithioacetals, cyclic acetals, metal o-quinone complexes, protonated forms, acetone adducts, etc.
[0046] A non-limiting list of enzymes that can be used in conjunction with the new mediators is provided in Table 1.
[0000]
TABLE 1
1.1.1.1
Alcohol Dehydrogenase
1.1.1.27
Lactate Dehydrogenase
1.1.1.31
3-Hydroxybutyrate Dehydrogenase
1.1.1.49
Glucose-6-phosphate Dehydrogenase
1.1.1.47
Glucose Dehydrogenase
1.2.1.46
Formaldehyde Dehydrogenase
1.1.1.37
Malate Dehydrogenase
1.1.1.209
3-hydroxysteroid Dehydrogenase I
[0047] Amperometric enzyme sensors adopting the mediators of the present invention generally use a test element, for example, a single-use strip. A disposable test element can carry a working electrode, for example, with the test reagents including the enzyme, the nicotinamide cofactor (i.e., NAD + or NADP + ), the mediators of the present invention for generation of a current indicative of the level of analyte, and a reference/counter electrode. The test reagents can be in one or more ink-based layers associated with the working electrode in the test element. Accordingly, the sensor electrodes can, for example, include an electrode area formed by printing, spraying, or other suitable deposition technique.
[0048] Referring to FIGS. 1 and 2 , an electrode support 1 , typically made of PVC, polycarbonate, or polyester, or a mixture of polymers (e.g., Valox, a mixture of polycarbonate and polyester) supports three printed tracks of electrically conducting carbon ink 2 , 3 , and 4 . The printed tracks define the position of the working electrode 5 onto which the working electrode ink 16 is deposited, the reference/counter electrode 6 , the fill indicator electrode 7 , and contacts 8 , 9 , and 10 .
[0049] The elongated portions of the conductive tracks are respectively overlaid with silver/silver chloride particle tracks 11 , 12 , and 13 (with the enlarged exposed area 14 of track 12 overlying the reference electrode 6 ), and further overlaid with a layer of hydrophobic electrically insulating material 15 that leaves exposed only positions of the reference/counter electrode 14 , the working electrode 5 , the fill indicator electrode 7 , and the contact areas 8 , 9 , and 10 . This hydrophobic insulating material serves to prevent short circuits. Because this insulating material is hydrophobic, it can serve to confine the sample to the exposed electrodes. A suitable insulating material is Sericard, commercially available from Sericol, Ltd. (Broadstairs, Kent, UK). Optionally, a first mesh layer 17 , a second insulative layer 18 , a second mesh layer 19 , a third insulative layer 20 , and a tape 21 can overlay the hydrophobic insulating material.
[0050] Respective ink mixtures can be applied onto a conductive track on a carrier, for example, in close proximity to a reference electrode 14 connected to a second track. In this way, a sensor can be produced, which is capable of functioning with a small sample of blood or other liquid covering the effective electrode area 5 . The mixtures are preferably, but not exclusively, applied to the carrier by screen printing.
[0051] In general, NAD(P)-dependent dehydrogenases catalyze reactions according to the equation:
[0000] RH 2 +NAD(P) + →R+NAD(P)H+H +
[0000] where RH 2 represents the substrate (analyte) and R the product. In the process of the forward reaction, NAD(P) + (i.e., NAD + or NADP + ) is reduced to NAD(P)H. Suitable amperometric biosensors provide an electrochemical mediator that can reoxidize NAD(P)H, thereby regenerating NAD(P) + . Reoxidation occurs at an electrode to generate a current that is indicative of the concentration of the substrate.
[0052] In one embodiment, a dry sensor is provided. The sensor includes an elongated electrically insulating carrier having a pair of longitudinal, substantially parallel, electrically conducting tracks thereupon, each track being provided at the same end with means for electrical connection to a read-out and provided with an electrode, one of the electrodes being the reference/counter electrode and the other being the working electrode, together with test reagents. The sensor can be configured in the form of a supporting strip of electrically insulating carrier material such as a synthetic polymer (e.g., PVC, polycarbonate, or polyester, or a mixture of polymers such as Valox) carrying the two electrodes supported on electrically conductive tracks between its ends. For example, the electrodes can take the form of two rectangular areas side by side on the carrier strip, as shown in FIG. 2 (i.e., electrodes 14 and 16 ). Such areas can be designed as a target area to be covered by a single drop of sample, such as whole blood, for testing the analyte. If desired, non-rectangular areas (e.g., diamond-shaped, semicircular, circular, or triangular areas) can be employed to provide a target area for optimized contact by a liquid sample.
[0053] The carrier includes at least two electrodes, namely a reference/counter electrode and a working electrode. Other electrodes such as a dummy electrode can also be included. These other electrodes can be of similar formulation to the working electrode (i.e., with the associated test reagents), but lacking one or more of the working electrode's active components. A dummy electrode, for example, can provide more reliable results, in that if charge passed at the dummy electrode is subtracted from charge passed at the working electrode, then the resulting charge can be concluded to be due to the reaction of interest.
[0054] A membrane can be provided at or above the target to perform a filtration function. For example, a membrane can filter blood cells from a sample before the sample enters the test strip. Examples of commercially available membranes that can be used include Hemasep V, Cytosep, and Hemadyne (Pall Biosupport, Fort Washington, N.Y. 11050). As an alternative, a filtration or cellular separation membrane can be cast in situ. This can be achieved by casting hydrophobic polymers such as cellulose acetate, polyvinyl butyral and polystyrene and/or hydrophilic polymers such as hydroxypropyl cellulose, polyvinylpyrrolidone, polyvinyl alcohol and polyvinyl acetate.
[0055] In another embodiment, there is provided a single use disposable electrode strip for attachment to signal readout circuitry of a sensor system. The strip can detect a current representative of an analyte in a liquid mixture. The strip includes an elongated support adapted for releasable attachment to the readout circuitry; a first conductor extending along the support and including a conductive element for connection to the readout circuitry; a working electrode on the strip in contact with the first conductor and positioned to contact the mixture; a second conductor extending along the support, comprising a conductive element for connection to the readout circuitry; and a reference/counter electrode in contact with the second conductive element and positioned to contact the mixture and the second conductor as depicted in FIG. 1 .
[0056] The working electrode can include a printed layer on the support, and the printed layer itself can include an NAD- or NADP-dependent dehydrogenase enzyme capable of catalyzing a reaction involving a substrate for the enzyme. This layer can also include the corresponding nicotinamide cofactor and a mediator of the present invention capable of transferring electrons between the enzyme-catalyzed reaction and the first conductor via NADH or NADPH, to create a current representative of the activity of both the enzyme and the analyte.
[0057] The first conductive element and the active electrode can be spaced apart from the second conductive element and the reference/counter electrode, and the electrodes sized and positioned to present a combined effective area small enough to be completely covered by a drop of blood or other test sample; typically the reaction zone is 5 mm 2 but can be as large as 25 mm 2 . The test sample completes an electrical circuit across the active electrode and the reference/counter electrode for amperometric detection of the activity of the enzyme.
[0058] In a preferred embodiment of the present invention a working electrode is produced by using a formulation which includes not only the enzyme, nicotinamide cofactor and the mediator but also filler and binder ingredients which cause the working electrode to give an increasing monotonic response to concentrations of interest for the analyte being sensed when measured in a kinetic mode in which oxidation and reduction of the mediator both occur during the measurement. The concept is to provide a stable reaction layer on the surface of the working electrode when the sample is applied. This allows the use of mediators which are sparingly soluble in the sample. As the mediator is reduced by reaction with the enzyme, cofactor and analyte, it is retained in close proximity to the electrode surface so that it can be readily reoxidized without significant loss to precipitation. The maintenance of this thin reaction layer also allows the overall analytical reaction to occur in a small volume of the overall sample so in effect what is measured is the flux of analyte from the bulk specimen to this reaction layer.
[0059] This reaction layer needs to remain stable for at least the time to conduct a reproducible kinetic measurement. Typical times for such a measurement range between about 5 and 60 seconds, although stability for longer times is preferred. Typically, the disposable electrode strips of interest are mass produced and therefore it is desirable to have a safety margin with regard to any required property to account for the inherent variability in any mass manufacturing process.
[0060] The stability of the reaction layer can be improved by a proper combination of fillers and binders. The layer is preferably sufficiently stable to give an approximately linear reproducible response in a kinetic measurement over the concentration range of interest for a given analyte. For instance, for Ketone bodies (measured as hydroxybutyrate) this would be between about 1 and 8 mM while for glucose it would be between about 2 and 40 mM.
[0061] The kinetic measurement involves the cycling of the mediator between an oxidized state and a reduced state. The rate of this cycling, which is reflected in the current observed during the course of the test, is dependent upon the concentration of the analyte in the sample. The greater the concentration of the analyte the more enzyme cofactor which is reduced in the course of the enzyme oxidizing the analyte. The mediator in turn becomes reduced in reoxidizing the cofactor and is then reoxidized at the electrode surface. However, because of its very low solubility only a small amount of mediator is immediately available to react with the reduced cofactor. Consequently mediator which reacts with reduced cofactor and is reoxidized at the electrode will then react with further reduced cofactor and this continues through the course of a kinetic measurement. Thus the greater the concentration of the reduced cofactor (reflective of a greater concentration of analyte in the sample) the greater the driving force for the cycling of the mediator and thus the greater the rate of cycling.
[0062] In some cases the cofactor may also engage in cycling between an oxidized state and a reduced state during the kinetic measurement. This depends upon whether there is a sufficient quantity of cofactor initially present to convert all the analyte present in the reaction layer. If there is insufficient cofactor initially present as oxidized cofactor is regenerated it promotes the oxidation of any analyte remaining in the reaction layer by becoming reduced again.
[0063] However, what is critical is that a given concentration of analyte reproducible results in the production of the same signal in the kinetic test for a particular electrode strip design and that the signal increases monotonically, preferably linearly, with the concentration of the analyte (in other words that the signal be a true function of the analyte concentration) over the concentration range of interest. This allows the manufacturer of the electrode strips to establish a universal calibration for a given lot of electrode strips such that any given signal obtained from a given strip under standard test conditions uniquely correlates to a particular analyte concentration. Thus it is important that within the concentration range of interest there be no uncontrollable variable other than the analyte concentration which would substantially affect the signal.
[0064] The signal may be the current observed at a fixed time after the test is initiated or it may be the current integrated over some period occurring some fixed time after the test is initiated (in essence the charge transferred over some such period). The test is conducted by covering the working electrode and a reference/counter electrode with sample and then applying a potential between them. The current which then flows is observed over some time period. The potential may be imposed as soon as the sample covers the electrodes or it may be imposed after a short delay, typically about 3 seconds, to ensure good wetting of the electrodes by the sample. The fixed time until the current or current integration is taken as the signal should be long enough to ensure that the major variable affecting the observed current is the analyte concentration.
[0065] The reference electrode/counter electrode may be a classic silver/silver chloride electrode but it may also be identical to the working electrode in construction. In one embodiment the two separate conductive tracks may both be coated with an appropriate formulation of enzyme, cofactor and mediator in a binder and filler containing aqueous vehicle to yield a coating. In those cases in which the coating is non-conductive, e.g. when the filler is a non-conductor, a common coating may overlay both electrodes. When a potential is applied one of the electrodes will function as a reference/counter electrode by absorbing the electrons liberated at the other, working, electrode. The mediator at the reference/counter electrode will simply become reduced as a result of interaction with the electron flow at its electrode.
[0066] The reaction layer which yields the desired behavior is obtained by formulating the working electrode with binder and filler ingredients. The object is to allow the sample to interact with the enzyme, cofactor and mediator but to also ensure that these chemically active ingredients remain in the immediate vicinity of the surface of the electrode. The binder ingredient should include materials which readily increase the viscosity of aqueous media and promote the formation of films or layers. Typical of such materials are the polysaccharides such as guar gum, alginate, locust bean gum, carrageenan and xanthan. Also helpful are materials commonly known as film formers such as polyvinyl alcohol (PVA), polyvinyl pyrrole, cellulose acetate, carboxymethyl cellulose and poly (vinyl oxazolidinone). The filler ingredient should be a particulate material which is chemically inert to the oxidation reduction reactions involved in the measurement and insoluble in aqueous media. It may be electrically conductive or non-conductive. Typical materials include carbon, commonly in the form of graphite, titanium dioxide, silica and alumina.
[0067] The active electrode may be conveniently produced by formulating the enzyme, cofactor, mediator and binder and filler ingredients into an aqueous vehicle and applying it to the elongated, electrically insulating carrier having conducting tracks. The formulation may be applied by printing such as screen printing or other suitable techniques. The formulation may also include other ingredients such as a buffer to protect the enzyme during processing, a protein stabilizer to protect the enzyme against denaturation and a defoaming agent. These additional ingredients may also have an effect on the properties of the reaction layer.
[0068] The working electrode typically has a dry thickness between about 2 and 50 microns preferably between about 10 and 25 microns. The actual dry thickness will to some extent depend upon the application technique used to apply the ingredients which make up the working electrode. For instance thicknesses between about 10 and 25 microns are typical for screen printing.
[0069] However, the thickness of the reaction layer is not solely a function of the dry thickness of the working electrode but also depends upon the effect of the sample on the working electrode. In the case of aqueous samples the formulation of the working electrode ingredients will effect the degree of water uptake this layer displays.
[0070] The filler typically makes up between about 20 and 30 weight percent of the aqueous vehicle. The amounts of the other ingredients are typically less than about 1 weight percent of the aqueous vehicle and are adjusted empirically to achieve the desired end properties. For instance, the amount of buffer and protein stabilizer are adjusted to achieve the desired degree of residual enzyme activity. In this regard one may use more enzyme and less stabilizer or less enzyme and more stabilizer to achieve the same final level of enzyme activity. The amount of binder and defoaming agent should be adjusted to give suitable viscosities for the method of application with higher viscosities being suitable for screen printing and lower viscosities being suitable for rotogravure printing.
[0071] A suitable aqueous ink formulation can be formulated in accordance with Table 2 with the balance being deformer, buffer, enzyme activity enhancers and water to make up 1 gram of formulated ink.
[0000]
TABLE 2
Enzyme (such as Glucose Dehyrogenase
200 to 4000 Units
or 3-hydroxybutyrate Dehydrogenase)
Nicotinamide cofactor (such as NAD)
5 to 30 weight percent
Mediator (such as 1,10 phenanthroline
0.1 to 1.5 weight percent
quinone)
Filler (such as ultra fine carbon or
10 to 30 weight percent
titania)
Binder (such as alginate or guar gum)
0.01 to 0.5 weight percent
Protein stabilizer (such as Trehalose
0.01 to 2 weight percent
or Bovine Serum Albumin)
[0072] The stability of the reaction layer can be readily evaluated using cyclic voltammetry with various time delays. The working electrode formulation is evaluated by exposing it to a sample containing a relatively high concentration of analyte and subjecting it to a steadily increasing potential to a maximum value and then a steadily decreasing potential back to no applied potential. The resulting current increases to a peak value and then drops off as the voltage sweep continues. Such cyclic voltammetry evaluations are conducted after various delay periods after the working electrode is exposed to the sample. The change in peak current with increasingly long delay periods is a measure of the stability of the reaction layer. The more stable the reaction layer the smaller the decrease in peak current.
[0073] An evaluation was conducted to compare the stability of a working electrode formulated in accordance with the teachings of the present invention to that of a “working electrode” formulated according to the teachings of Geng et al. at pages 1267 to 1275 of Biosensors and Bioelectronics, Volume II, number 12 (1996). The working electrode representative of the present invention was formulated with about 25 weight percent filler (ultra fine carbon), binder, protein stabilizer and deformer as taught hereinabove and the working electrode representative of Geng was formulated with a high molecular weight poly (ethylene oxide) as described at page 1267 of the Geng article. In each case a potential was applied at a scan rate of 50 millivolt per second up to 400 mV versus a silver/silver chloride reference electrode after exposing the working electrode to a 20 mM aqueous solution of glucose for 3 seconds and 60 seconds. The formulation according to the present invention yields a stable reaction layer in which the peak current after 60 seconds is 60% of that observed after 3 seconds while the formulation according to the Geng article yields an unstable reaction layer in which no peak current is observable after 60 seconds exposure.
[0074] This is attributed to a dissolution of the electrode with a loss of the reagents to the bulk solution. The respective voltammograms are shown in FIGS. 9 and 10 .
[0075] The test strips of this invention can detect analytes that are substrates of NAD- or NADP-dependent dehydrogenase enzymes using a mediator selected from the compounds disclosed herein, such as 1,10-PQ.
[0076] Test strips according to this invention are intended for use with electronic apparatus and meter systems. These control the progress of the electrochemical reaction (e.g., by maintaining a particular potential at the electrodes), monitor the reaction, and calculate and present the result. A particular feature that is desirable in a meter system for use with test strips of this type is the capability of detecting the wetting of the reaction zone by sample fluid, thus allowing timely initiation of the measurement and reducing the potential for inaccuracies caused by user error. This goal can be achieved by applying a potential to the electrodes of the test strip as soon as the strip is inserted into the meter; this potential can be removed for a short time to allow wetting to be completed before initiation of measurement.
[0077] The meter can also feature a means for automatically identifying test strips for measuring different analytes. This can be achieved, for example, when one or more circuit loops are printed on the test strip; each loop can provide a resistance characteristic of the type of strip, as described in U.S. Pat. No. 5,126,034 at column 4, lines 3 to 17. As a further alternative, notches or other shapes might be cut into the proximal end of the test strip; switches or optical detectors in the meter can detect the presence or absence of each notch. Other strip-type recognition techniques include varying the color of the strips and providing the meter with a photodetector capable of distinguishing the range of colors; and providing the strips with barcodes, magnetic strips, or other markings, and providing the meter with a suitable reading arrangement.
[0078] In one example of a test strip for large scale production, the strip electrodes have a two-electrode configuration comprising a reference/counter electrode and a working electrode. The carrier can be made from any material that has an electrically insulating surface, including poly (vinyl chloride), polycarbonate, polyester, paper, cardboard, ceramic, ceramic-coated metal, blends of these materials (e.g., a blend of polycarbonate and polyester), or another insulating substance.
[0079] A conductive ink is applied to the carrier by a deposition method such as screen printing. This layer forms the contact areas, which allow the meter to interface with the test strip, and provides an electrical circuit between the contacts and the active chemistry occurring on the strip. The ink can be an air-dried, organic-based carbon mixture, for example. Alternative formulations include water-based carbon inks and metal inks such as silver, gold, platinum, and palladium. Other methods of drying or curing the inks include the use of infrared, ultraviolet, and radio-frequency radiation.
[0080] A layer forming the reference/counter electrode is printed with an organic solvent-based ink containing a silver/silver chloride mixture. Alternative reference couples include Ag/AgBr, Ag/AgI, and Ag/Ag 2 O. The print extends to partially cover the middle track of the carbon print where it extends into the reaction zone. It is useful if separate parts of this print are extended to cover parts of other carbon tracks outside the reaction zone, so that the total electrical resistance of each track is reduced.
[0081] A layer of dielectric ink can optionally be printed to cover the majority of the printed carbon and silver/silver chloride layers. In this case, two areas are left uncovered, namely the electrical contact areas and the sensing area which will underlie the reactive zone as depicted in FIGS. 1 and 2 . This print serves to define the area of the reactive zone, and to protect exposed tracks from short circuit.
[0082] For the working electrode, one or more inks are deposited to a precise thickness within a defined area on top of one of the conductive tracks within the reaction zone, to deposit the enzyme, cofactor and a mediator of the present invention. It is convenient to do this by means of screen printing. Other ways of laying down this ink include inkjet printing, volumetric dosing, gravure printing, flexographic printing, and letterpress printing. Optionally, a second partially active ink can be deposited on a second conductive track to form a dummy electrode.
[0083] Polysaccharides can optionally be included in the ink formulation. Suitable polysaccharides include guar gum, alginate, locust bean gum, carrageenan and xanthan. The ink can also include a film former; suitable film-forming polymers include polyvinyl alcohol (PVA), polyvinyl pyrrole, cellulose acetate, CMC, and poly (vinyl oxazolidinone). Ink fillers can include titanium dioxide, silica, alumina, or carbon.
[0084] The following are illustrative, non-limiting examples of the practice of the invention:
EXAMPLE 1
Mediators:
[0085] Meldola's Blue (MB) (Compound 3) was obtained as the hemi-ZnCl 2 salt from Polysciences, Inc. 2,6-Dichloroindophenol (DCIP) (Compound 6) and Tris buffer were purchased from Sigma. The phosphate buffered saline (PBS) solution (Dulbecco's formula) was prepared from tablets supplied by ICN Biomedicals, Ltd.
[0086] D-3-Hydroxybutyrate dehydrogenase (HBDH; EC 1.1.1.30) from Pseudomonas sp. was purchased from Toyobo Co., Ltd. p-Nicotinamide adenine dinucleotide (NAD + ) and D,L-3-hydroxybutyric acid were supplied by Boehringer Mannheim.
[0087] 1,10-Phenanthroline quinone (1,10-PQ) (Compound 7) was prepared according to the method of Gillard et al. ( J. Chem. Soc. A, 1447-1451, 1970). 1,7-Phenanthroline quinone (1,7-PQ) (Compound 8) was synthesized using the procedure described by Eckert et al. ( Proc. Natl. Acad. Sci. USA, 79:2533-2536, 1982). 2,9-Dimethyl-1,10-phenanthroline quinone (2,9-Me 2 -1,10-PQ) (Compound 10) was synthesized as a byproduct of the nitration of neocuproine as disclosed by Mullins et al. ( J. Chem. Soc., Perkin Trans. 1, 75-81, 1996). 1-Methoxy phenazine methosulphate (1-MeO-PMS) (Compound 5) was prepared via the methylation of 1-methoxy phenazine adapted from the method described by Surrey ( Org. Synth. Coll. Vol. 3, Ed. E. C. Horning, Wiley, N.Y., 753-756). 1-Methoxy phenazine was synthesized by a modified Wohl-Aue reaction as reported by Yoshioka ( Yakugaku Zasshi, 73:23-25, 1953). 4-Methyl-1,2-benzoquinone (4-Me-BQ) (Compound 4) was prepared via oxidation of 4-methyl catechol with o-chloranil according to a general procedure by Carlson et al. ( J. Am. Chem. Soc., 107:479-485, 1985). The 1,10-PQ complex [Ru(bpy) 2 (1,10-PQ)] (PF 6 ) 2 (Compound 12) was obtained from [Ru(bpy) 2 Cl 2 ] (Strem Chemicals, Inc.) as reported by Goss et al. ( Inorg. Chem., 24:4263-4267, 1985).
[0000] Preparation of 1-Me-1,10-phenanthrolinium quinone trifluoromethane sulphonate (1-Me-1,10-PQ + ) (Compound 11):
[0088] Methyl trifluoromethane sulphonate (Aldrich) (1.0 ml) was added to a solution of 1,10-PQ (0.50 g, 2.38 mmol) in anhydrous methylene chloride (25 ml) under nitrogen. Immediate precipitation occurred and the resulting mixture was stirred for 24 hours. Filtration followed by washing with methylene chloride afforded 1-Me-1,10-PQ + (0.65 g, 73%) as a fine yellow powder.
Evaluation of Meldola's Blue and 1,10-PQ as NADH Mediators in Dry Strips:
[0089] Screen-printed electrodes incorporating 1,10-PQ and MB were produced from an organic carbon ink containing these NAD(P)H mediators at a level of 3.5 mg/g ink. The solid mediators were mixed into a commercial conducting carbon ink (Gwent Electronic Materials).
[0090] The dose response curve for the electrodes containing 1,10-PQ tested with aqueous NADH solutions (0-16.7 mM) in PBS at a poise potential of +400 mV versus a printed Ag/AgCl reference electrode is shown in FIG. 3 . A slope of 0.58 μA mM −1 NADH was recorded. The dose response curve for the electrodes containing MB tested with aqueous NADH solutions (0-12.4 mM) at a poise potential of +100 mV versus a printed Ag/AgCl reference electrode is shown in FIG. 4 . An increased slope of 8.48 μA mM −1 NADH was observed.
Assessment of Mediator Inhibition of D-3-Hydroxybutyrate Dehydrogenase:
[0091] A series of 18 solutions (2.5 ml each) were prepared, each containing 50 U/ml HBDH and 1.29 or 2.58 mg of the following NAD(P)H mediators: MB(3), 4-Me-BQ(4), I-Me0-PMS(5), DCIP(6), 1,10-PQ(7), 1,7-PQ(8), 2,9-Me 2 -1,10-PQ(10), 1-Me-1,10-PQ + (11), and [Ru(bpy) 2 (1,10-PQ)](PF 6 ) 2 (12) in Tris buffer (50 mM, pH 8.2). A control solution was also prepared, containing enzyme but no mediator. The solutions were incubated for 0.5 hours at 37.5 C, then assayed (in triplicate) for NADH at 340 nm, using a Sigma Diagnostics D-3-hydroxybutyrate kit. The extent of the interference of the added mediator with the assay rate compared to the control afforded a quantitative measure of the mediator's efficiency as an oxidant of NADH.
[0092] The enzyme was then reisolated from the mediator solutions by filtration through a polysulfone membrane (nominal molecular weight cut-off: 30,000) in a microcentrifuge filter (Millipore). The enzyme remaining on the filter was dissolved in Tris buffer (0.2 ml), and the resulting solution was assayed (in triplicate) with the Sigma kit. By comparing the results of the assays before and after filtration, the effect of any covalently and/or irreversibly bound mediator on the enzyme activity could be determined.
[0093] The results of the two assays on each solution before and after filtration are collected in Table 3.
[0000]
TABLE 3
Assay Rate (absorbance units/min)
control
before
after
Mediator (Compound No.)
(no mediator)
filtration
filtration
1,10-PQ
0.167
0.149
0.160 (96%)
1,7-PQ
0.155
0.115
0.150 (97%)
MB
0.167
0.008
0.026 (16%)
4-Me-BQ
0.170
0.005
0.007 (4%)
1-MeO-PMS
0.150
0.009
0.071 (47%)
DCIP
0.150
0.104
0.085 (57%)
2,9-Me 2 -1,10-PQ
0.197
0.189
n/a
1-Me-1,10-PQ +
0.197
0.150
0.185 (94%)
[Ru(bpy) 2 (1,10-PQ)](PF 6 ) 2
0.197
0.114
0.193 (98%)
[0094] Although these results demonstrated that the phenanthroline quinone mediators were relatively inefficient NADH mediators compared to Meldola's Blue and 1-MeO-PMS (i.e., the assay rate “before filtration” was depressed only to a small extent), over 90% of the original enzyme activity for the solutions containing 1,10-PQ, 1,7-PQ, 1-MeO-1,10-PQ, or [Ru(bpy) 2 (1,10-PQ)](PF 6 ) 2 was restored “after filtration.” This was not the case for MB, 1-MeO-PMS, DCIP, or 4-Me-BQ. Indeed, the quinone mediator 4-Me-BQ proved to be the most potent inhibitor with only 4% of the original activity remaining “after filtration.” Thus, the latter four mediators partially inactivate HBDH while the newly described mediators advantageously had little or no effect on enzyme activity.
[0095] The percentage residual enzyme activities for each mediator are displayed as a bar chart in FIG. 5 , which reveals that the mediators of the present invention, represented by black bars, are not strong inhibitors of HBDH. In contrast, MB, 4-Me-BQ, 1-MeO-PMS, and DCIP all irreversibly inhibited HBDH, with concomitant losses in activity ranging from 43 to 96%; these results are represented by grey bars in FIG. 5 .
EXAMPLE 2
Evaluation of Meldola's Blue and 1,10-PQ in Dry Strips Containing HBDH:
[0096] Screen-printed electrodes were produced from an aqueous carbon ink incorporating 1,10-PQ or MB at a level of 2.4 or 4.3 mg/g ink, respectively, together with the enzyme HBDH (120 units/g ink) and NAD + (110 mg/g ink). The ink also contained a polysaccharide binder.
[0097] The dose response curves for the electrodes containing 1,10-PQ are given in FIG. 6 . The electrodes were tested after 4, 14, and 26 weeks of storage (30° C., desiccated) with aqueous D-3-hydroxybutyrate solutions (0-25 mM) in PBS at a poise potential of +400 mV versus a printed Ag/AgCl reference electrode. All three dose responses were non-linear and levelled out with a current of 8.5 μA being recorded at 24 mM D-3-hydroxybutyrate. This demonstrated that the response of the dry electrodes was stable for at least 26 weeks.
[0098] The dose response curves for the electrodes containing MB are provided in FIG. 7 . The electrodes were tested after 2 and 14 weeks storage (30° C., desiccated) with aqueous D-3-hydroxybutyrate solutions (0-28 mM) in PBS at a poise potential of +100 mV versus a printed Ag/AgCl reference electrode. The dose response curves were similar to those in FIG. 4 . A current of 8.6 μA was recorded at 24 mM D-3-hydroxybutyrate for these electrodes after 2 weeks storage. This is almost identical to responses obtained from dry strips containing 1,10-PQ.
[0099] This result demonstrated that the ability of a compound such as MB to mediate very efficiently with NADH compared to 1,10-PQ is outweighed by the fact that it inhibits HBDH. Furthermore, the stability of the electrode response to D-3-hydroxybutyrate is compromised through the inactivation of HBDH by MB. FIG. 7 shows that the response of these electrodes dropped by an unacceptable margin of approximately 7% after 14 weeks storage.
[0100] In summary, biosensor electrodes containing a mediator of the present invention displayed responses which were stable after at least 26 weeks storage. In contrast, those electrodes incorporating a traditional mediator such as MB which is an irreversible enzyme inhibitor exhibited responses which declined after only 14 weeks storage.
EXAMPLE 3
Evaluation of 1,10-PQ in Dry Strips Containing Glucose Dehydrogenase (GDH):
[0101] Screen-printed electrodes were produced from an aqueous carbon ink incorporating 1,10-PQ or MB at a level of 2.4 or 4.3 mg/g ink, respectively, together with the enzyme Glucose dehydrogenase (120 units/g ink) and NAD + (110 mg/g ink). The ink also contained a polysaccharide binder.
[0102] The calibrated dose response curve for the electrodes is given in FIG. 8 . The electrodes were tested with whole blood containing physiologically relevant concentrations of glucose ranging from 3.3 to 26 mM. A poise potential of +50 mV was maintained against a printed Ag/AgCl electrode. The electrodes produced a linear response over the glucose range. Thus, it was demonstrated that a mediator of the present invention can be used to construct a clinically useful glucose sensor which operates at a particularly low applied potential.
EXAMPLE 4
[0103] Electrode strips were prepared utilizing the construction illustrated in FIGS. 1 and 2 with a silver/silver chloride reference/counter electrode and a working electrode prepared by screen printing a formulation in accordance with Table 2. In one case, the filler was 25 weight percent ultra fine carbon and in the other case the filler was 25 weight percent titania. In both cases the enzyme was Glucose Dehydrogenase (GDH), the cofactor was NAD, the mediator was 1,10-PQ, the binder was guar gum, the protein stabilizer was Bovine serum albumin (BSA) and the buffer was Tris (0.325 weight percent).
[0104] These electrode strips were evaluated by applying a 200 mV potential between the reference/counter electrode and the working electrode while an aqueous glucose solution covered both electrodes. The observed current from 15 to 20 seconds after the application of the potential was integrated and plotted against the glucose contents of the test solutions. The carbon-filled formulation gave a slope of 2.6 microcoulomb per mM of glucose and an X axis intercept of −1 microcoulomb while the titania-filled formulation gave a slope of 1.5 microcoulomb per mM of glucose and an X axis intercept of 0.6 microcoulomb. The plots are shown in FIGS. 11 and 12 .
OTHER EMBODIMENTS
[0105] It is to be understood that while the invention has been described in conjunction with the detailed description thereof, that the foregoing description is intended to illustrate and not to limit the scope of the invention. Other aspects, advantages, and modifications are within the scope of the invention. | The present invention is based on the discovery of NAD + and NADP + mediator compounds that do not bind irreversibly to thiol groups in the active sites of intracellular dehydrogenase enzymes. Such mediator compounds avoid a common mode of enzyme inhibition. The mediators can therefore increase the stability and reliability of the electrical response in amperometric electrodes constructed from NAD- or NADP-dependent enzymes. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the construction industry and, in particular, concerns a method of interconnecting building members with paired connectors and tie rods.
2. Description of the Related Art
In typical residential and light industrial and commercial building frame wall construction, load bearing frame walls comprise a series of studs and posts that are anchored to the foundation and covered with sheathing material installed over both sides of the frame. Typically, the frame is constructed from a number of vertically extending studs that are positioned between and connected to horizontally extending top and bottom plates. The bottom plate and the vertical studs are typically anchored to the foundation by some means. The sheathing material, which can be plywood, gypsum wallboard, siding, plaster, or the like, is then attached over the studs.
Natural forces commonly impose vertical and horizontal forces on the structural elements of the buildings. These forces can be the result of earth movements in an earthquake and from high-velocity winds, as in a hurricane or tornado. If these forces exceed the structural capacity of the building, they can cause structural failures leading to anything from minor damage to catastrophic destruction of the building, attendant economic loss, and injuries or fatalities.
The typical method of interconnecting the stories of a building is to use lengths of coil strap to tie the studs of an upper to story to the studs of the story below. The disadvantages of coil strap are manifold. Coil strap cannot be installed within a wall because of the intervening sill plates. Coil strap cannot accommodate any offset in the upper and lower studs. Wood shrinkage after strap installation across horizontal wood members can cause the strap to buckle outward. Coil strap is a general-purpose utility strap that is not tailored to the specific connection. Vertically-paired holdowns can eliminate some of the disadvantages of the coil strap, but holdowns are typically engineered for higher load values that are necessary in a floor-to-floor connection and therefore waste material and increase costs.
SUMMARY OF THE INVENTION
The present invention provides a single-piece connector that uses less material, and is therefore more economical to produce, than connectors in the prior art. In particular the diagonally-slanted support leg, preferably reinforced with shallow walls on either side, eliminates the need for an additional member to support or reinforce the seat member.
The present invention provides a connector that can be used, and a connection that can be made, inside the walls of the structure, thereby eliminating the exposure of coil strap, as in the prior art, which must be attached to the outer faces of the wall studs.
The present invention provides a connector with obround openings that permit limited adjustability and ease installation in narrow wall cavities.
The present invention provides a connection that is easy to install because it uses standard all thread rod, which is easily procured and can be easily run through a hole or holes drilled in the sill plates of the floor structure between the connected wall studs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the connector of the present invention.
FIG. 2 is a perspective view of the connection of the present invention.
FIG. 3 is a front elevation view of the connector of the present invention.
FIG. 4 is a side elevation view of the connector of the present invention.
FIG. 5 is a top plan view of the connector of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The connector 1 of the present invention is preferably formed out of galvanized sheet steel using automated machinery. The connector 1 is preferably formed by cutting, punching and bending the sheet steel. However, the connector 1 can be formed by any appropriate method and material, for instance by casting metals such as aluminum and molding plastics.
At its most basic, the connector 1 of the present invention comprises a first substantially planar attachment tab 2 , a first substantially planar seat member 3 , a first substantially planar support leg 6 , and a second substantially planar attachment tab 9 .
Preferably, the first attachment tab 2 has an attachment face 20 and an opposite outer face 21 . Preferably, the first attachment tab 2 is elongated, with two relatively long and parallel side edges 44 and a relatively short end edge 45 that connects the two side edges 44 . The end edge 45 preferably has two diagonal end portions 46 that cut off what would otherwise be sharp corners on the first attachment tab 2 .
The first seat member 3 preferably has an inner face 22 and an opposite outer face 23 . The first seat member 3 has a first tie member opening 4 , which is preferably obround to allow a degree of adjustability. The first seat member is integrally connected to the first attachment tab 2 at a first bend line 5 , which is preferably straight.
Preferably, the first support leg 6 has an inner face 24 and an opposite outer face 25 . The first support leg 6 has a second tie member opening 7 . The first support leg 6 is integrally attached to the first seat member 3 at a second bend line 8 , which is preferably straight. The first bend line 5 and the second bend line 8 are substantially parallel to each other and are separated from each other by the first seat member 3 .
The second substantially planar attachment tab 9 preferably has an attachment face 26 and an opposite outer face 27 . The second attachment tab 9 is integrally attached to the first support leg 6 at a third bend line 10 , which is preferably straight. The second bend line 8 and said third bend line 10 are substantially parallel to each other and separated from each other by said first support leg 6 .
Preferably, the first attachment tab 2 and the first seat member 3 are substantially orthogonal. The inner face 22 of the first seat member 3 and said inner face 24 of the first support leg 6 preferably define a first angle 28 that is acute. Preferably, the outer face 25 of the first support leg 6 and the outer face 27 of said second attachment tab 9 define a second angle 29 that is obtuse.
The first seat member 3 preferably has a first edge 30 and a second edge 31 . Preferably, the first edge 30 of the first seat member 3 is bent toward the outer face 23 of the first seat member 3 to form a first reinforcing side wall 32 . The second edge 31 of the first seat member 3 is preferably bent toward the outer face 23 of the first seat member 3 to form a second reinforcing side wall 33 .
Preferably, the first seat member 3 has a central portion 43 between the first reinforcing side wall 32 and the second reinforcing side wall 33 of the first seat member ( 3 ). The first reinforcing side wall 32 and the second reinforcing side wall 33 of the first seat member 3 preferably converge between the first bend line 5 and the second bend line 8 so that the central portion 43 of the first seat member 3 narrows between the first bend line 5 and the second bend line 8 . Preferably, the first reinforcing side wall 32 is bent up along a first bend 47 and the second reinforcing side wall 33 is bent up along a second bend 48 . The first bend 47 and the second bend 48 preferably form two shallow inward-facing arcs in the first seat member 3 .
The first support leg 6 preferably has a first edge 34 and a second edge 35 . Preferably, the first edge 34 of the first support leg 6 is bent toward the outer face 25 of said first support leg 6 to form a first reinforcing side wall 36 . The second edge 35 of the first support leg 6 is preferably bent toward the outer face 25 of the first support leg 6 to form a second reinforcing side wall 37 .
Preferably, the first support leg 6 has a central portion 41 between the first reinforcing side wall 36 and the second reinforcing side wall 37 of said first support leg 6 . The first reinforcing side wall 36 and the second reinforcing side wall 37 of the first support leg 6 preferably converge between the second bend line 8 and the third bend line 10 so that the central portion 41 of the first support leg 6 narrows between the second bend line 8 and the third bend line 10 . Preferably, the first reinforcing side wall 36 is bent up along a first bend 49 and the second reinforcing side wall 37 is bent up along a second bend 50 . The first bend 49 and the second bend 50 preferably form two shallow inward-facing arcs in the first support leg 6 .
Preferably, the first bend line 5 has a first reinforcing gusset 38 that bridges the first bend line 5 from the outer face 21 of the first attachment tab 2 to the outer face 23 of the first seat member 3 .
The first tie member opening 4 preferably has a reinforcing rim 39 that is bent toward the outer face 23 of the first seat member 3 . Preferably, the first tie member opening 4 is preferably obround to provide a degree of lateral adjustability.
The second tie member opening 7 is preferably obround. Because of the angle of the first support leg 6 , the second tie member opening must be elongated.
Preferably, the first attachment tab 2 has a plurality of fastener openings 40 , and the second attachment tab 9 also has a plurality of fastener openings 40 . Most preferably, the first attachment tab 2 has twelve fastener openings and the second attachment tab 9 has three fastener openings 40 . The fastener openings 40 in the first attachment tab 2 and said second attachment tab 9 preferably are obround, providing a degree of lateral adjustability.
The connector 1 of the present invention is preferably formed first by cutting the connector 1 from sheet metal, preferably 12 gauge galvanized sheet steel. Preferably, the first seat member 3 is bent up from the first attachment tab 2 at the first bend line 5 . The first support leg 6 is preferably bent down from the first seat member 3 at the second bend line 8 . Preferably, the second attachment tab 9 is bent up from the first support leg 6 at the third bend line 10 .
At its most basic, the connection 11 of the present invention comprises a first structural member 12 , a second structural member 15 , a third structural member 18 between the first structural member 12 and the second structural member 15 , a first connector 1 attached to the first structural member 12 , a second connector 1 attached to the second structural member 15 , and a first tie member 19 interconnecting the first connector 1 and the second connector 1 .
Preferably, the first structural member 12 has a first side face 13 and a first end 14 . The second structural member 15 preferably has a first side face 16 and a first end 17 . Preferably, the third structural member 18 is sandwiched between the first end 14 of the first structural member 12 and the first end 17 of the second structural member 15 .
The first connector 1 is preferably attached to the first side face 13 of the first structural member 12 . Preferably, the second connector 1 is attached to the first side face 16 of the second structural member 15 .
Preferably, the first tie member 19 is restrained against the first seat member 3 of the first connector 1 and restrained against the first seat member 3 of the second connector 1 . Preferably, the first tie member 19 is all thread rod (ATR), preferably ⅜″ (0.9525 centimeter) in diameter. The first tie member 19 is preferably 4 to 5 feet (1.2192 to 1.524 meters) long and grade A307 or better. Preferably, the first tie member 19 is restrained with matching nuts 51 , preferably augmented with cut washers. The first tie member 19 preferably passes through the first tie member opening 4 and the second tie member opening 7 in the first connector ( 1 ), and the first tie member 19 passes through the first tie member opening 4 and the second tie member opening 7 in the second connector 1 .
Preferably, the first structural member 12 and the second structural member 15 are vertically oriented, the third structural member 18 is horizontally oriented, and the first tie member 19 is vertically oriented. In the preferred embodiment, the connection 11 of the present invention is a vertical floor-to-floor connection 11 . However, the connector 1 of the present invention could be used in a horizontal purlin-to-purlin connection 11 or the like. The connector 1 of the present invention could also be used singly, rather than paired, for example as a holdown.
The first structural member 12 is preferably an upper-storey wall stud 12 . The second structural member 15 is preferably a lower-storey wall stud 15 . The third structural member 18 is preferably an intervening floor 18 .
Preferably, the floor 18 comprises a horizontal bottom plate 20 , a floor diaphragm 21 and a floor beam 22 . The bottom plate 20 supports the first structural member 12 , the first end 14 of the first structural member 12 resting on the bottom plate 20 . The floor diaphragm 21 supports the bottom plate 20 . The floor beam 22 supports the floor diaphragm and preferably rests on a top plate 23 . The top plate 23 rests on the first end 17 of said second structural member 15 and the top plate 23 is supported by the second structural member 15 . In this embodiment, the first end 14 of the first structural member 12 is the lower end 14 of the first structural member 12 and the first end 17 of the second structural member 14 is the upper end 17 of the second structural member 14 .
The top plate 23 is preferably a double top plate 23 . Preferably, the first structural member 12 , the second structural member 15 , the bottom plate 20 , and the top plate 23 are all formed from nominal 2×4″ lumber. The connector 1 of the present invention is preferably used on at least a single 2× stud. The lumber is preferably Douglas Fir, Larch or Southern Pine. Alternatively, Spuce, Pine, Fir or Hem Fir may be used. The allowable tension load (the maximum load that the connection 11 is designed to provide) for the connection 11 of the present invention 1830 pounds (830.074 kilograms) with Douglas Fir, Larch or Southern Pine and 1570 pounds (712.140 kilograms) with Spuce, Pine, Fir or Hem Fir. Load values are based on a minimum lumber thickness of 1½″ (3.81 centimeters).
Preferably, a first plurality of fasteners 24 attaches the first attachment tab 2 of the first connector 1 to the first side face 13 of the first structural member 12 . A second plurality of fasteners 24 preferably attaches the second attachment tab 9 of the first connector 1 to the first side face 13 of the first structural member 12 . Preferably, a third plurality of fasteners 24 attaches the first attachment tab 2 of the second connector 1 to the first side face 16 of the second structural member 15 . A fourth plurality of fasteners 24 preferably attaches the second attachment tab 9 of the second connector 1 to the first side face 16 of the second structural member 15 . Although separate mechanical fasteners 24 are preferred, integral mechanical fasteners 24 such as nail prongs could be employed, for instance if the connectors 1 were factory preinstalled on the structural members. Similarly, fasteners 24 could be eliminated if the connectors 1 were attached with a sufficiently strong adhesive or if they were welded or otherwise bonded to structural members made of materials other than wood, such as metals or plastics, particularly if the connectors 2 were likewise. Most preferably, the fasteners 24 are nails 24 , specifically fifteen 10 d×1½″ (0.148 inch [0.375 92 centimeter] diameter by 1.5 inches [3.81 centimeters] long) nails. Preferably, the nails 24 are driven straight into the first structural member 12 and the second structural member 15 , but the connection 11 of the present invention preferably allows for the nails 24 to be driven in at up to a 30 degree angle with no reduction in load capacity.
The first connector 1 is preferably attached to the first side face 13 of the first structural member 12 proximate the first end 14 of the first structural member 12 , preferably no more than 18″ (45.72 centimeters) from the third structural member 18 . Preferably, the second connector 1 is attached to the first side face 16 of the second structural member 15 proximate the first end 17 of the second structural member 15 , preferably no more than 18″ (45.72 centimeters) from the third structural member 18 .
The preferred method of making the connection 11 of the present invention consists first of selecting the first structural member 12 , the second structural member ( 15 ), and the third structural member ( 18 ). The preferred method then consists of placing the third structural member 18 between the first end 14 of the first structural member 12 and the first end 17 of the second structural member ( 15 ). As most preferably practiced, this is done as part of erecting a multistory structure, with a plurality of wall studs in each story wall and a floor between each pair of stories. The preferred method then consists of attaching the first connector 1 to the first side face 13 of the first structural member 12 , and attaching the second connector 1 to the first side face 16 of the second structural member 15 .
Then a hole 42 is preferably drilled in, and though, the third structural member 18 . Preferably, the hole 42 is ½″ to ¾″ (1.27 to 1.905 centimeters) in diameter and approximately 1½″ (3.81 centimeters) away from the first side face 13 of the first structural member 12 and the first side face 16 of the second structural member 15 . The preferred method then consists of passing the first tie member 19 through the hole 42 in the third structural member 18 , passing the first tie member 19 through the first tie member opening 4 ) and the second tie member opening 7 in the first connector 1 , and passing the first tie member 19 through the first tie member opening 4 and the second tie member opening 7 in the second connector 1 .
Finally, the method of making the connection 11 of the present invention consists of restraining the first tie member 19 against the first seat member 3 of the first connector 1 and against the first seat member 3 of the second connector 1 . The first tie member 19 , which is preferably ⅜″ (0.9525 centimeter) all thread rod (ATR), is preferably restrained with matching nuts 51 and standard cut washers. Preferably, the connectors 1 are offset no more than 3″ (7.62 centimeters) from each other. | A connector for connecting wall studs of two adjacent floors in a light frame building structure, the connector having a first attachment tab, a seat member, a diagonally slanted support leg, and a second attachment tab, all substantially planar. The connector is intended to be paired and the paired connectors joined by an elongated tie member that pierces the sill plates of the intervening floor structure. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to compression clips, and more specifically, to compression clips used to cause hemostasis of blood vessels located along the gastrointestinal tract delivered to a target site through an endoscope.
BACKGROUND
[0002] Gastrointestinal (“GI”) bleeding is often associated with peptic ulcer disease (PUD) and can be fatal if not treated immediately. Hemorrhaging is the most dangerous procedure with which a Gastro-Intestinal Endoscopist has to deal. It is his/her only unplanned, emergency procedure where time is critical in determining the outcome. It is also the one problem the Endoscopist faces that is generally not an outpatient procedure. A bleeding PUD can be a critical clinical event as there is internal hemorrhaging. Ulcers are classified from clean to active spurting bleeding. The most worrisome are active bleeders and visible vessels. Untreated visible vessels are likely to bleed.
[0003] Suspected bleeding PUD patients can be diagnosed and treated endoscopically in an emergency room, an ICU or the GI suite. Surgery generally results in higher cost, morbidity and mortality than endoscopy. Therefore, laparoscopy or open surgery is not preferred unless there is no endoscopic alternative or endoscopy has failed. If the diseased tissue is beyond repair, a surgical gastric resection may be performed.
[0004] Currently, the endoscopist has two commonly used treatments and some lesser used therapies to achieve hemostasis of the ulcer. The most widely used treatments are thermal therapy and injection therapy. Some of the less common options are Olympus Endoclips, lasers and argon plasma cautery.
[0005] With thermal therapy, a catheter with a rigid heating element tip is passed through the working channel of an endoscope after the bleed is visualized and diagnosed. After the rigid catheter tip has exited the scope, the scope is manipulated to press the tip against the bleed site. Thermal power is applied, either through a resistive element in the tip or by applying RF energy through the tissue, thus desiccating and cauterizing the tissue. The combination of the tip compressing the tissue/vessel and the application of heat theoretically welds the vessel closed.
[0006] Although thermal treatment is fairly successful in achieving hemostasis, it often takes more than one attempt (irrigation is applied after the initial treatment to see if hemostasis has occurred) and there is frequent re-bleeding. Generally several pulses of energy are applied during each attempt. If early re-treatment is needed, there is a risk of perforation with the heat probe. Another disadvantage is that both types of thermal therapy require a specialized power generator and the equipment can be expensive.
[0007] With injection therapy, a catheter with a distally extendable hypo needle is passed through the working channel of the endoscope after the bleeding has been visualized and diagnosed. Once the catheter tip has exited the scope, the scope is manipulated to the bleed site, the needle is extended remotely and inserted into the bleed site. A vasoconstricting (narrowing of blood vessels) or sclerosing (causing a hardening of tissue) drug is then injected through the needle. Multiple injections in and around the bleeding site are often needed, until hemostasis has been achieved. As with thermal therapy, re-bleeding is also a problem.
[0008] The treatment used in any specific instance is highly dependent on geographic region. In some regions, especially in the United States, injection therapy is often combined with thermal treatment since neither therapy is completely effective alone.
[0009] The primary success rate of endoscopic treatment is about 90%. The other cases are usually referred to surgery. All identified ulcers may re-bleed at a later time, but the re-bleed rate for endoscopically treated active bleeds and a visible vessel is 10-30%. Even with the introduction of new treatments and devices, these rates have not improved significantly in decades. Surgery's short and long-term success for permanent hemostasis is virtually 100%.
[0010] Surgery has a higher success rate because the bleeding site is compressed mechanically, causing better hemostasis. Using devices such as clamps, clips, staples, sutures (i.e. devices able to apply sufficient constrictive forces to blood vessels so as to limit or interrupt blood flow), the bleeding vessel is ligated or the tissue around the bleed site is compressed, ligating all of the surrounding-vessels.
[0011] An existing device that incorporates the advantages of surgery into a less-invasive endoscopic procedure is the Olympus EndoClip. The goal of the device is to pinch the bleeding vessel to create hemostasis. The problem with this device is that once jaw closure begins, it is not possible to reopen them, and the endoscopist is committed to firing the clip. In other words, jaw closure is not reversible. Because the vessel is frequently difficult to see, often several clips must be deployed in order to successfully pinch the vessel and achieve hemostasis. Additionally, the Olympus EndoClip is a semi-reusable device, causing the performance of the device to degrade with use.
SUMMARY OF THE INVENTION
[0012] The present invention provides medical devices for causing the hemostasis of blood vessels located along the gastrointestinal tract. The goal of the invention is to give the endoscopist a technique and device which: 1) has a success rate in line with the surgical option; 2) is easier to set-up than the Olympus EndoClip; and 3) is easier to deploy than the Olympus EndoClip. The design intent is to eliminate surgery and its associated mortality and morbidity.
[0013] The medical devices of the present invention include: a compression clip used to cause hemostasis of blood vessels and a mechanism for deploying the clip that includes an arrangement for closing the clip and for reversing the closing process to reopen the clip after closure has begun. Embodiments of the invention may include a lock arrangement for locking the clip closed; a control wire connected to the clip and able to be disconnected from the clip; an axially rigid sheath enclosing the control wire and communicating a compressive force opposing a tensile force of the control wire; a handle connected to the axially rigid sheath; and/or a trigger enclosed within the handle and engaging the control wire to close and lock the clip and to uncouple the control wire from the clip.
[0014] There are several key advantages of the invention disclosed here over existing devices. The device's ability to repeatedly open and close the clip until the desired tissue pinching is accomplished will lead to a quicker procedure, requiring less clips to be deployed, with a higher success rate. In particular embodiments, this higher success rate will be improved even more due to the device's ability to be easily rotated so that the clip legs can be adjusted relative to the bleeding vessel. In particular embodiments, the time required to perform the overall procedure will also be further reduced due to the fact that the device is completely set up, with the clip already attached to the delivery device, unlike the competitive device. A more robust delivery device may allow a larger, stronger clip to be delivered. Combinations of these features will provide for a device that is easier to use.
[0015] Another advantage inherent to particular embodiments of this design is the feature of being completely disposable. The competitive device, the Olympus Endoclip, uses a “semi-reusable” delivery device, capable of firing several clips before it fails. This causes the device's functionality to degrade over the course of its use, until it is no longer able to deploy a clip. The competitive delivery device must be loaded manually, which is cumbersome to the operator and time-consuming, especially in the context of an unplanned emergency procedure. The “single-use” (disposable) embodiments of the invention disclosed here would function the same with each clip, in each procedure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is an enlarged partial view of a first embodiment of the medical device of the present invention.
[0017] FIG. 2 is an enlarged partial view of the distal end of the embodiment of FIG. 1 .
[0018] FIG. 3 is an enlarged view of the clip of the embodiment of FIG. 1 .
[0019] FIG. 4 is an enlarged view of the lock sleeve of the embodiment of FIG. 1 .
[0020] FIG. 5 is an enlarged view of the j-hook of the embodiment of FIG. 1 .
[0021] FIG. 6 is an enlarged partial view of the control wire, retainer, and clip of the embodiment of FIG. 1 .
[0022] FIG. 7 is an enlarged partial view of the handle of the embodiment of FIG. 1 .
[0023] FIG. 8A is an enlarged partial view of the distal end of another embodiment of the medical device of the present invention.
[0024] FIG. 8B is an enlarged partial end view of the embodiment of FIG. 8A .
[0025] FIG. 8C is an enlarged partial view of a clip leg of the embodiment of FIG. 8A .
[0026] FIG. 8D is an enlarged partial view of a clip locking mechanism of the embodiment of FIG. 8A .
[0027] FIG. 8E is an enlarged partial view of a clip locking mechanism and clip legs of the embodiment of FIG. 8A .
[0028] FIG. 8F shows enlarged partial side views of various embodiments of clip leg shapes available for use in the medical device of the present invention.
[0029] FIG. 8G shows enlarged partial end views of various embodiments of clip leg shapes available for use in the medical device of the present invention.
[0030] FIG. 9A is an enlarged partial view of the distal end of another embodiment of the medical device of the present invention.
[0031] FIG. 9B is an enlarged partial view of the embodiment of FIG. 9A being deployed.
[0032] FIG. 10A is an enlarged partial view of another embodiment of the medical device of the present invention.
[0033] FIG. 10B is an enlarged partial view of the embodiment of FIG. 10A being deployed.
[0034] FIG. 11 is an enlarged partial view of another embodiment of the medical device of the present invention.
[0035] FIG. 12A is an enlarged partial view of another embodiment of the medical device of the present invention showing the clip in an open position.
[0036] FIG. 12B is an enlarged partial view of the embodiment of FIG. 12A showing the clip in a closed position.
[0037] FIG. 13A is an enlarged partial view of another embodiment of the medical device of the present invention showing the clip in a closed position prior to disconnecting the clip.
[0038] FIG. 13B is an enlarged partial view of the distal end of the embodiment of FIG. 13A showing the clip in a closed position after disconnecting the clip.
[0039] FIG. 13C is an enlarged partial view of the embodiment of FIG. 13A showing the clip in a closed position after disconnecting the clip.
[0040] FIG. 14A is an enlarged partial view of another embodiment of the medical device of the present invention.
[0041] FIG. 14B is an enlarged partial side view of the embodiment of FIG. 14A .
[0042] FIG. 14C is an enlarged partial view of the distal end of the medical device of the embodiment of FIG. 14A after the clip has been released.
[0043] FIG. 15A is an enlarged partial view of another embodiment of the medical device of the present invention.
[0044] FIG. 15B is an enlarged partial view of the clip of the embodiment of FIG. 15A in a closed position.
[0045] FIG. 15C is an enlarged partial view of the clip of the embodiment of FIG. 15A in an open position.
[0046] FIG. 15D is an enlarged partial view of the distal end of the medical device of the embodiment of FIG. 15A -after the clip has been released.
[0047] FIG. 16A is an enlarged partial view of another embodiment of the medical device of the present invention.
[0048] FIG. 16B is an enlarged partial close-up side view of the end of a clip leg of the embodiment of FIG. 16A .
[0049] FIG. 16C is an enlarged partial close-up edge view of the end of a clip leg of the embodiment of FIG. 16A .
[0050] FIG. 16D is an enlarged partial view of the embodiment of FIG. 16A with the clip in an open position.
[0051] FIG. 16E is an enlarged partial view of the embodiment of FIG. 16A with the dip in a closed position.
[0052] FIG. 17A is an enlarged partial view of another embodiment of the medical device of the present invention.
[0053] FIG. 17B is an enlarged partial view of the embodiment of FIG. 17A , showing the clip in an open position.
[0054] FIG. 18A is an enlarged view of clip legs of another embodiment of the medical device of the present invention.
[0055] FIG. 18B is an enlarged partial view of an embodiment of the medical device of the present invention using the clip legs of FIG. 18A .
[0056] FIG. 18C is an enlarged partial view of the embodiment of FIG. 18B , showing the clip in a closed position.
[0057] FIG. 18D is an enlarged edge view of the clip of the embodiment of FIG. 18B .
[0058] FIG. 18E is an enlarged partial end view of the embodiment of FIG. 18B .
[0059] FIG. 18F is an enlarged partial side view of the embodiment of FIG. 18B .
[0060] FIG. 19A is an enlarged partial edge view of another embodiment of the medical device of the present invention.
[0061] FIG. 19B is an enlarged partial side view of the embodiment of FIG. 19A .
[0062] FIG. 19C is an enlarged partial view of a clip leg of the embodiment of FIG. 19A .
[0063] FIG. 20A is an enlarged partial end view of another embodiment of the medical device of the present invention.
[0064] FIG. 20B is an enlarged partial side view of the embodiment of FIG. 20A .
[0065] FIG. 20C is a side-by-side comparison of two parts of the embodiment of FIG. 20A .
[0066] FIG. 21 is an enlarged partial view of the distal end of another embodiment of the medical device of the present invention.
DETAILED DESCRIPTION
[0067] In a first embodiment of the invention as shown in FIG. 1 , medical device 100 includes a clip 101 having first clip leg 102 and second clip leg 103 . Clip leg 102 has at least one lock hole 104 therein of any suitable shape (e.g. circular, rectangular, square, etc.). Likewise, clip leg 103 has at least one lock hole 105 therein of any suitable shape. Clip 101 is further characterized by a cut-out 106 on the proximal end. J-hook 107 is inserted into cut-out 106 . J-hook 107 is formed on the distal terminal end of control wire 108 . A retainer release 109 is formed by bends in the control wire 108 , the bends formed proximally from the j-hook 107 . The control wire 108 is enclosed within sheath 111 proximally from the retainer release 109 . Retainer 110 is coupled to control wire 108 and engages lock sleeve 113 . Retainer release 109 acts to disengage retainer 110 from lock sleeve 113 when a tensile force applied to control wire 108 is sufficient to cause such disengagement. An outer sleeve 112 is connected on the distal side of sheath 111 , and lock sleeve 113 is connected to a distal side of outer sleeve 112 . Lock sleeve 113 incorporates lock pawl 114 , which engages lock hole 104 in clip leg 102 , and lock pawl 115 , which engages lock hole 105 in clip leg 103 .
[0068] The clip 101 is a deformable, multi-legged, grasping device attached to the distal portion of a flexible shaft (the sheath 111 ) via a frangible link (the j-hook 107 ). The flexible shaft is connected at its proximal end to a handle ( FIG. 7 ), the handle analogous to biopsy forceps. A semi-rigid wire (the control wire 108 ), which is routed from the handle to the clip 101 , acts as a means of actuating the clip 101 between the open and closed position. The clip 101 can be actuated between the open and closed position multiple times as long as the lock holes 104 and 105 do not become engaged with the lock pawls 114 and 115 in the lock sleeve 113 . Once the operator decides the clip 101 should be permanently deployed, the handle can be fully actuated, which causes the retainer release 109 to pull the retainer 110 free from the outer sleeve 112 and lock sleeve 113 . After the retainer 110 is released, increasing force will begin straightening the j-hook 107 . The j-hook 107 is then pulled from the cut-out 106 on the proximal side of clip 101 . At this point, the retainer 110 and control wire 108 are no longer attached to the distal portion of the device (the clip 101 and lock sleeve 113 ) and the delivery device (e.g. an endoscope, not shown) can be removed while leaving the clip 101 (with lock sleeve 113 ) in place.
[0069] The sheath 111 serves three key functions in this embodiment. In its primary function it acts as a housing for the control wire 108 . In this function the sheath 111 supplies a resistive, compressive force opposite the tensile force applied to the control wire 108 , via the handle, as the lever ( FIG. 7 ) in the handle is moved to close the clip 101 . The forces reverse when the lever is moved in the opposite direction, and the control wire 108 is compressed to push the clip 101 forward. In this function, the combination of control wire 108 and sheath 111 act as a simple push-pull, cable actuation mechanism.
[0070] In the secondary function of sheath 111 , it acts as a means by which the clip 101 can be easily rotated. Ideally this rotation would be of a ratio of 1:1. In other words, one complete rotation of the sheath 111 at the proximal end would translate to one complete rotation of the clip 101 . This rotation however, depends on several factors. The relationship of the outside diameter of sheath 111 to the inside diameter of the working channel (not shown) of the endoscope (not shown), is one factor. Another factor is the amount of friction between the sheath 111 and the working channel caused by the path of the endoscope in the anatomy. Because these factors vary from endoscope to endoscope, and patient to patient, the rotation ratio will not always be the same. This ease of rotation is a key function and benefit of this embodiment in that it allows relatively precise orientation of the clip 101 to the vessel. Depending on the exact construction of the sheath 111 , and the other factors just listed, rotation of the device may be different in one direction of rotation versus the other direction. By taking advantage of the mechanical properties of the sheath 111 , this embodiment accomplishes rotation without the need for additional handle components. Eliminating the need for such components will: reduce the overall cost of the device; simplify how the device is operated; and make rotation more repeatable. In turn, all of these benefits will make for a faster procedure with a higher success rate.
[0071] The sheath 111 accomplishes a high rotation ratio by using a spiral wound, multiple-wire, stainless steel, flexible shaft, with an outside diameter of slightly less than the inside diameter of the working channel of the endoscope. Because the sheath 111 is made of a multiple-wire configuration, it is soft and bendable, yet rigid in rotation. In other words, the sheath 111 is flexible enough to be manipulated through a flexible endoscope, but has a very low angle of twist about its central axis.
[0072] In the third function of the sheath 111 , it acts as a component of the mechanism by which the clip 101 is released. The outer sleeve 112 , which is rigidly attached to the sheath 111 by methods known in the prior art (e.g. adhesives, welding, swaging, etc.), is made of a rigid tube, with two retainer cut-outs (not shown), situated 180° apart from each other. These retainer cut-outs house the two tabs 118 , 119 ( FIG. 6 ) of the retainer 110 . As the control wire 108 is actuated, drawing the clip 101 back into the lock sleeve 113 , the retainer release 109 forces the retainer 110 to be disengaged from the outer sleeve 112 .
[0073] FIG. 2 shows the clip 101 in the closed position but prior to release of the j-hook 107 . In the closed, locked position shown in FIG. 2 , lock hole 104 of clip leg 102 is engaged by lock pawl 114 , and lock hole 105 of clip leg 103 is engaged by lock pawl 115 . The fit between the lock sleeve 113 and outer sleeve 112 is such that the lock sleeve 113 (and therefore the clip 101 ) will easily release from the outer sleeve 112 once the j-hook 107 has been straightened and the retainer disengaged from the outer sleeve 112 .
[0074] The clip 101 , shown in FIG. 3 , is manufactured of a single piece of stainless steel, or any suitable biocompatible material, and is bent into a two-legged geometry. The clip legs 102 and 103 have a rectangular cross section of approximately 0.06 inches by 0.01 inches and are approximately 0.50 inches in length. The profile of the legs serves three purposes: first, the distal portion grasps the tissue during the procedure; second, the distal portion acts as the compression mechanism to hold the clip in place after deployment; and third, the profile between the distal grasping portion and the proximal end will interface with the lock pawls (not shown), via lock hole 104 in clip leg 102 and lock hole 105 in clip leg 103 . The interface between the lock holes and the lock pawls creates the mechanical lock that will keep the clip 101 closed after deployment. The proximal end of the clip 101 is formed with a cut-out 106 into which the j-hook ( FIG. 2 ) is attached.
[0075] The lock sleeve 113 shown in FIG. 4 consists of a tubular proximal section, which fits into the distal end of the outer sleeve 112 . Retainer hole 116 and opposite retainer hole (not shown) in the lock sleeve 113 receive the retainer tabs 118 , 119 ( FIG. 6 ). The distal end of the lock sleeve 113 has a lock sleeve cut-out 117 slightly larger than the cross section of the clip legs ( FIG. 3 ). As the clip leg are pulled through cut-out 117 , the clip legs are compressed toward each other, thus compressing the tissue (not shown) situated between the clip legs. The cut-out 117 has lock pawls 114 and 115 , which align with the two lock holes ( FIG. 3 ) in the clip legs. After the desired tissue purchase has been acquired, the clip can be pulled back far enough to engage the lock pawls 114 and 115 into the two lock holes.
[0076] Forming the end of the control wire 108 into a j-hook 107 makes a frangible link shown in FIG. 5 . This relatively simple configuration eliminates extraneous components that take up space and complicate the assembly. The control wire 108 is bent such that it wraps around the proximal end of the clip ( FIG. 3 ), through a cut-out ( FIG. 3 ). Another bend in the wire, proximal to the j-hook 107 , acts as a retainer release 109 . The retainer release 109 operates to release the retainer 110 ( FIG. 6 ) from the lock sleeve 113 ( FIG. 4 ). As the control wire 108 is actuated and the clip is locked into the lock sleeve, the retainer release 109 pulls the retainer 110 back, disengaging the retainer tabs 118 , 119 from the two retainer holes 116 ( FIG. 4 ) in which the retainer normally resides. After this disengagement is complete, the j-hook 107 is then straightened by force, in turn releasing the clip. The j-hook 107 is able to deform to a straightened position (i.e. release) at a predetermined tensile load, which is slightly greater than the load required to grasp the tissue (not shown), compress the tissue, and engage the lock pawls ( FIG. 4 ) in the lock holes ( FIG. 3 ).
[0077] The control wire 108 shown in FIG. 6 is a simple stainless steel wire used to actuate the clip 101 via a handle ( FIG. 7 ), at the proximal end of the sheath ( FIG. 1 ). In this embodiment of the invention, the frangible link (the j-hook 107 ) is formed in the distal end of the control wire 108 as a one-piece design. The proximal end of the control wire 108 is terminated inside the handle. The control wire 108 also has the retainer release 109 formed in it, behind the j-hook 107 . The retainer release 109 causes the outer sleeve ( FIG. 1 ) to disengage from the retainer 110 . This is done sequentially, after the lock holes ( FIG. 3 ) in the clip 101 have engaged the lock sleeve ( FIG. 4 ). After the lock holes engage the lock sleeve, tensile force applied to control wire 108 first straightens j-hook 107 so that j-hook 107 releases from cut-out 106 , then retainer release 109 engages and deforms retainer 110 so that retainer tabs 118 and 119 disengage from the outer sleeve ( FIG. 1 ) and the lock sleeve ( FIG. 4 ). Alternatively, retainer release 109 could engage and deform retainer 110 before j-hook 106 straightens and disengages from cut-out 106 .
[0078] The handle shown in FIG. 7 is attached to the proximal end of the sheath 111 at a sheath-handle attachment point 120 . The handle configuration is unlike a handle found on conventional endoscopic forceps known in the prior art. The handle provides a mechanism by which the amount of linear actuation required in the handle body 121 is greater than that which is translated to the tip of the device ( FIG. 1 ). In other words, actuation of the activator or handle lever 122 of 1.00 inch in turn may only move the clip ( FIG. 3 ) by 0.10 inch. This feature allows for a more tactile feel when placing the clip on the vessel (not shown). In effect, very subtle amounts of movement in the clip can be accomplished by more exaggerated, less precise movements of the operator's hand. This is accomplished because the activator or lever 122 pivots about a pivot point 123 that is close to the attachment point 124 of the control wire 125 .
[0079] An alternative embodiment of the device may be made up of clips with more than two legs. FIGS. 8A through 8E show a clip with four legs. FIG. 8A shows a view from the side, showing clip legs 801 . This embodiment could be actuated and released in the same way the previous embodiment is activated and released, through a clip locking mechanism 802 . The use of a control wire (not shown) would actuate the multiple-legged clip in and out of an outer sleeve 803 until such time that the operator desires to release the clip. Alternatively, actuation of the control wire might move the outer sleeve 803 in and out over the multiple-legged clip to open and close the clip legs 801 , until such time that the operator desires to release the clip. FIG. 8B shows the four-legged clip of FIG. 8A from the perspective of the targeted tissue looking proximally. The four clip legs 801 are shown in an open position and are situated at 90° from each other. FIG. 8C shows a profile view of a single clip leg 801 . FIG. 8D shows a view along the axis of clip locking mechanism 802 . FIG. 8E shows another view of a four-legged clip with clip legs 801 and clip locking mechanism 802 .
[0080] FIG. 8F shows alternative side profiles of the clip geometry. Use of such geometries in a clip with two or more legs allows for improved grasping ability in different situations. Given the large variation in tissue thickness and tissue strength, it is likely that different clip profiles would excel in different procedures. FIG. 8G shows alternative end profiles of the clip geometry. As with the varying side profiles, different end profiles would provide a broader range of grasping capabilities.
[0081] FIGS. 9A and 9B illustrate an alternative embodiment of the device using a different method to lock the clip in the closed position. This alternative method uses an expanded coil spring 901 released over the outside of the clip legs 904 and 905 to lock the clip legs 904 and 905 closed. FIG. 9A shows this embodiment in a predeployment state. FIG. 9A shows a stretched coil spring 901 , twisted to a diameter larger than that of the relaxed state of coil spring 901 . Stretched coil spring 901 is placed over a rigid tube 903 at the distal end of the clip device. Within this similar to the manner described for the previous embodiments), between the opened and closed position via a control wire (not shown). When the desired clip location has been achieved, the sheath 902 is used to push the coil spring 901 off of the rigid tube 903 , onto the clip legs 904 and 905 , as shown in FIG. 9B . The inward radial forces present in the recovered coil spring 901 act to keep the clip legs 904 and 905 compressed.
[0082] FIGS. 10A and 10B illustrate another alternative embodiment. In this embodiment, a flexible linkage 1002 and pill 1003 are used to lock the clip legs 1001 . In this embodiment the clip legs 1001 are actuated via a control wire 1006 , as described in previous embodiments. However, in this embodiment, the clip legs are not closed by pulling the clip legs 1001 through some feature smaller than the open clip. Instead the clip legs 1001 are closed by drawing the two flexible links 1002 proximally, in the direction of the control wire 1006 , while a compressive force is applied to the base of the clip legs 1001 by a rigid sheath (not shown). This in turn pulls the legs of the clip toward each other. FIG. 10A shows the clip legs 1001 in an open position. FIG. 10B shows the clip legs in a closed position. The clip legs 1001 are locked in a closed position when the pill 1003 , located at the center of the flexible linkage 1002 , is drawn through a one way hole 1004 in the center of the clip legs 1001 . The one way hole 1004 is tapered, with a diameter slightly larger than the diameter of the pill 1003 on its distal side and a diameter smaller than the diameter of the pill 1003 on its proximal side. The pill stretches the material around the hole 1004 as it passes through moving proximally. Alternatively, the pill 1003 itself can be made of an elastic material and would deform slightly while passing proximally through hole 1004 . This funneling effect of the pill 1003 through the hole 1004 only allows the pill 1003 to easily pass through in the locking direction. This locking action is maintained after the clip is released by positioning the frangible link 1005 in a proximal direction on control wire 1006 from the pill 1003 , thus maintaining tissue compression. In this embodiment the frangible link 1005 is a taper in control wire 1006 , enabling the link to be broken at a specific position (proximal from the pill 1003 ) with a predetermined tensile load.
[0083] One alternative to the j-hook type frangible link previously described is shown in FIG. 11 . This embodiment uses a threaded fitting that is a combination of a male thread 1103 and a female hub 1102 to attach the control wire (not shown) to the clip 1001 . The clip 1001 can be actuated from the opened position (not shown) to the closed position (shown) as described in previous embodiments. In this embodiment, the lock sleeve 1105 is shorter and engages dimples 1106 . After the lesion (not shown) is properly targeted, the clip 1101 can be released. The clip 1101 is released when a predetermined tensile load is applied to the male thread 1103 , in a similar fashion to the predetermined tensile load applied to straighten the j-hook. This force causes the male thread 1103 to detach from the female hub 1102 . The female hub 1102 may be constructed of a spiral wound wire component with a pitch equal to the thread pitch formed to make the male thread 1103 . The fit of the threaded components is such that the predetermined force will overcome the engaged threads of the male thread 1103 and the female hub 1102 , causing them to separate, or “strip” away from one another.
[0084] Another alternative to the j-hook type frangible link is shown in FIGS. 12A and 12B . This embodiment uses a ball 1202 fitting into a socket, where the socket is defined by socket tabs 1203 , to attach the control wire 1207 to the clip 1201 . An outer sleeve 1204 is attached by way of a breakaway connection (not shown) to the sheath 1206 . This breakaway connection may be a light interference fit, or a light adhesive joint. The breakaway connection must be weak enough that when the sheath 1206 is pulled back through the working channel (not shown) of the endoscope (not shown), the outer sleeve 1204 will release with the clip 1201 . The clip 1201 is released when the socket tabs 1203 at the proximal end of the clip 1201 are aligned with cut-outs 1205 in the outer sleeve 1204 . These cut-outs 1205 act as a relief area into which the socket tabs 1203 can be deformed when a predetermined tensile load is applied to them via the ball 1202 formed on the end of the control wire 1207 . The outer sleeve 1204 is released with clip 1201 so that the clip 1201 remains locked after deployment.
[0085] Another alternative to the j-hook type frangible link is shown in FIGS. 13A, 13B and 13 C. All the figures show the clip 1301 in a closed and locked state. FIG. 13A shows the clip 1301 in a closed position but before it is released and shows a portion of outer sleeve 1303 cut away to show the internal workings of the clip mechanism. FIGS. 13B and 13C show the clip 1301 after being released. In this embodiment, the actuation is still performed via a control wire 1304 , however the direction of action is reversed. As the control wire 1304 is pushed forward, the clip 1301 is closed by the advancement of outer sleeve 1303 and lock ring 1302 over the clip legs. The locking sleeve 1302 and clip geometry, including dimples 1306 , is the same as that explained in the embodiment of FIG. 11 .
[0086] A difference between the embodiment shown in FIGS. 13A, 13B and 13 C and the prior embodiments is the mechanism by which the clip 1301 is released from the rest of the device. An interference fit between the outer sleeve 1303 , sheath 1305 , and male threaded hub 1308 is created when the device is assembled. The distal end of the sheath 1305 , in its manufactured (but unassembled) state, has an outside diameter greater than the inside diameter of the outer sleeve 1303 . When the outer sleeve 1303 and sheath 1305 are assembled together part of the interference fit is created. The distal end of the sheath 1305 , again in its manufactured (unassembled) state, has an inside diameter greater than the diameter of the male threaded hub 1308 . During assembly, as the distal end of the sheath 1305 is compressed to fit inside the outer sleeve 1303 , it is compressed down onto the male threaded hub 1308 to create a sandwich of the sheath 1305 between the male threaded hub 1308 on the inside and the outer sleeve 1303 on the outside. During the medical procedure, at the time the operator wishes to release the clip 1301 , this interference fit is overcome. The interference fit is overcome by advancing the outer sleeve 1303 so far forward, by creating a compressive force in the control wire 1304 in opposition to a tensile force on the sheath 1305 , that the outer sleeve 1303 is no longer in contact with the distal end of the sheath 1305 .
[0087] The outer sleeve 1303 and the control wire 1304 serve two purposes in this embodiment. The outer sleeve 1303 and the control wire 1304 supply the closing force to the clip 1301 . In FIGS. 13A, 13B , and 13 C, a lock ring 1302 is used to maintain the closing force on the clip legs 1307 . The outer sleeve 1303 and the control wire 1304 also act as key components of the release mechanism. As previously described, once the outer sleeve 1303 is moved to its forward-most position, the end of the sheath 1305 is no longer contained within the outer sleeve 1303 , and is free to separate from the male threaded hub 1308 . The sheath 1305 is free to release because of the manner in which the distal end of the sheath 1305 is manufactured/assembled.
[0088] When the outer sleeve 1303 is advanced forward, allowing the distal end of the sheath 1305 to be free, the distal end of the sheath 1305 expands to its original, manufactured state. This allows the inside of the sheath 1305 to release from the male threaded hub 1308 . The male threaded hub 1308 , and thus the clip 1301 , are now free from the sheath 1305 and the rest of the delivery device. As shown in FIG. 13C , the outer sleeve 1303 remains connected to the control wire 1304 at connection point 1310 , and both can be removed with the sheath 1305 . The distal portion of control wire 1304 is bent towards, and connects with, outer sleeve 1303 at connection point 1310 . The distal portion of control wire 1304 passes male threaded hub 1308 during deployment through slot 1309 in male threaded hub 1308 .
[0089] FIGS. 14A, 14B , and 14 C show an alternative embodiment of the present invention. In the embodiment of FIGS. 14A, 14B , and 14 C, the relaxed state of the clip is closed, and it is forced open and allowed to close naturally. FIG. 14A shows a side view of the clip 1401 in a closed, pre-released state, and FIG. 14B shows an edge view of the clip 1401 in a closed, pre-released state. In this embodiment, because the clip 1401 is manufactured such that the clip legs 1407 are naturally closed, the primary function of the control wire 1406 is changed from having to close the clip 1401 , to having to open the clip 1401 . The clip 1401 is manufactured in a generally x-shaped geometry, where each tab 1403 at the proximal end of the clip 1401 controls a clip leg 1407 opposite at the distal end of the clip 1401 . The action/reaction of the clip 1401 is similar to that of a common clothes pin. As the tabs 1403 are brought together, the clip legs 1407 are spread apart. As the tabs 1403 are released, the clip legs 1407 come together. A u-ring 1402 attached to the end of the control wire 1406 is used to bring the tabs 1403 together, thus opening the clip 1401 . Pulling on the control wire 1406 pulls the u-ring 1402 into contact with tabs 1403 creating a compressive force to open clip legs 1407 because clip 1401 is positioned against fulcrum point 1408 . Advancing control wire 1406 advances u-ring 1402 , thereby removing the compressive force on tabs 1403 and allowing clip legs 1407 to close. Advancing control wire 1406 further to a deployment position pushes u-ring 1402 against clip legs 1407 , causing clip 1401 to move out of outer sleeve 1404 into a deployed state.
[0090] The control wire 1406 is constructed of material having a shape memory, and the distal end of the control wire 1406 , where the u-ring 1402 is attached, is pre-bent to one side. While a minimum tension exists in control wire 1406 , the u-ring remains around the constriction. However, when the desired location for the clip 1401 has been achieved, and the clip tabs 1403 have been advanced beyond outer sleeve 1404 , the control wire 1406 can be advanced to its most distal position. Because the control wire 1406 is pre-bent, as it is advanced the u-ring 1402 becomes disengaged from the clip 1401 when the tension in control wire 1406 falls below a pre-determined amount, as shown in FIG. 14C . This allows the clip 1401 to be released.
[0091] FIGS. 15A, 15B , 15 C, and 15 D show another embodiment in which the clip is manufactured in a naturally closed position. FIG. 15A shows the distal end of medical device 1509 with the clip 1501 in a closed position before deployment. FIG. 15B shows only the clip 1501 in a closed position. FIG. 15C shows the clip 1501 in an open position. FIG. 15D shows the device after the clip is released. The clip 1501 is shaped such that, as the control wire 1503 is pulled in a proximal direction, the clip legs 1508 are forced apart from one another. This is accomplished using a pill 1502 attached to the end of the control wire 1503 as explained in previous embodiments. Two rigid arms 1504 , located between the clip legs 1508 , translate the tensile force on the control wire 1503 to an outward radial force on the clip legs 1508 . When the desired location for the clip 1501 has been achieved, the control wire 1503 can be advanced to its most distal position. Because the control wire 1503 is constructed of material that has a shape memory, and because the control wire 1503 is pre-bent close to the pill 1502 , as the control wire 1503 is advanced, the pill 1502 becomes disengaged from the pill well 1507 . When the pill 1502 moves out and away from the pill well 1507 , the clip 1501 is) released and disengages from the control wire 1502 , the sheath 1506 , and the outer sleeve 1505 .
[0092] FIGS. 16A, 16B , 16 C, 16 D, and 16 E show another embodiment in which the clip is manufactured in a naturally closed position. FIG. 16A shows the clip 1607 in a closed, predeployed, state. FIG. 16B shows a side view of one clip leg 1601 with the pill 1603 still resting in pill well 1604 . FIG. 16C shows an edge view of one clip leg 1601 with the pill 1603 still resting in pill well 1604 . FIG. 16D shows a clip 1607 in an open position. FIG. 16E shows a clip 1607 in a closed position. This embodiment uses two control wires 1605 . Alternatively, a branched control wire may be used. By using a branched control wire or two control wires 1605 , the force can be transmitted to a point further away from the fulcrum (bending point) 1606 of the clip 1607 . The greater this distance, the lesser the force required to open the clip legs 1601 . As in the previous embodiments, the control wires 1605 are disengaged from the clip 1607 by pushing them forward. This action disengages the pills 1603 from the clip 1607 by moving the pills 1603 out of pill wells 1604 ; The control wires 1605 are made from a material with a shape memory, so that when freed from pill wells 1604 , the pills 1603 move away from the pill wells 1604 , and the clip 1607 is deployed.
[0093] Another embodiment is shown in FIGS. 17A and 17B . In this embodiment, the control wire or wires 1701 are routed to gain mechanical advantage. In this embodiment, the clip 1702 is naturally closed, with the control wire(s) 1701 routed to leverage points 1704 further away from the fulcrum (bending point) 1705 of the clip 1702 . In this embodiment, the control wire(s) 1701 are looped around pins positioned at leverage points 1704 at the ends of the clip legs 1706 . The control wire(s) 1701 are then routed to a point at the proximal end of the clip. The control wire(s) 1701 are then terminated at this point. For ease of manufacture, the control wire(s) 1701 could essentially be one, continuous wire, with both ends terminated in the handle (not shown). To release the clip 1702 , one end of control wire 1701 could be detached from the handle and pulled free from the clip 1702 . Because the control wire 1701 is only wrapped around pins positioned at leverage points 1704 on the clip 1702 , by pulling on one end of control wire 1701 , control wire 1701 could be easily detached when the desired location for clip 1702 has been achieved by continuing to pull on one end of control wire 1701 until all of control wire 1701 has been detached from the clip 1702 .
[0094] FIGS. 18A, 18B , 18 C, 18 D, 18 E, and 18 F show an embodiment of a clip which incorporates the natural compressive forces present in a simple elastic band (or o-ring) 1802 to hold the clip legs 1801 in the closed position. FIG. 18A shows two clip legs 1801 in a disassembled state. FIG. 18B shows a clip with the control wire 1803 engaging a second elastic band 1804 to open clip legs 1801 . In this embodiment, the control wire 1803 is attached to the proximal end of the clip legs 1801 via a frangible link. In this embodiment, the frangible link is a second elastic band (or o-ring) 1804 that will deform as the control wire 1803 is pulled back. In this embodiment, the clip is housed in the end of a sheath 1806 such that, as the control wire 1803 is pulled back, the second elastic band 1804 delivers an increasing compressive force to the clip legs 1801 proximal to a pin joint 1805 , thereby causing the clip legs 1801 distal from the pin joint to open against the compressive force of elastic band 1802 . In this manner, the clip legs 1801 move to an open position, as shown in FIG. 18B . FIG. 18C shows the clip in a closed, predeployed state. FIG. 18D shows a profile view of clip legs 1801 , and FIG. 18E shows an end-on view of clip legs 1801 within sheath 1806 . FIG. 18F shows a close-up view of clip legs 1801 without first elastic band 1802 but showing band slots 1809 . FIG. 18F shows second elastic band 1804 resting over nubs 1807 and coupled to control wire 1803 . When the desired clip location has been achieved, the second elastic band 1804 , which makes up the frangible link, is overcome by pulling the control wire 1803 to its most proximal position. This has the effect of breaking second elastic band 1804 . Alternatively, second elastic band 1804 could be designed to release over nubs 1807 . In a third alternative, after placing clip legs 1801 in the desired location, control wire 1803 can be released so that elastic band 1802 again closes clip legs 1801 . In this third embodiment, control wire 1803 is made of a suitable material, such as a shape memory material, and has a bend in the distal region such that moving control wire 1803 to a maximum distal position acts to unhook hook 1808 from second elastic band 1804 .
[0095] FIGS. 19A, 19B , and 19 C show another embodiment of the invention utilizing a naturally closed clip. Clip 1901 is held in the naturally closed position by a torsion spring 1903 . The clip 1901 is actuated from the closed to the opened position in a different way than prior embodiments. A plunger 1904 , located within the outer sleeve 1905 at the end of the sheath (not shown), is used to push on the tabs 1906 on the proximal end of the clip 1901 . The tabs 1906 are pushed through an opening 1907 in the end of the outer sleeve 1905 . This moves tabs 1906 close together, in turn moving the clip legs 1902 to the open position. When the desired clip location has been achieved, the clip 1901 can be released by advancing the plunger 1904 to its most distal position. FIG. 19B shows the clip 1901 from a profile view. FIG. 19C shows a single clip leg 1902 and connection point 1908 for pivotally connecting clip legs 1902 to each other.
[0096] FIGS. 20A, 20B , and 20 C describe the embodiment of a three-legged clip and delivery device. The clip 2001 is manufactured to be in the naturally open position. The clip 2001 is characterized by male threads 2002 on its outer surface. The delivery device consists of a sheath 2003 similar to those described in previous embodiments. An inner sleeve 2004 located within the distal end of the sheath 2003 is used to actuate the clip 2001 from its naturally open position to the closed position. The inner sleeve 2004 has female threads (not shown) on its inside diameter. A control wire (not shown) is used in this device to transmit rotational force rather than tensile/compressive force. Rotating the sheath 2003 with respect to the control wire, with the handle (not shown) actuates the clip 2001 . This rotation force is translated to the female threads, causing them to be threaded onto the clip 2001 . As the naturally open clip legs 2005 move toward the inner sleeve 2004 , the clip legs 2005 are closed. The clip 2001 and inner sleeve 2004 are released from the sheath 2003 via some form of frangible link (not shown) as described in the previous embodiments. FIG. 20A shows the clip legs 2005 and inner sleeve 2004 from the perspective of the target area. FIG. 20C shows the size relationship between the female threads on the inner sleeve 2004 and the male threads 2002 on the clip 2001 .
[0097] FIG. 21 shows another embodiment of a naturally open clip and delivery device. FIG. 21 shows the distal portion of the medical device with a portion of the outer sleeve 2102 cut away to show the inner mechanics of the clipping device. The delivery device consists of a sheath 2103 similar to those described in previous embodiments. The clip 2101 is actuated from the open to the closed position via a control wire 2104 , as described in the primary embodiment. A frangible link is implemented in this embodiment by a breakable link 2105 . In this embodiment the lock sleeve is eliminated. Eliminating the lock sleeve reduces the number of components and the overall size of the device. In this embodiment the outer sleeve 2102 is used to hold the clip 2101 in the closed position. Therefore, the outer sleeve 2102 must be deployed from the sheath 2103 when the clip 2101 is released. To create a positive mechanical lock between the clip 2101 and outer sleeve 2102 , the clip 2101 has two deformable tabs 2106 formed in its proximal end. When the desired tissue purchase has been accomplished, the control wire 2104 is further actuated by the handle (not shown) so that the tabs 2106 reach a position where they are in the same plane as the cut-outs 2107 in the outer sleeve 2102 . Once the tabs 2106 have reached this point, further actuation of the control wire 2104 forces the tabs 2106 to deform through the cut-outs 2107 in the outer sleeve 2102 . As in the first embodiment, a retainer 2108 is used to create a mechanical lock between the sheath 2103 and outer sleeve 2102 . In this embodiment the retainer 2108 passes through slots 2109 in the outer sleeve 2102 and a sheath connector 2110 . The sheath connector 2110 is simply a rigid connector, applied to the end of the sheath 2103 by some means known in the art (e.g. welding, adhesive, swaging, etc.). As the tabs 2106 become engaged, a tensile load in the control wire 2104 is translated to the breakable link 2105 . At a predetermined tensile load, the breakable link 2105 breaks. As the control wire 2104 is further actuated, a distal portion of control wire 2104 , which is preformed into a shape that will function as a retainer release, engages the retainer 2108 . The retainer 2108 is pulled from the outer sleeve 2102 by the control wire 2104 , in a similar manner to that described in the primary embodiment. Once this is done, the sheath connector 2110 (and therefore the sheath 2103 ) is released from the outer sleeve 2102 .
[0098] The materials utilized in construction of the clip of the present invention include many bio-compatible materials (metals, polymers, composites, etc.). A stainless steel grade material, which offers good spring properties, may be used. The clip can also be coated, or plated, with a material like gold to improve radiopacity.
[0099] The lock sleeve, lock pawls, retainer and outer sleeve may be comprised of any of the same materials as the clip component. For example, stainless steel may be used.
[0100] The control wire in the first embodiment may be a stainless steel wire. Because the wire must offer sufficient strength in both tension and compression, the material properties of the wire are important to the functionality of the device. Also, the end of the wire, where the j-hook is formed, must deform when a predetermined tensile load is applied. The device's ability to release the clip is dependent on this property. Other embodiments of the device may incorporate a two (or more) piece wire so that certain sections of the wire have different material properties or geometries. Different material properties or geometries could allow for more control over how and when the wire detaches from the distal tip of the device. This could also be accomplished by several other methods, as well. For example, localized heat treating and/or coatings could be used along portions of the wire to alter the material characteristics. Additionally, some embodiments of the present invention require a control wire constructed of a material with a shape memory.
[0101] The sheath, in the first embodiment, is made up of several round, stainless steel wires, wound in a helical pattern to create a hollow, semi-rigid shaft. Sheaths made in this fashion are well known in the prior art. In other embodiments, the sheath could be made up of non-round wires. Other embodiments may be made up of one or more wires formed in a pattern other than a single helix, as in the first embodiment. A multiple-helix or braided pattern may be used. The sheath may also be coated with a protective coating of Polytetrafluoroethylene (PTFE), or similar materials. The use of such coatings could be used to alter the flexibility of the shaft. Such coatings could also be used to increase the lubricity (decrease the coefficient of friction) between the endoscope working channel and the device. Similar materials could also be used to encapsulate the sheath's base material. This would create a matrix material, providing a combination of material properties not feasible with one single material. Other embodiments may use materials other than stainless steel as the base material. Materials such as titanium, nitinol, and/or nylon fibers may be incorporated.
[0102] A method of using the endoscopic hemostatic clipping device is provided. The method involves placing an endoscope in a body cavity as is known in the art. The device provided herein is then inserted through the endoscope. At the distal end, the endoscope is positioned near the target area. As noted above, the target area may be a lesion, a bleeding ulcer, a tumor, other abnormality, or any number of other tissues to be pinched, marked, tagged, or to which the operator wishes to apply a pinching pressure for whatever reason. The device provided is then positioned so that the clip legs embrace the target area, then the actuator is activated to close the clip legs. The success or failure of the application of pressure can be reviewed through the optical components provided separately in the endoscope. If the pinching is unsuccessful or only marginally successful, the clip legs of the device may be opened by reversing the actuation of the activator. Alternatively, if the pinching is successful, and the operator wishes to deploy the device, the actuator is fully activated, or the alternative deployment activator is activated. Finally, the remaining portion of the medical device and the endoscope are removed from the body.
[0103] It will be obvious to those skilled in the art, having regard to this disclosure, that other variations on this invention beyond those specifically exemplified here may be made. These variations include, but are not limited to, different combinations of clips, closing mechanisms, locking mechanisms, frangible links, and clip leg formations. Such variations are, however, to be considered as coming within the scope of this invention as limited solely by the following claims. | Medical device used to cause hemostasis of blood vessels using a clip arrangement delivered to a target region through an endoscope. Method for using the device to cause hemostasis of a blood vessel through an endoscope. Medical device including a reversibly closeable clip, a locking arrangement, a control wire, a sheath, and a handle with an actuating trigger. Through the endoscope, hemostatic clipping device that is fully reversible and lockable. Hemostatic clip that reversibly targets and clips bleeding ulcers. | 0 |
This application is a division of application Ser. No. 08/529,199, filed Sep. 15, 1995 now abandoned.
The present invention relates to the field of surgical repair of injuries of the anterior cruciate ligament in the human knee using a substantially immunologically compatible ligament or tendon from a non-human animal to replace the damaged human anterior cruciate ligament.
BACKGROUND OF THE INVENTION
The anterior cruciate ligament of the knee (hereinafter the ACL) functions to resist anterior displacement of the tibia from the femur at all flexion positions. The ACL also resists hyperextension and contributes to rotational stability of the fully extended knee during internal and external tibial rotation. The ACL may play a role in proprioception. Structurally, the ACL attaches to a depression in the front of the intercondyloid eminence of the tibia extending postero-superiorly to the medial wall of the lateral femoral condyle.
Partial or complete tears of the ACL are very common, comprising about 30,000 outpatient procedures in the U.S. each year. The preferred treatment of the torn ACL is ligament reconstruction, using a bone-ligament-bone autograft. Cruciate ligament reconstruction has the advantage of immediate stability and a potential for immediate vigorous rehabilitation. However, the disadvantages to ACL reconstruction are significant: for example, normal anatomy is disrupted when the patellar tendon or hamstring tendons are used for the reconstruction; placement of intraarticular hardware is required for ligament fixation; and anterior knee pain frequently occurs. Moreover, recent reviews of cruciate ligament reconstruction indicate an increased risk of degenerative arthritis with intraarticular ACL reconstruction in large groups of patients.
A second method of treating ACL injuries, referred to as "primary repair", involves suturing the torn structure back into place. Primary ACL repair has the potential advantages of a limited arthroscopic approach, minimal disruption of normal anatomy, and an out-patient procedure under a local anesthetic. The potential disadvantage of primary cruciate ligament repair is the perception that over the long term ACL repairs do not provide stability in a sufficient number of patients, and that subsequent reconstruction may be required at a later date. The success rate of anterior cruciate ligament repair has generally hovered in the 60% to 70% range.
Much of the structure and many of the properties of original tissues may be retained in transplants through use of xenogeneic or heterograft materials, that is, tissue from a different species than the graft recipient. For example, tendons or ligaments from cows or other animals are covered with a synthetic mesh and transplanted into a heterologous host in U.S. Pat. No. 4,400,833. Flat tissues such as pig pericardia are also disclosed as being suitable for heterologous transplantation in U.S. Pat. No. 4,400,833. Bovine peritoneum fabricated into a biomaterial suitable for prosthetic heart valves, vascular grafts, burn and other wound dressings is disclosed in U.S. Pat. No. 4,755,593. Bovine, ovine, or porcine blood vessel heterografts are disclosed in WO 84/03036. However, none of these disclosures describe the use of a xenograft for ACL replacement.
Xenograft materials must be chemically treated to reduce immunogenicity prior to implantation into a recipient. For example, glutaraldehyde is used to cross-link or "tan" xenograft tissue in order to reduce its antigenicity, as described in detail in U.S. Pat. No. 4,755,593. Other agents such as aliphatic and aromatic diamine compounds may provide additional crosslinking through the sidechain carboxyl groups of aspartic and glutamic acid residues of the collagen polypeptide. Glutaraldehyde and diamine tanning also increases the stability of the xenograft tissue.
Xenograft tissues may also be subjected to various physical treatments in preparation for implantation. For example, U.S. Pat. No. 4,755,593 discloses subjecting xenograft tissue to mechanical strain by stretching to produce a thinner and stiffer biomaterial for grafting. Tissue for allograft transplantation is commonly cryopreserved to optimize cell viability during storage, as disclosed, for example, in U.S. Pat. No. 5,071,741; U.S. Pat. No. 5,131,850; U.S. Pat. No. 5,160,313; and U.S. Pat. No. 5,171,660. U.S. Pat. No. 5,071,741 discloses that freezing tissues causes mechanical injuries to cells therein because of extracellular or intracellular ice crystal formation and osmotic dehydration.
SUMMARY OF THE INVENTION
The present invention provides a substantially non-immunogenic ligament or tendon heterograft for implantation into a human in need of ACL repair. The invention further provides methods for processing xenogeneic ligaments with reduced immunogenicity but with substantially native elasticity and load-bearing capabilities for heterografting into humans. The method of the invention, which may include, alone or in combination, treatment with radiation, one or more cycles of freezing and thawing, treatment with a chemical cross-linking agent, treatment with alcohol, or ozonation, provides a heterograft having substantially the same mechanical properties of a native ligament.
In one embodiment, the invention provides an article of manufacture comprising a substantially non-immunogenic ligament heterograft for implantation into a human.
In another embodiment, the invention provides a method of preparing an ligament heterograft for implantation into a human, which comprises removing at least a portion of a ligament from a knee joint of a non-human animal to provide a heterograft; washing the heterograft in water and alcohol; and subjecting the heterograft to at least one treatment selected from the group consisting of exposure to ultraviolet radiation, immersion in alcohol, ozonation, and freeze/thaw cycling, whereby the heterograft has adequate mechanical properties to perform as a substitute ligament.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The xenogeneic ligament or tendon heterograft produced in accordance with the method of the invention is substantially non-immunogenic, while generally maintaining the mechanical properties of a native ligament. While the ligament may undergo some shrinkage during processing, a xenogeneic ligament heterograft prepared in accordance with the invention will have the general appearance of a native ligament. The xenogeneic ligament heterograft may also be cut into segments, each of which may be implanted into the knee of a recipient as set forth below.
The invention provides, in one embodiment, a method for preparing or processing a xenogeneic ligament or tendon for engraftment into humans. As defined herein, "xenogeneic" means originate from any non-human animal. Thus ligament or tendon may be harvested from any non-human animal to prepare the heterografts of the invention. Ligament from transgenic non-human animals or from genetically altered non-human animals may also be used as heterografts in accordance with the present invention. Preferably, bovine, ovine, or porcine knee joints serve as sources of the ligament used to prepare the heterografts. More preferably, immature pig, calf or lamb knee joints are the sources of the ligament, since the tissue of younger animals may be inherently more elastic and engraftable than that of older animals. Most preferably, the age of the source animal is between six and eighteen months at time of slaughter. Additionally, the patellar tendon, the anterior or posterior cruciate ligaments, the Achilles tendon, or the hamstring tendons may be harvested from the animal source and used as a donor ligament.
In the first step of the method of the invention, an intact ligament or tendon is removed from the knee of a non-human animal. The joint which serves as the source of the ligament should be collected from freshly killed animals and preferably immediately placed in a suitable sterile isotonic or other tissue preserving solution. Harvesting of the joints should occur as soon as possible after slaughter of the animal and should be performed in the cold, i.e., in the approximate range 5-20° C., to minimize enzymatic and/or bacterial degradation of the ligament tissue. The ligament are harvested from the joints in the cold, under strict sterile technique. The joint is opened by standard surgical technique. Preferably, the ligament is harvested with a block of bone attached to one or both ends, although in some forms of the invention the ligament alone is harvested. In one form of the invention, a block of bone representing a substantially cylindrical plug of approximately forty millimeters in diameter by forty millimeters in depth may be left attached to the ligament. The ligament is carefully identified and dissected free of adhering tissue, thereby forming the heterograft.
The heterograft is then washed in about ten volumes of sterile cold water to remove residual blood proteins and water soluble materials. The heterograft is then immersed in alcohol at room temperature for about five minutes, to sterilize the tissue and to remove non-collagenous materials. After alcohol immersion, the heterograft may be directly implanted into a knee. Alternatively, the heterograft may be subjected to at least one of the treatments set forth below. When more than one treatment is applied to the heterograft, the treatments may occur in any order. In one embodiment of the method of the invention, the heterograft may be treated by exposure to radiation, for example, by being placed in an ultraviolet radiation sterilizer such as the Stragene™ Model 2400, for about fifteen minutes. In another embodiment, the heterograft may be treated by again being placed in an alcohol solution. Any alcohol solution may be used to perform this treatment. Preferably, the heterograft is placed in a 70% solution of isopropanol at room temperature. In another embodiment, the heterograft may be subjected to ozonation.
In another embodiment, the heterograft may be treated by freeze/thaw cycling.
For example, the heterograft may be frozen using any method of freezing, so long as the heterograft is completely frozen, i.e., no interior warm spots remain which contain unfrozen tissue. Preferably, the heterograft is dipped into liquid nitrogen for about five minutes to perform this step of the method. More preferably, the heterograft is frozen slowly by placing it in a freezer. In the next step of the freeze/thaw cycling treatment, the heterograft is thawed by immersion in an isotonic saline bath at room temperature (about 25° C.) for about ten minutes. No external heat or radiation source is used, in order to minimize fiber degradation.
The heterograft may optionally be exposed to a chemical agent to tan or crosslink the proteins within the interstitial matrix, to further diminish or reduce the immunogenic determinants present in the heterograft. Any tanning or crosslinking agent may be used for this treatment, and more than one crosslinking step may be performed or more than one crosslinking agent may be used in order to ensure complete crosslinking and thus optimally reduce the immunogenicity of the heterograft. For example, aldehydes such as glutaraldehyde, formaldehyde, adipic dialdehyde, and the like, may be used to crosslink the collagen within the interstitial matrix of the heterograft in accordance with the method of the invention. Other suitable crosslinking agents include aliphatic and aromatic diamines, carbodiimides, diisocyanates, and the like. When glutaraldehyde is used as the crosslinking agent, for example, the heterograft may be placed in a buffered solution containing about 0.05 to about 5.0% glutaraldehyde and having a pH of about 7.4. Any suitable buffer may be used, such as phosphate buffered saline or trishydroxymethylaminomethane, and the like, so long as it is possible to maintain control over the pH of the solution for the duration of the crosslinking reaction, which may be from one to fourteen days, and preferably from three to five days. The crosslinking reaction should continue until the immunogenic determinants are substantially removed from the xenogeneic tissue, but the reaction should be terminated prior to significant alterations of the mechanical properties of the heterograft. When diamines are also used as crosslinking agents, the glutaraldehyde crosslinking should occur after the diamine crosslinking, so that any unreacted diamines are capped. After the crosslinking reactions have proceeded to completion as described above, the heterograft should be rinsed to remove residual chemicals, and 0.01-0.05 M glycine may be added to cap any unreacted aldehyde groups which remain.
Prior to treatment, the outer surface of the heterograft may optionally be pierced to increase permeability to agents used to render the heterograft substantially non-immunogenic. A sterile surgical needle such as an 18 gauge needle may be used to perform this piercing step, or, alternatively a comb-like apparatus containing a plurality of needles may be used. The piercing may be performed with various patterns, and with various pierce-to-pierce spacings, in order to establish a desired access to the interior of the heterograft. Piercing may also be performed with a laser. In one form of the invention, one or more straight lines of punctures about three millimeters apart are established circumferentially in the outer surface of the heterograft.
Prior to implantation, the ligament or tendon heterograft of the invention may be treated with limited digestion by proteolytic enzymes such as ficin or trypsin to increase tissue flexibility, or with glycosidases to remove surface carbohydrate moieties, or coated with anticalcification agents, antithrombotic coatings, antibiotics, growth factors, or other drugs which may enhance the incorporation of the heterograft into the recipient knee joint. The ligament heterograft of the invention may be further sterilized using known methods, for example, with additional glutaraldehyde or formaldehyde treatment, ethylene oxide sterilization, propylene oxide sterilization, or the like. The heterograft may be stored frozen until required for use.
The ligament or tendon heterograft of the invention, or a segment thereof, may be implanted into a damaged human knee joint by those of skill in the art using known arthroscopic surgical techniques. Specific instruments for performing arthroscopic techniques are known to those of skill in the art, which ensure accurate and reproducible placement of ligament implants. Initially, complete diagnostic arthroscopy of the knee joint is accomplished using known methods. The irreparably damaged ligament is removed with a surgical shaver. The anatomic insertion sites for the ligament are identified and drilled to accommodate a 10 millimeter bone plug. The xenogeneic ligament is brought through the drill holes and affixed with interference screws. Routine closure is performed.
Those of skill in the art will recognize that the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The presently described embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all variations of the invention which are encompassed within the meaning and range of equivalency of the claims are therefor intended to be embraced therein. | The invention provides an article of manufacture comprising a substantially non-immunogenic ligament or tendon heterografts for implantation into humans. The invention further provides a method for preparing an ligament heterograft by removing at least a portion of an ligament from a non-human animal to provide a heterograft; washing the heterograft in saline and alcohol; subjecting the heterograft to at least one treatment selected from the group consisting of exposure to ultraviolet radiation, immersion in alcohol, ozonation, freeze/thaw cycling, and optionally to chemical crosslinking. In accordance with the invention the heterograft has substantially the same mechanical properties as the native xenogeneic ligament. | 0 |
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a method for operating a torque-transmitting system,
which is coupled on the input side to an output shaft of a drive unit and on the output side to an input shaft of a transmission arrangement, so that a torque flux runs from the drive unit to the transmission arrangement via the torque-transmitting system, and which comprises: a hydrodynamic torque converter via which a hydraulic path of the torque flux runs, a lockup clutch which is arranged functionally parallel to the torque converter and via which a mechanical path of the torque flux runs, and a control unit which controls distribution of the torque flux between the hydraulic path and the mechanical path in such a way that a predetermined overall torque profile is set at the input shaft of the transmission arrangement.
The invention also relates to a torque-transmitting system,
which is coupled on the input side to a drive shaft of a drive unit and on the output side to an input shaft of a transmission arrangement, so that a torque flux runs from the drive unit to the transmission arrangement via the torque-transmitting system, and which comprises: a hydrodynamic torque converter via which a hydraulic path of the torque flux runs, a lockup clutch which is arranged functionally parallel to the torque converter and via which a mechanical path of the torque flux runs, and a control unit which controls distribution of the torque flux between the hydraulic path and the mechanical path in such a way that a predetermined overall torque profile is set at the input shaft of the transmission arrangement.
PRIOR ART
Such methods and devices are known from DE 195 04 935 A1.
This document discloses a torque-transmitting system of a engine vehicle between a drive unit which is connected upstream and a transmission which is connected downstream. The system comprises a hydrodynamic torque converter and a slip-controlled lockup clutch.
The use of hydrodynamic torque converters for transmitting a torque from a drive unit to a transmission has been known for a long time. In particular during starting processes it is known to transmit the entire torque via this hydraulic path. However, in the case of high rotational speeds at the transmission input, the torque transmission via a purely mechanical path is usually more favorable. Hydrodynamic torque converters are therefore typically arranged parallel to a lockup clutch, which can be embodied, for example, as a friction clutch. In classic starting processes, the vehicle is then frequently started by means of the torque converter with the lockup clutch open, and the lockup clutch is closed when sufficient rotational speeds are reached, so that the torque is transmitted via the mechanical path.
However, in particular in conjunction with modern electric drives or hybrid drives, the requirements made of the torque branching during the transmission have significantly increased in complexity. Against the background of a use of energy which is as efficient as possible, in modern vehicles there is frequently a change in the working point of the drive unit in order to allow the latter to run as continuously as possible in the most efficient operating mode. In this context torque jumps may occur on the output side of the torque-transmitting system, which are sensed by the driver of the engine vehicle as unpleasant and unpredictable.
The cited document combats this problem by means of slip control of the lockup clutch. This is advantageous in terms of energetic considerations.
OBJECT OF THE INVENTION
The object of the present invention is to make the generic torque-transmitting systems and their operating methods more efficient.
PRESENTATION OF THE INVENTION
This object is achieved in conjunction with the features of the preamble of the primary method claim, by means of the following method steps which are carried out by means of the control unit:
determination of the torque which is currently transmitted by the lockup clutch, comparison of the determined torque with a predetermined setpoint overall torque and calculation of a corresponding difference torque, determination of the current output speed of the torque converter, calculation of a setpoint input speed of the torque converter which would be necessary to transmit the difference torque via the hydraulic path when the output speed is determined, and setting of the output speed of the drive unit to the calculated input speed or a value which corresponds thereto taking into account intermediately connected transmission elements.
This object is also achieved in conjunction with the features of the preamble of the primary device claim in that the control unit:
determines the torque which is currently transmitted by the lockup clutch, compares the determined torque with a predetermined setpoint overall torque and calculates a corresponding difference torque, determines the current output speed of the torque converter, calculates a setpoint input speed of the torque converter which would be necessary to transmit the difference torque via the hydraulic path when the output speed is being determined, and sets the output speed of the drive unit to the calculated input speed or a value which corresponds thereto taking into account intermediately connected transmission elements.
Advantageous embodiments and developments of the invention are the subject matter of the dependent claims.
The core of the invention is to dispense with the slip control of the lockup clutch, which is replaced by a speed control of the input side of the hydrodynamic converter. If a changeover is necessary, for example during the starting process for the hybrid vehicle, from a torque flux which is transmitted completely or mainly via the mechanical path to a torque flux which is transmitted mainly or completely via the hydraulic path, in order, for example, to allow the drive unit to operate at a more favorable operating point, the lockup clutch can be opened essentially without a process, i.e. without slip control. The value of the torque transmitted via the mechanical branch, which decreases in the process, is continuously determined. This determination can be carried out by direct measurement of the torque transmitted at the lockup clutch or by a calculation. The preferred case of calculation requires knowledge of a torque characteristic curve, which represents the respectively transmitted torque as a function of the clutch position. The clutch position can either be measured or is known on the basis of the actuation, for example with actuating engines or stopping engines. The torque which is actually transmitted via the lockup clutch is compared with a setpoint overall torque. That torque which is to be applied to the input of the transmission arrangement is to be understood as the setpoint overall torque. This can be determined, for example, by the driver's request, expressed, for example, by the position of the accelerator pedal or by a control unit. It is to be noted that this is not a static torque, or rather typically a torque profile which varies over time. In particular embodiments, said torque profile can be predefined or extrapolated by means of suitable models.
The comparison of the torque which is transmitted by the lockup clutch with the setpoint overall torque leads to the calculation of a difference torque. The difference torque is that torque which has to be additionally transmitted to the torque transmitted by the lockup clutch by the torque converter, so that the setpoint torque is present at the transmission input as a sum of the partial torques which are transmitted via the mechanical path and the hydraulic path.
Subsequently, the system attempts also to transmit the difference torque actually via the torque converter. The essential criterion here is to transmit this torque at the rotational speed which is currently present at the transmission input, i.e. essentially the current output speed of the torque converter. A typical torque converter has a design-related passive transmission characteristic. This relates the transmitted torque at a given output speed to an input speed of the converter. Given knowledge of this transmission characteristic, it is therefore possible to calculate the input speed of the converter which is necessary to transmit the difference torque at the current output speed of the converter. This calculation takes place in the control unit. For the purpose of implementation, the drive unit is set to the corresponding rotational speed.
A corresponding method with the same determination steps, calculation steps and setting steps can also be used in the opposite case of the closing of the lockup clutch.
As mentioned, the knowledge of the passive transmission characteristic of the converter is necessary to calculate the setpoint input speed of the torque converter. In one embodiment of the invention there is provision that the calculation is carried out on the basis of stored computational rules which take into account the passive transmission characteristics of the torque converter, i.e. the setpoint input speed is continuously newly calculated using stored formulas and algorithms. Alternatively or additionally, the setpoint input speed of the torque converter can be calculated on the basis of a stored characteristic diagram, i.e. can be read off essentially from corresponding tables. Combinations of the two methods can comprise, for example, a rough calculation by reading from a rough characteristic curve diagram and fine adjustment by extrapolation or interpolation.
The drive unit can comprise one or more electric engines and/or one or more internal combustion engines. In the case of the internal combustion engine, it is to be noted that the latter always requires a minimum speed in the switched-on state. This can be taken into account by virtue of the fact that the method according to the invention is carried out under the peripheral condition of a minimum output speed of the internal combustion engine. In the case of a hybrid drive, this can mean that the internal combustion engine is switched off as soon as there is the risk of the minimum output speed being undershot. Alternatively, in such a situation it is also possible to use an additional slip control of the lockup clutch.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 shows a schematic illustration of the design of a torque-transmitting system,
FIG. 2 shows a schematic illustration of the profiles for the torque and rotational speed within the scope of the method according to the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows, in a highly schematic illustration, a torque-transmitting system 10 which is suitable for applying the present invention. The torque-transmitting system 10 connects a drive unit 12 to a transmission 14 , connected downstream, of an engine vehicle. The transmission 14 is typically connected to further components of a drive train (not illustrated). The illustrated torque-transmitting system 10 comprises a hydrodynamic torque converter 16 and a lockup clutch 18 which is connected in parallel therewith and is embodied in the present case as a friction clutch. At a front branching point 20 , which constitutes an interface between the torque-transmitting system 10 and the drive unit 12 , the torque flux branches into a hydraulic path 22 , which leads via the hydrodynamic converter 16 , and into a mechanical path 24 , which leads via the lockup clutch 18 . In a rear branching point 26 , which constitutes an interface between the torque-transmitting system 10 and the transmission 14 , the paths 22 , 24 are combined again. Depending on the setting of the system, the overall torque which is supplied by the drive unit 12 can flow completely via the hydraulic path 22 , completely via the mechanical path 24 or partially via the hydraulic path 22 and partially via the mechanical path 24 .
FIG. 1 shows, in an illustration using dashed lines, a further drive unit 12 ′ and further torque-transmitting elements 16 ′, 16 ″ and 18 ′, 18 ″, respectively. This is intended to indicate that the present invention is not restricted to systems with an engine 12 , a hydrodynamic converter 16 and a lockup clutch 18 . Instead, it can also be applied to extended systems with basically any desired number of engines and any desired number of torque-transmitting elements.
FIG. 2 shows purely by way of example and in a highly schematic form the profile of torques and rotational speeds in an arrangement according to FIG. 1 when the method according to the invention is applied. The graph 112 shows the overall torque which is output to the drive train. In the illustrated example, the overall torque 112 is to be kept constant according to the driver's request or according to a presetting by a superordinate control device. The graph 113 shows the drive torque which is generated by the drive unit. The graph 122 shows the partial torque which is transmitted via the hydraulic path 22 . The graph 124 shows the partial torque which is transmitted via the mechanical path.
The graph 116 shows the rotational speed applied on the input side of the torque converter 16 . Said rotational speed corresponds to the output speed of the drive unit 12 in an arrangement according to FIG. 1 . In other embodiments it is basically conceivable that the transmission stage be arranged between the output of the drive unit 12 and the input of the torque converter 16 , which transmission stage has to be taken into account in the implementation of the method according to the invention. The significant concept of the invention is, however, easier to recognize for a person skilled in the art on the basis of the simplified cases illustrated in the figures.
FIG. 2 reflects a scenario in which the engine torque 113 is firstly transmitted completely via the mechanical path 24 . In other words, the drive occurs with the clutch 18 closed. The transmitted overall torque 112 is therefore initially equal to the partial torque 124 which is transmitted via the mechanical path 24 and equal to the engine torque 113 . The partial torque 122 which is transmitted via the hydraulic path is essentially zero. In this situation, the drive unit 12 operates at a comparatively low rotational speed level 116 .
If the drive unit 12 is, for example, an electric engine, it may be the case that disadvantageously high currents have to flow in order to apply a high overall torque 112 at a low rotational speed 116 . If, on the other hand, the drive unit 12 is an internal combustion engine it may be the case, for example, that the applied low rotational speed 116 is not sufficient to produce the required overall torque 112 or that the internal combustion engine operates at an unfavorable operating point considered in terms of consumption. For these or other reasons, a control unit (not illustrated in more detail) may make the decision to shift the current working point of the drive unit 12 to a relatively high rotational speed. However, this is to take place without adverse effects on the comfort for the driver and in particular without jumps in torque or rotational speed at the input of the transmission 14 .
Therefore, at the time t 1 when the method according to the invention is applied, a change of working point is initiated which is terminated at the time t 2 . The lockup clutch 18 is opened during the change of working point. The opening takes place essentially without a process, i.e. through direct actuation and without control mechanisms, like a slip control, for example. The opening of the lockup clutch 18 causes the partial torque 124 transmitted via the mechanical path 24 to drop to zero in the completely opened state of the lockup clutch 18 . It is to be noted that complete opening of the clutch 18 is not absolutely necessary, but rather is assumed here only for the sake of illustration. This drop in the partial torque 124 is recorded by the control unit. This advantageously occurs on the basis of a known torque characteristic curve which is stored in the memory of the control unit, and by means of which the maximum torque which can be transmitted as a function of the clutch position is known. Furthermore, the required overall torque 112 is known to the control unit. In order to determine said overall torque 112 it is possible to use any desired methods which can comprise, for example, interpretation of an accelerator pedal position as a driver's request, presettings of an automatic controller with or without interpolations or extrapolations of the chronological torque profile.
From the required overall torque 112 and the mechanically transmitted partial torque 124 which has dropped during the transition, the control unit determines a difference torque. In order to make available the overall torque 112 , the difference torque has to be transmitted via the hydraulic path 22 in addition to the partial torque 124 which is transmitted via the mechanical path 24 , and said difference torque therefore corresponds to the partial torque 122 which is transmitted via the torque converter 16 and which has to be correspondingly raised during the transition between t 1 and t 2 .
The raising of the partial torque 122 which is transmitted via the hydraulic branch 22 is carried out with rotational speed control of the drive unit 12 . For this purpose, the passive characteristic of the torque converter 16 must be known to the control unit, for example in the form of a stored characteristic diagram. The control unit can therefore calculate which input speed has to be present at the torque converter 16 for the latter to supply the required torque at its output at the current output speed. This calculated rotational speed is then set at the drive unit, wherein transmission stages which are possibly intermediately shifted are taken into account. In this context, the converter increase 117 is taken into account so that after t 2 the engine torque 113 is lower than before t 1 . Furthermore, during the transition between t 1 and t 2 the composition of the torque of the static component 114 and dynamic component 115 is taken into account.
As a result, in the illustrated embodiment the overall torque profile 112 at the output is constant while the torque is transmitted from the mechanical branch 24 to the hydraulic branch 22 , specifically with control of the rotational speed of the drive unit 12 . The clutch 18 can be opened essentially without a process.
Of course, the embodiments discussed in the specific description and shown in the drawings are only illustrative exemplary embodiments of the present invention. In light of this disclosure, a person skilled in the art is provided with a wide spectrum of variation possibilities. In particular, the design and number of the torque-transmitting elements, 16 , 16 ′, 16 ″, . . . and 18 , 18 ′, 18 ″, . . . as well as the number and design of the drive units 12 , 12 ′, . . . can be freely selected by a person skilled in the art in accordance with the respective individual case.
List of Reference Numerals
10 Torque-transmitting system 12
12 Drive unit
12 ′ Drive unit
14 Transmission
16 Hydraulic torque converter
16 ′ Further torque-transmitting element
16 ″ Further torque-transmitting element
18 Lockup clutch
18 ′ Further torque-transmitting element
18 ″ Further torque-transmitting element
20 Front branching point
22 Hydraulic path
24 Mechanical path
26 Rear branching point
112 Graph of the overall torque
113 Engine torque
114 Static component of 113
115 Dynamic component of 113
116 Graph of the rotational speed at the input of 16
117 Converter increase
122 Partial torque transmitted via 22
124 Partial torque transmitted via 24 | A method for operating a torque-transmitting system, which is coupled on the input side to an output shaft of a drive assembly and on the output side to an input shaft of a transmission. A torque flux from the drive assembly to the transmission passes via the torque-transmitting system. The torque-transmitting system includes a hydrodynamic torque converter via which a hydraulic path of the torque flux passes, a converter lockup clutch which is arranged functionally in parallel with the torque converter and via which a mechanical path of the torque flux passes, and a control unit which controls distribution of the torque flux between the hydraulic and mechanical paths in such a way that a predetermined overall torque profile is established at the input shaft of the transmission. | 8 |
BACKGROUND OF THE INVENTION
The double glazing of windows is well known for the purpose of heat insulation and to reduce solar heat loads, and it is known to add a tinted, reflective or the like pane to an existing clear glass pane. Various methods and means for accomplishing such retroglazing have been proposed, some of which have been commercially used, among which, for example, have been methods and means in accord with U.S. Pat. Nos. 3,971,178, 2,684,266 and 3,928,953. Reference may be had also to U.S. Pat. Nos. 3,226,903; and 3,105,274.
Taught by such patents are arrangements in which a hollow metal spacer member containing a desiccant is sealed to a peripheral portion of a surface of a new pane which is applied to an existing pane in a window sash. The spacer may comprise a slit therealong through which the desiccant is exposed to the dead air space between the two panes in the completed installation. U.S. Pat. No. 3,226,903 suggests that silica gel be inserted into the spacer and the spacer then be held in dry heated condition until the installation is to be completed. U.S. Pat. No. 3,928,953 relates to the sealing together of two new panes at the factory, with the desiccant open to the sealed space between the two new panes until they are separated in preparation for final installation. U.S. Pat. No. 3,971,178 suggests substitution of a strippable overlay of sheet material against the exposed side of the spacer in a prefabricated subassembly comprising only one pane of glass.
SUMMARY OF THE INVENTION
In accordance with the invention there is provided a method of adding a new pane of glass to an existing pane installed in a window sash by pre-attaching and sealing a spacer element containing a desiccant sealed therein to a new pane of glass, retaining such new pane in position with the spacer toward the existing pane while introducing a sealant compound into the space outwardly around the spacer element, and finally forcing a resilient rod into such space between the new pane and the surrounding sash. Prior to bringing the new pane into position, the seal which protects the desiccant in the spacer element from moisture is opened so that the desiccant will be exposed to the air space between the panes in the completed installation.
The invention further contemplates a retroglazed window sash characterized in that the spacer element is effectively sealed to the existing pane by sealant material urged into place so as to minimize voids by a preferably heat-insulating resilient rod wedged into and retained in place between the new pane and the sash, and which is further characterized by the provision of support means to take the weight of the new pane off of the adhesive which retains the spacer element against the old or existing pane.
According to the invention, a new pane of glass is pre-assembled to a spacing element, and such pre-assembly may be efficiently accomplished in the field at the job site, in a job shop typically located within easy trucking distance of a particular job, or on an assembly line in a manufacturing plant. For a job comprised entirely of uniformly sized window lights, it will normally be preferred to fabricate all of the pre-assemblies, if the lights are of a standard size, in a factory or in a job shop, but for a job wherein some of the lights are of odd sizes, it is an advantage that the same materials lend themselves to pre-assembly at the job site. Specifically, the spacing elements may be made adjustable over a small range or may be cut to appropriate lengths at the job site, while the final appearance of the installation will be uniform regardless of where the pre-assemblies are fabricated.
Among the objects of the invention are to provide improved methods, apparatus, materials and assemblies of elements for retroglazing, to result in a rapidly and easily installed second or new pane of glass spaced from an original pane in a glazed window, wherein the completed assembly is attractive in appearance and is characterized by improved thermal efficiency, particularly as to reduced thermal conductivity around the edges of the new pane.
Another object is to provide methods, apparatus, materials and elements for retroglazing of window panes of differing sizes and shapes and adapted to factory, job shop and field pre-assembly of elements for field installation.
The novel features which are believed to be characteristic of this invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and method 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, in which:
FIG. 1 is a front or inside elevational view of a retroglazed window partially broken away and in fragment in accord with my invention;
FIG. 2 is a sectional view on an enlarged scale taken along line 2--2 of FIG. 1;
FIG. 3 is a similar sectional view taken along line 3--3 of FIG. 1;
FIG. 4 is a sectional view similar to FIG. 3 but showing a modified spacing element and with compressible rod in position for insertion into place;
FIG. 5 is a sectional view taken along line 5--5 of FIG. 3 showing a corner arrangement of the spacing element;
FIG. 5A is a sectional view similar to FIG. 5 showing a modified corner arrangement;
FIG. 6 is a top plan view of a portion of a spacing element or of a desiccant cartridge according to my invention;
FIG. 7 is a perspective view, partially broken away and in section, showing a modified spacing element with a desiccant cartridge disposed therein;
FIGS. 8, 9, 11, 14, 15, 17 and 18 are sectional views similar to FIGS. 2, 3 and 4, and
FIGS. 10, 12, 13 and 16 are front inside elevational fragmental views, of a window and retroglazing elements and materials showing the steps of installation of a new or second pane in accord with my invention;
FIG. 19 is a back or outside elevational fragmental view showing a window retroglazed in accord with my invention;
FIG. 20 is a sectional view similar to FIG. 4 showing a combination trim and sealant pressing rod element being inserted into position;
FIGS. 21, 22, 23 and 24 are sectional views on a scale enlarged with respect to FIG. 20, of other forms of combination trim and sealant pressing rod elements;
FIGS. 25, 26 and 27 are sectional views, similar to FIGS. 21-24 of other forms of sealant pressing rods;
FIG. 28 is a sectional view similar to FIG. 3 of a completed installation comprising a trim strip;
FIGS. 29 and 30 are sectional views of alternative trim strips for the installation;
FIG. 31 is a sectional view similar to FIG. 28 comprising a further alternative trim strip; and
FIG. 32 is a sectional view similar to FIG. 3 of a double retroglazed window.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The general organization of the invention will be understood with reference to FIG. 1. The window sash 1, which is shown as a wood sash but which may be of other material, such as metal or plastic, or a combination of such materials, is glazed with an existing pane of glass 2. According to the invention, a second or new pane of glass 3 is positioned parallel to and spaced inwardly of the inner surface 4 of pane 2. The width dimension of the new pane between its side edges 5 and 6 is less, typically by about one-half inch, or between about one-quarter of an inch to one inch, than the internal width dimensions of the original light as defined by inner sash portions 7 and 8, and the height dimension of the new pane is similarly less than the height dimension of the original light.
Spacing means 9, preferably of metal, are disposed adjacent the side edges 5 and 6, and the lower edge 10 and upper edge (not shown), of the new pane, being adhered to the face of the pane which is disposed toward the original pane by suitable adhesive means, such as by a strip 11 of rubber-like tape of which the faces are self adhesive. According to the invention, the new pane 3, adhesive tape 11 and spacing means 9 are pre-assembled, and this pre-assembly is adhered to the face 4 of the original pane, such as by a self adhesive tape strip 12 similar to tape 11.
At the time of application of the sub-assembly, a pair of small temporary supporting blocks 13, 14 of hard rubber or other suitable material are positioned under the lower edge 10 of the new pane on respectively opposite sides of the center to rest on the lower sash member or rail 15 to carry the weight of the new pane. The blocks 13, 14 are represented by broken lines since they are later removed after two permanent supporting blocks 16 and 17, preferably of hard rubber or the like, are positioned on respective sides of the center of pane 3 between the lower edge of the pane and the lower sash.
As more particularly described hereinafter, a sealing compound bead 18 is positoned, such as by squeezing such compound through a nozzle, up against the inner surface 4 of the existing pane in the space radially outwardly around pane 3 and spacer 9 and inwardly of the sash 1 for the whole distance around the pane and spacer except for the lengths of such space taken up by the temporary blocks 13 and 14. Thereafter the permanent blocks 16 and 17 are pressed into place against the sealing compound, the temporary blocks 13 and 14 are removed, sealing compound is squeezed into the space exposed upon removal of the temporary blocks, and finally one length of flexible resilient rod 19 is urged or forced between the edge of the new pane and the sash into deforming contact with the bead of sealant along the lower edge 10 between the blocks 16 and 17, and a second length of such rod is so urged or forced into place along the space extending from one block to the adjacent corner, up along one side edge, across the top, down the other side edge and around the corner to the next block.
In this manner the air space 20 as seen in FIGS. 2 and 3 has been hermetically sealed, and, as later explained, a desiccant will have been exposed and will remain exposed in this space. FIG. 2 shows existing pane 2 in place in sash 1 and the sub-assembly, comprising spacing element 21 adhered to new pane 3 by sealant strip 11 and sealed thereto by sealant 22, supported by permanent block 16. The sealant bead 18, being characterized by plasticity, has been forced into all of the interstices between the sash member 15 and the spacing element 21 and up against the adhesive strip 12, which acts as a dam to prevent the flow of sealant into the vision area thus to present a uniform appearance when viewed from the opposite surface. The sub-assembly is adhered to existing pane 2 by strip 12 and by sealant 18.
FIG. 3 is a section at a position along the bottom edge of pane 3 spaced from the support blocks and shows a completed installation, to which, however, trim may be added, if desired, as later described.
The spacer element 21 is in the form of an elongated tube, preferably of thin metal, which has opposite side walls 23 and 24, adhered respectively, to the new pane 3 and to the existing or original pane 2, and an outer wall 25 continuous with the side walls. The inner wall 26 completes a square cross-section spacer element in this embodiment of the invention, and the hollow interior of the spacer contains a desiccant 27, which may be molecular sieve or silica gel.
The adhesive shown as strip 11 is preferably moisture resistant and is not only adhesive but, preferably, acts as an hermetic sealant as well. Butyl, polysulfide, or polybutadiene, adhesive materials are among known adhesives which may be spread as a ribbon or bead on the spacer side wall 23, or on the marginal perimeter of the new pane, to adhere the spacer to the new pane and thereby to complete the sub-assembly. Alternatively, the adhesive may be in the form of sealant strip or tape material. As shown, additional sealing and structural strength is provided by applying sealant material 22 into any crevice which remains between the lower portion of the pane 3 and preferably over at least the adjacent portion of the bottom wall 25 of the spacer element, the sealant 22 having been squeezed and smoothed in place such as by a spatula or by a dispensing nozzle.
It is to be noted as shown in FIGS. 2 and 3 that the outer wall 25 of spacer element 21 is spaced radially inwardly of the extreme outer edge 10 of the new pane 3 thereby to expose a narrow peripheral area of the new pane outwardly of sealant and adhesive strip 11 to structural and sealant material 22, which, when so applied, bonds to the outer wall surface 25 and to such narrow peripheral margin of the pane.
The completed retroglazed window pane assembly further comprises adhesive dam 12 between spacer wall 24 and face 4 of the original window pane 2, the body of sealant 18 filling all interstices and crevices radially outwardly around adhesive strip or dam 12, up to and in sealing contact with the glass surface 4 which lies between the adhesive dam 12 and the sash 1, and along the surface portions of the sash adjacent pane 2 and of the spacer wall 25 and the previously applied sealant 22. This is accomplished by pressing the foam rubber or similar resilient plastic foam rod 19 into place against sealant 18 to cause it to ooze or flow. The rod 19 is shown as compressed into a generally ovaloid shape between the edge of pane 3 and the sash and in contact with the sealant 18.
It is preferred to employ materials for strips 11 and 12 which are moisture resistant, have long life, and which have amply sufficient bond strength, to the glass and to the space material, to support the new pane 3. The sealant 22 and sealant 18 should be of material which provide hermetic sealing between the surfaces with which they are in contact and would, of course, be water resistant. It is preferred that the adhesive strips or layers 11 and 12 be of materials which not only provide adherent strength but which also provide hermetic seals, and it is similarly preferred that the sealants at 22 and 18 provide additional support for the new pane and the spacer, but non-hardening or non-curing sealants have been found satisfactory. Appropriate sealants are polysulfide materials, or butyl-based compounds or polybutadiene.
FIG. 4 shows a new pane 3 and spacer in the process of being installed in a sash 1. The spacer element 21' is of a modified keystone shape providing shallow side grooves, such as groove 28, for receiving a bead of adhesive 11' bonding the spacer to the pane 3 to form a sub-assembly, the opposite groove similarly receiving a similar adhesive bead 28' which serves as a dam barrier for sealant 18, and which adheres the sub-assembly to the original pane 2. With this and similar shaped spacers, the adhesive dam 28' may be omitted as long as intimate contact of the spacer is maintained to the original pane 2 to prevent sealant 18 from flowing nonuniformly into the dead air space or vision area. Sealant 22' has been pre-applied to fill the crevice between the new pane 3 and the adjacent inclined wall portion 29 of the spacer element. The spacer element 21' is seen to contain desiccant 27. A resilient foam rubber rod 19 is shown in position for introduction into the space between the edge of pane 3 and the sash 1 against the sealant 18 and thus to force the plastically deformable sealant 18 into all of the remaining crevices and space between the spacer element, the pane 2 and the sash, the rod then to remain in its flattened shape in the space between the edge of pane 3 and the sash. The rod 19 when in final position, as shown in FIG. 3, will be held in place by being so compressed and, in addition, preferably by bonding to the sealant 18.
The foam rod has a diameter, before compression, greater than the clearance distance between the edge of the new pane and the sash element, while the perpendicular distance from the exposed face of the new or added pane to the existing pane is typically, about three times such clearance distance or about twice such diameter.
FIG. 5 shows a corner construction of the spacer means, wherein desiccant 27 is disposed in one hollow spacer element 21 and is retained by a wool, felt or the like plug 30 which is spaced from an end 31 of the spacer element 21. An elbow element 32 of solid metal or plastic comprises arm 33, which is proportioned to pass through the open end 31 of element 21 and into the portion 34 between plug 30 and end 31. A quantity of sealant 35, which may have been inserted into the end portion 34 before insertion of the arm 33 so as to be displaced by the arm, seals around the arm so that the arm and sealant completely fill the otherwise hollow portion 34. The second arm 36 of the elbow element, which is at right angles to arm 33, is similarly inserted and sealed in the similar end portion 37 of the next adjacent element of the spacing means 9. Additional sealant material 38 is smoothed into place around portions of the elbow element between the ends of the adjoining spacer elements at each corner to finish off the corner of the spacer means to conform to the external shape and dimensions of the spacer elements. Minor adjustments to the width and height of the spacer element may be accomplished by inserting the arms more or less deep in the hollow spacer element tubes.
Alternatively, it may be found more economical to form a closed corner by mitering at 45 degrees the ends of spacer elements or tubes, such as spacer element 21 or 21', and, as shown in FIG. 5A, adjoin such mitered ends and to solder, braze or weld along the meeting line 40, such as by solder 41. When the corners are so formed, the interior of the spacer means may be continuously hollow throughout, and this interior is completely or partially filled with desiccant 27. Alternatively to or additionally to such soldering of mitered corners, an elbow member may be employed, and the meeting line may be sealed by sealant material, if not soldered.
Each of the four corners of the rectangular spacing means 9 is completed by one or the other of the above explained arrangements.
Referring to FIGS. 5 and 6, at least some, and preferably all four, of the two horizontal and two vertical runs of the spacer means contain a quantity of desiccant which may be poured in through openings, such as opening 42, in the inner wall 26 of the spacer elements, this wall being that which is, in the completed installation, exposed to the air space 20 between the new and original panes 3 and 2. Each such opening is then plugged, to retain the desiccant, with a small vapor-pervious plug 43 of wool or the like, which may be pushed into place through the hole and, except in those instances in which the desiccant is poured into the spacer immediately before installation of the sub-assembly, a protective metal foil or other moisture-impervious adhesive tape strip 44 is applied to the wall 26 in covering relation to the hole 42 to seal the desiccant against moisture absorbance prior to installation of the new pane. The seal is broken by pealing tape 44 away and discarding it immediately before installing the sub-assembly.
FIG. 7 shows an alternative arrangement wherein the spacer element 21" is in the form of an open trough, generally U-shaped in cross-section, and provided with a desiccant-containing cartridge 45, the desiccant being exposed through an opening 42' plugged with a wool or the like plug 43'. The cartridge may be held in place by contact adhesive 46, or, preferably, by providing an inturned edge 47 of one or each of the side walls of the spacer element. The side walls may spring apart slightly to permit the cartridge to be snapped or clipped in place, the cartridge thereafter to be retained by the inturned edge or edges 47.
The several steps of installing a new pane and spacer means according to the invention comprise the cutting of a pane to be, typically, one-half inch less in height and in width than the dimensions of the existing light, or as much as about one inch less for large panes or as little as one-quarter inch for small panes, and the providing of a rectangular spacer element having outside dimensions equal to or, preferably, slightly less, by up to about one-quarter inch, than the new pane dimensions. The spacer element is adherred to the peripheral border portion of one face of the new pane by adhesive and sealed thereto, as above described, to form the sub-assembly as shown at 48 in FIG. 8. It may be appropriate to clamp or otherwise force the spacer 21 against the new pane 3 while adhesive sealant 11 and/or 22 sets or cures. Desiccant material will have been deposited in the spacer element 21 in the meantime, and a plug as previously described will have been placed in the spacer element opening. If the sub-assembly 48 is prepared and provided with desiccant at at a factory or plant the plugged opening will have been closed by impermeable adhesive tape strips, although if prepared and provided with desiccant in the field for installation without delay, such tape strip closures will not normally be necessary. If the spacer has been provided with an adhesive layer or tape strip 12 at a factory or plant, and if the surface 49 thereof, that is, the surface which will attach to the existing pane, has been protected by a Holland cloth or the like protective strip, such strip will now be peeled away, as will any cover strip 44 which has been used to seal the desiccant, and the sub-assembly will be brought adjacent the existing pane 2. As seen in FIGS. 9 and 10, temporary supporting blocks 13 and 14 are positioned on the lower sash member or rail 1' and used as guides to retain the sub-assembly in the correct vertical position, with the new pane centered between the vertical sash members 7 and 8, and the sub-assembly is manually advanced and pressed to engage the adhesive surface 49 firmly against the existing pane surface 4 thus to form a sealant barrier or dam. The elements are now in the positions according to FIG. 10 as viewed from the interior of the building.
The next step understood in connection with FIGS. 10, 11 and 12 is to deposit a quantity of sealing compound 18 into the space between the outer edges of the new pane 3 and the sash, such as between edge 10 and lower sash member or rail 15, completely around the new pane and spacer, except where the temporary support blocks deny access. The compound is preferably supplied through a nozzle, such as from a caulking gun, and is preferably inserted so as to be deep within the space and in contact with the portion of the existing pane at and adjacent the sash. The sealing compound 18 is now positioned as shown in FIGS. 11 and 12.
FIGS. 13 and 14 illustrate the next step which is to press permanent support blocks 16 and 17, of firm semi-hard rubber or the like, into position on opposite sides of the center of pane 3 against the sealing compound and into the position shown in FIG. 14. Pushing of these blocks into place will cause the sealant, which is plastic, that is, characterized by plasticity, to flow or ooze into all of the crevices and corners so as to displace the air pockets from and to fill completely all parts of the space inwardly of the block, and so as to be in unbroken contact with and to seal between the sash 15, the existing pane surface 4, the adhesive strip 12, any thereto exposed surfaces of spacer element 21 and of sealant 22, and to the surfaces of block 16 and block 17. With the permanent support blocks 16 and 17 in place, as seen in FIG. 13, the temporary blocks 13 and 14 are removed, leaving gaps or spaces such as gap 50, into which additional sealing compound is then introduced.
With compound now in place completely around the new pane 2, resilient rod 19 is next forced in between the peripheral edge 10 of the new pane and the sash members are indicated in FIGS. 4 and 16, starting, for example, next to block 17 with one end 51 of one length of rod 19 toward and around corner 52, working upwardly along one side of the new pane, across the top, downwardly along the other side around corner 53 and across the lower edge of pane 3 to block 16, the excess end portion 54 of the rod being then cut off so that this length terminates at block 16. A short length 55 of rod 19 is similarly forced into position between blocks 16 and 17 along the lower edge of pane 3.
Any excess of sealing compound 18 which is forced out by the blocks 16 and 17 while the blocks are being forced into position or which is forced out while rod 19 is being inserted into the space around the pane 3 is scraped off, such as by a spatula, and any remaining residue may be wiped away by a rag which may be wet with a suitable solvent.
A completed installation with the permanent blocks and the foam rod in place is shown in FIGS. 2, 3, 14 and 17.
Further, however, it may be desired to add, as seen in FIG. 18, finishing trim in the form of a strip or band 56 to shield from view, from a position internally of the building, the adhesive band or layer 11, the sealant 22 and the rod 19. Such trim strip may be of metal, synthetic resin plastic material, or, if cost is a factor, simply an opaque adhesive strip.
While it is suggested above that excess sealant material 18 which may squeeze out as the rod 19 and blocks 16 and 17 are forced into place may be scraped off, it may be desired, particularly if the sealant material is adherant to the material of the trim strip 56, to force such trim against any such sealant material thereby to attach the trim strip, followed by the removal of any excess sealant which may be squeezed out beyond the edges of the trim strip. Alternatively, the strip 56 may be glued in place.
A complete installation as viewed from outside of the building will appear as in FIG. 19, wherein the sealant material 18 will be seen through the existing pane 2 immediately inwardly of the boundaries 57 of the original light, and with the adhesive or adhesive band 12 similarly visible immediately inwardly of the sealant material 18. The new light is defined between the inner edges 58 of the adhesive strip 12.
FIG. 20, which is similar to FIG. 15, discloses a resilient rubber, polystyrene, vinyl or the like element comprising an integral hollow rod portion 19' and trim portion 56'. When the rod portion 19' is forced into position as explained for rod 19, the sealant material 18 is similarly forced to fill the voids, and the trim portion 56' is retained in position to shield the peripheral border of the new pane 3 in substantially the same manner as for trim strip 56.
FIG. 21 shows a combination rod and trim element similar to that of FIG. 20 but which comprises a rod portion 119 which is of foam rubber or the like and which, accordingly, may be solid rather than hollow. FIGS. 22, 23 and 24 show other configurations of combination unitary rod and trim elements, the forms of FIGS. 23 and 24 being particularly adapted to be of foam rubber, while the form of FIG. 22 may be of resilient solid rubber or the like in that the rod portion 19" thereof is hollow.
Other shapes of members which may be substituted for rod 19 are shown in FIGS. 25, 26 and 27. The shapes of FIGS. 25 and 27 may be of foam rubber or the like, or of soft and readily compressible rubber or polystyrene or the like resilient material, while the shape of FIG. 26 is of resilient but somewhat less soft rubber or the like in view of being hollow.
FIGS. 28, 29 and 30 disclose trim elements, which may be of extruded metal, or of other rigid material, and each of which includes a rigid lip 59 adapted to be forced between the rod 19 and the sash of an installation otherwise completed according to FIG. 17, or completed with a rod element in accord with FIGS. 25, 26 or 27. The longitudinal ridges or elongated teeth 60 of the lip engage upwardly into the rubber rod 19 to retain the element in place with its trim strip portion 61 in position to shield from interior view the rod 19, the sealant material 22 and the adhesive or adhesive strip 11. The trim strip portion 61 may be flat as seen in FIG. 29 or slightly curved as seen in FIG. 28. The trim strip portion 61' of the extension of FIG. 30 is square in cross-section, and may be desirably employed in those instances in which the sash extends inwardly beyond the plane of the inner face of pane 3 by a substantial distance.
According to FIG. 31 a trim strip 62 comprises a lower panel portion 63 which is screwed to sash 1 and an upper panel portion 64 which overlies the peripheral margin portion of pane 3 and which not only shields adhesive 11 from view but which also affords substantial additional support and security for pane 3. In this, as in other cases, it is desirable to dispose a gasket 65 between metal trim and any glass with which such trim would otherwise be in contact, although such gasket will not, ordinarily, be needed for plastic trim material.
FIG. 32 shows a double retroglazed window wherein a first new or added pane 3 is held in place adjacent existing pane 2 in the manner previously described, with spacing element 21 interposed, but in this case a second new or added pane 103 is held in position spaced from pane 3, with spacer element 121 interposed and sealed to the confronting faces of panes 103 and 3 by adhesive tape strips 111 and 112, respectively, which correspond to strips 11 and 12, and structurally secured by sealant material positioned as shown at 122 and otherwise corresponding to material 22. The foam rubber rod 19 is seen in FIG. 32 appropriately proportioned to squeeze the sealing compound 18 as before into the space defined between spacer 21, pane 2 and sash member 1.
It will be apparent that sub-assemblies of a new pane adhered and sealed to a spacer element as disclosed are adapted for volume manufacture in standard sizes or for large orders. Such manufactured sub-assemblies may include self adhesive strip 12 of which the face adapted to adhere to the existing pane of a window is covered by a pealable paper or the like tape to protect the adhesive, or no such adhesive strip may be applied at the factory but an adhesive bead may be applied to the spacer element in the field at the time of installation. Similarly, such manufactured sub-assemblies may be provided with desiccant sealed in the spacer element by a foil or the like tab 44, or similarly sealed cartridges 45 may be supplied either in place in the spacer element or separately for gluing or clipping in to the spacer elements in the field. Alternatively the desiccant may be inserted into the spacer element, or into a cartridge, in the field.
Where numbers of different sizes of window for a particularly job are to be fitted, the sub-assemblies are readily adapted to be fabricated at a job shop, or they may be completely assembled in the field at the job site, particularly if the job is small or if there are many different size window panes to be fitted.
While the invention has been described with respect to certain specific embodiments, it will be appreciated that many modifications and changes may be made by those skilled in the art without departing from the spirit of the invention. It is intended, therefore, by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the invention. | A retroglazed glass pane of a window, wherein a spacing element, which is attached and sealed to the peripheral portion of a face of a new or second pane slightly smaller than the original light of the first or existing pane, is bonded to the confronting face of the first pane in a position such that a space remains between the sash elements and the edge of the second pane and the radially outward side of the spacing element, wherein such space is partially filled with a sealant material, which seals between the spacer and the first pane, and which such space is further filled with a resiliently compressible rod, typically of a rubberlike foam material, the rod being preferably characterized by low thermal conductivity; and a method of retroglazing wherein a desiccant is contained in such spacing element, protected against exposure prior to installation of the second pane, and wherein such rod is forced into the space between the edge of the second pane and the sash to force sealant material pre-deposited in such space to seal effectively between the spacing element and such confronting face of the first pane. | 4 |
TECHNICAL FIELD
[0001] The invention basically relates to a strap obtained by weaving, whereof the primary feature resides in the fact that it has areas of variable widths.
[0002] In the rest of the specification, and in the claims, the term “width” means the smallest dimension of the strap in the general plane in which it is inscribed. The term strap should itself be interpreted in its primary acceptance, that is a flat band. In doing so, in the context of the invention, it is important to distinguish between the width of the strap and its thickness, consisting of its dimension in a direction perpendicular to the plane containing the strap.
[0003] The invention further relates to products suitable for using such a strap. It also relates primarily to a loop or ring, and in general, any structure closed on itself, prepared from this woven strap and, more particularly, intended for the field of mountaineering and climbing, safety and lifting, and also, in general, for all fields involving a load.
[0004] It also relates to leads for animals, straps for musical instruments, bracelets, purely decorative or watch straps, bag handles, etc.
PRIOR ART
[0005] In the more specific framework of climbing, the climbers use rings prepared from a strap, generally woven, in particular but repeated situations. This ring is, for example, joined to the shoulder-belt worn by the user and, furthermore, to a snap hook fixed at an appropriate anchoring point. This ring may also serve as a support element for the knees or feet of the user.
[0006] In a known manner, such rings must combine both mechanical strength and lightness. Moreover, at least some of them must meet standards, such as in particular standard NF EN 566 “Ring” of April 1997. This states that for a 9 millimeter wide strap ring, the mechanical strength must be greater than or equal to 2,200 daN.
[0007] To prepare such a ring, it has been proposed, for example in document WO03/059462, to use a loop consisting of a tubular fabric or mesh provided with two ends, these two ends being joined to each other at a connecting point by the introduction of one of the two ends into the other end, and by stitching said ends at this connecting point.
[0008] While from the mechanical standpoint, such a loop or such a ring is likely to meet the prescribed requirements and optionally, those of the standard recalled above, it nevertheless has the following drawbacks:
firstly, the cost of production of such a loop is encumbered by the labor necessary for its production, insofar as it is necessary to thread one of the ends of the component material into the other, an operation which can only be done manually, and which also requires a certain dexterity; secondly, the component material is conventionally produced on looms of a type known per se, and the resulting band is cut at regular intervals corresponding to the desired length of the loop; this cutting is generally performed using a hot blade, which, in addition to the cutting, also seals the tubular fabric or mesh, which must therefore be reopened, to permit the introduction of one of its ends into the other, thereby also representing a time consuming operation.
[0011] In the more general field of straps, and in particularly in the context of leads for animals and other gripping handles for bags and baskets, the user usually wishes to enjoy a degree of comfort at the level of the pulling or gripping area. In doing so, it has been proposed to add to these areas elements of a different nature from that of the active area of the lead or the handles. However, here also, such an operation further increases the production costs.
SUMMARY OF THE INVENTION
[0012] The invention primarily relates to a strap obtained by weaving, satisfactorily meeting a number of objectives discussed above.
[0013] More particularly, the invention relates to a woven strap comprising at least two consecutive or continuous areas or parts of different widths, the modification of said widths being obtained by changing the weave.
[0014] The strap according to the invention may also have a plurality of areas of modified width, particularly for a decorative function.
[0015] Furthermore, and according to the invention, the strap has a modification of width at one or both of its two ends, reflected by the presence of a tubular structure, also resulting from a change of weave.
[0016] In this context, the invention thus relates to a loop or such a ring, suitable for use in the fields considered, and particularly climbing, indeed in any activity using a load, which is simultaneously lightweight, mechanically strong, and relatively easy to prepare in order to reduce the manufacturing costs.
[0017] This loop or this ring consists of a strap prepared by weaving, whereof the two ends are joined to each other by stitching.
[0018] It is characterized:
in that limitatively, the stitching areas of each of the two ends are tubular, the rest of the ring being flat. and in that said stitching areas are superimposed on one another.
[0021] In doing so, considering that only the stitching areas, that is the two ends of the strap making up the loop or ring, are tubular, a significant reduction in weight is achieved.
[0022] Advantageously, the length of one of the stitching areas of one of the ends is greater than the other. In doing so, and according to another advantageous feature of the invention, a wear and/or overload indicator is located in the immediate neighborhood of the stitching area. This indicator consists of the folding upon itself of the base of the stitching area thereby forming a triple thickness at this level, followed by stitching of these three thicknesses, said wear and/or overload indicator also being prepared in the tubular part of the strap.
[0023] Advantageously, a ribbon is inserted between at least two of the folds of said wear and/or overload indicator. This ribbon is preferably brightly colored compared with the rest of the strap making up the loop or ring, for the obvious purpose of attracting the user's attention upon the breakage of the wear and/or overload indicator.
[0024] According to the invention, the stitching of the folds making up the wear and/or overload indicator is carried out using a stitching robot, wherein the respective needle yarn and spool yarn diameters are different.
[0025] In this configuration, the tubular area of one of the ends is folded upon itself or at the level of the width change, in order to define a gripping handle.
BRIEF DESCRIPTION OF THE FIGURES
[0026] The manner in which the invention can be implemented and the advantages resulting therefrom will appear more clearly from the embodiments that follow, provided for information and nonlimiting, with reference to the figures appended hereto.
[0027] FIG. 1 is a schematic representation of a cross section of a lead for animals, using a strap of the invention.
[0028] FIG. 2 is a flat view of the strap of FIG. 1 .
[0029] FIG. 3 is a view similar to that of FIG. 2 , of another embodiment of the invention.
[0030] FIG. 4 is a schematic perspective view of a ring of the prior art.
[0031] FIG. 5 is a schematic representation of the ring of the invention.
[0032] FIG. 6 is a flat view of part of the ring of FIG. 5 , for particularly illustrating the stitching area.
[0033] FIG. 7 is a view similar to that of FIG. 6 with an overload and/or wear indicator after breakage.
[0034] FIGS. 8 a to 8 d illustrate the operation of the wear and/or overload indicator of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0035] FIG. 1 therefore illustrates a lead using a strap ( 10 ) according to the invention. In this particular case, a snap hook ( 13 ) has been materialized at the level of one of the ends, intended in a known manner for the fixing of the lead to the collar, with which the animal is provided, and a handle ( 14 ) at the other end.
[0036] This handle ( 14 ) is produced by the stitching ( 15 ) of the strap on itself. A handle incorporated in the strap is thereby obtained.
[0037] According to the invention, the area of the strap making up the handle has a different width from the rest of the lead.
[0038] The strap ( 10 ) is a flat strap. It is prepared on a loom of the type marketed by MULLER (CH). The two distinct areas of the lead, that is the main part, of variable length, and the end constituting the handle ( 14 ), are prepared by modifying the weave of the loom. Thus the longer area, separating the two ends, is prepared with a twill weave, whereas the handle area is prepared with a taffeta weave. The reverse configuration is equally feasible.
[0039] At the level of the handle ( 14 ), a greater width is thereby provided, designed to enhance the user's comfort. Advantageously, the stitching area ( 15 ) of the end of the strap on itself occurs at the level of this change in width.
[0040] The strap is prepared from any material compatible with the intended application in terms of mechanical strength. Thus, if high mechanical strength is required, for example for a strap used as a bag handle, said material may consist of high tenacity polyethylene, such as, for example, marketed under the registered trademark Dyneema®.
[0041] Furthermore, in view of the weaving technique employed, the strap, and hence the product resulting therefrom, is capable of having all types of decoration, such as for example Jacquard. The width may also vary substantially, according to the intended application.
[0042] In a different version of the invention, it may even be feasible to arrange, in the main area of the strap, that is between its two ends, a plurality of variations in width, as illustrated in FIG. 3 . The technology employed is identical to that previously described, and only the pitch of the weave variations is different.
[0043] Alternatively, the variation in width of the strap also results from the passage from flat mode to tubular mode. Thus the handle consists of a tubular part. In doing so, the thickness of the strap is increased at this level, optimizing the feeling of comfort.
[0044] For this purpose, during the manufacturing phase with twill weave, to prepare the flat area of the strap, the warp yarns work side by side in pairs, while with a taffeta weave, to prepare the tubular area, said warp yarns become individualized, specifically to permit the production of such a tubular area.
[0045] As may have been understood, the strap of the invention can be prepared continuously, with periodic change of weave, to produce flat areas of variable width, or alternating flat areas and tubular areas. The band thereby prepared is also cut automatically using a heated blade, incidentally causing the sealing of the component yarns, for example, polyethylene. As may be imagined, in the presence of tubular areas, this cutting area limitatively occurs at the level of said tubular areas, so that the latter are systemically blocked due to the heating of the yarns.
[0046] These various embodiments are therefore suitable for implementation for the preparation of various products, such as leads for animals, collars, handles for bags and other baskets, bracelets, watch straps, straps for musical instruments, such as guitar, accordion, etc.
[0047] One particular application of the present invention relates to rings and other loops in the areas of safety, lifting, mountaineering and climbing, and in general, in all areas involving a load.
[0048] Thus, in relation to FIG. 4 , a loop or ring has been shown, more particularly intended for climbing according to the prior art. This loop or ring comprises a tubular strap ( 1 ) prepared by weaving, of which the two ends ( 2 , 3 ) are joined to each other by the introduction, in the example described, of the end ( 2 ) into the end ( 3 ), followed by stitching of the stitching area ( 4 ) thereby defined. This introduction is made possible by the tubular nature of the strap ( 1 ).
[0049] It may be understood, considering the tubular nature of the strap ( 1 ), that this stitch is therefore made on four thicknesses.
[0050] The particular application of the invention to this field is more particularly described in relation to the following figures and, in general, to FIG. 5 . According to the invention, the strap ( 10 ) used to prepare the loop or ring of the invention is a flat strap, whereof only the ends ( 5 , 6 ) are tubular. According to the invention, the strap ( 10 ) is therefore not tubular between its ends. It thus has a reduced width at this level, and, for example, in the illustration described, a width of 9 millimeters, whereas the width of the stitching area is typically 15 millimeters.
[0051] This strap ( 10 ) is also produced on a loom of the type marketed by MULLER (CH). The three distinct areas of the ring, that is the central band and the two ends, are prepared by modifying the weave of the loom. Thus the longer area, separating the two ends ( 5 , 6 ), is prepared with a twill weave, whereas the tubular areas, corresponding to the two ends, are prepared with a taffeta weave.
[0052] During the phase of manufacture with twill weave, the warp yarns work side by side in pairs, whereas with the taffeta weave, said warp yarns are individualized, specifically for preparing a tubular area. This tubular area is wider, as may be observed in FIGS. 6 and 7 .
[0053] According to the invention, the strap is prepared from high tenacity polyethylene, like the material marketed under the registered trademark Dyneema®. This material has mechanical properties compatible with the use of the ring in question.
[0054] According to the invention, the two ends ( 5 , 6 ) of the strap ( 10 ) are joined to each other by stitching by superimposing them upon one another. Four thicknesses are accordingly provided at this level, that is two thicknesses for each of the ends, the number of these thicknesses being inherent in the tubular nature of the strap at this level, and at this level only.
[0055] The stitching is carried out, for example, on stitching robots operating in (X, Y), of the type marketed by JUKI. Such a robot is suitable particularly for obtaining a number of stitching lines ( 11 ), substantially parallel to each other, and further describing an alternation of broken lines or “zigzags”. In the example described, the stitching area ( 7 ) comprises nine of these stitching lines. At this level, the diameter of the needle yarn of the stitching robot is equal to the diameter of the spool of said robot. The type of yarn is, for example, polyamide (nylon). It is suitable for conferring on the ring resulting from the closure of the strap thus prepared, a mechanical strength higher than or equal to 2,200 daN for a nominal strap width of 9 mm in the inter-end area, and 15 mm for the ends, that is, at the level of the stitching area ( 7 ), that is according to standard NF EN 566.
[0056] As already stated, the strap making up the ring of the invention is prepared on looms of a type known per se. Accordingly, it is prepared continuously, with periodic change of weave, to produce the flat areas and the tubular areas. The band thus prepared is also cut automatically, using a heated blade, incidentally causing the sealing of the component yarns of polyethylene. As may be understood, this cutting area limitatively occurs at the level of the tubular areas, so that the latter are systematically blocked by the heating of the yarns. However, this blocking has no effect, particularly in terms of labor and hence in terms of cost, because contrary to the prior art, there is no introduction of one of the ends into the other, but a superimposition of said ends.
[0057] According to one feature of this particular form of the invention, the ring is also provided with a wear and/or overload indicator ( 8 ). This is arranged at one ( 5 ) of the two ends of the strap ( 10 ). For this purpose, the tubular area of the end ( 5 ) has a greater length than the tubular area of the end ( 6 ), specifically to permit the production of this wear and/or overload indicator.
[0058] This is prepared by folding in three thicknesses at the base of said end ( 5 ) of the strap ( 10 ), as may be observed particularly in FIG. 5 . It extends along a length X.
[0059] After folding, therefore arranged flat, like the stitching area in ( 7 ) previously described, this area ( 8 ) is stitched, also using a stitching robot, for example of the JUKI type, following the same principle of a succession of stitching lines ( 12 ), substantially parallel to each other and forming zigzags.
[0060] However, for the preparation of this wear and/or overload indicator, the diameter of the needle yarn is different from the diameter of the spool yarn of said robot. In the present case, a smaller diameter is selected for the spool yarn compared with the diameter of the needle yarn. Furthermore, the number of stitching lines ( 12 ), without regard to the type of stitching yarn, depends on the value at which the overload and/or wear indicator is intended to break. Thus, this tripping or this breakage will occur when the spool yarns, forming loops after the actual stitching operation, will break due to their smaller diameter than that of the loops prepared by the needle yarn, and closed on said spool yarn loops in case of overload, or when the stitching yarns become worn out by repeated friction of the ring, and hence of the indicator ( 8 ) area, on rocks in particular.
[0061] When the wear and/or overload indicator has played its role, it extends along a length of 3× ( FIG. 7 ).
[0062] The various steps of tripping of the wear and/or overload indicator are shown in relation to FIGS. 8 a to 8 d with:
FIG. 8 a : state of indicator at rest, FIG. 8 b : incipient deformation of the indicator by pulling, FIG. 8 c : end of deformation and breakage of the stitching yarn, And finally, FIG. 8 d : breakage of the indicator with elongation of the ring by twice the respective length X of the indicator, due to the manner in which it is prepared.
[0067] Despite the effective breakage of the indicator ( 8 ) the ring or loop preserves a mechanical strength greater than or equal to its nominal value and in the example described, greater than or equal to 2,200 daN. In fact, this breakage does not affect the actual stitching area ( 7 ) on the one hand, because the stitching yarns of this area (needle and spool) have the same diameter, and on the other, the number of stitching lines ( 11 ) at this level is greater than the number of stitching lines ( 12 ) of the indicator ( 8 ). Furthermore, since this breakage is likely to occur only at a tubular area of the strap, it does not disorganize the intrinsic structure inherent in the weaving mode, because only the stitching yarns are concerned.
[0068] Advantageously, the interior of one or the other of the fold areas of the wear and/or overload indicator is provided with a ribbon ( 9 ) advantageously colored, for the purpose of attracting the attention of the user of the ring when said indicator actually breaks. This ring is simply stitched, for example by running straight stitches on the back and front of the strap, obviously directly at the actual indicator ( 8 ) area.
[0069] The value of the ring or loop of the invention is clearly understandable, due to its ease of production, incurring no excessive loss of time, and hence, unlikely to encumber the manufacturing cost, and also due to the use of such a wear and/or overload indicator, optimizing the conditions of safety and use of such a ring.
[0070] And in general, it is easy to understand the value of the strap of the invention, which, in a relatively simple and automated manner, provides the availability of an element that can be varied virtually to infinity, both in terms of dimensions and in terms of decoration, for any use involving a pulling or a lifting function, or even a simply decorative function, while optimizing the user's comfort. | A woven strap comprises at least two continuous parts having different widths, wherein the change in width results from a modification of the respective weave of said parts. The strap can thus be used to create a loop or a ring in order to attach or bear a load. The two ends of the strap are joined to each other by stitching. Only the stitching areas of each of the two ends are tubular. The rest of the ring is flat and the stitching areas are placed on top of each other. The loop or ring can include an integrated wear and tear and/or overload indicator. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a division of application Ser. No. 14/166,416 filed on Jan. 28, 2014, which is a continuation of PCT/NZ2012/000134 filed on Aug. 2, 2012, which claims foreign priority to New Zealand Application No. 594388 filed on Aug. 3, 2011. The entire contents of each of the above applications are hereby incorporated by reference.
TECHNICAL FIELD
The invention generally relates to the automation of the handling of the expenses of a traveller within an ERP (Enterprise Resource Planning) system.
More particularly the invention relates to the association of the itinerary of a traveller as lodged in an ERP system with the acceptance of expenses at appropriate times.
BACKGROUND ART
ERP systems manage the resources of an organisation, from the financial through personnel, project management, manufacturing, sales, service, customer relations management systems, document management, itinerary planning and such various other functions as the enterprise requires.
An ERP system typically is made up of a transactional database with software modules to handle one or more of the functions required. Interaction with the modules is typically by a web interface and the database and modules may be part of a cloud computing system.
The present invention is intended to deal with the situation in which an enterprise employee, manager or director is remote from the enterprise base. In such a situation the person has expenses which are paid by and should be recorded by the enterprise. This may prove difficult, requiring the collecting of receipts by the person concerned and the subsequent recording of these in the ERP system.
The use of credit cards reduces the problems to some extent but the recorded transaction may not reflect what is actually happening and typically requires reconciliation after the travel is completed.
Various efforts have been made to resolve some of the problems associated with recording expenses for a remote traveller. Among these are:
Patent application US20110119179 relates to processing payment transactions between enterprise resource planning systems and particularly relates to the conversion of the invoice format between the two systems.
Patent application US 2003/0046104 relates to a method for the approval of expense applications in which the expense is automatically approved if it falls within specified parameters.
U.S. Pat. No. 7,865,411 relates to an accounts payable process in which details from an invoice are matched against a purchase order.
U.S. Pat. No. 7,957,718 relates to a method and apparatus for telecommunication expense management which provides a pop-up query when a call is completed in order to allocate the expense of the call.
Patent application US 2007/0083401 relates to travel and expense management. The specification describes a travel approval system centrally storing travel data and integrated with the travelling users.
Patent application US 2005/0015316 A1 Methods for calendaring, tracking, and expense reporting, and devices and devices and systems employing same (abandoned 2008). The specification describes a system which stores an itinerary, tracks the traveller along points on the itinerary both physically and by time and automatically assigns expenses to appointments on that itinerary. The system is traveller centric but has an enterprise centralised computer system.
Such systems leave unanswered the question as to how the system ensures that the costs recorded are correct and how to reduce to a minimum the travellers interaction with payment systems during travel.
Also well known is the NFC (Near Field Communication) communications protocol which uses the NDEF protocol for the two way transfer of data between two devices by RFID tag transmissions. The protocol works by induction when two such devices are within a short distance of each other, typically 4 cm to 20 cm, and automatically establishes a connection between them.
It is known that the NFC system may be used for contactless payment systems, see for instance U.S. Pat. No. 8,215,546.
There remains the problem of ensuring that the ERP system correctly records and allocates the expenses of a remote traveller.
The present invention provides a solution to this and other problems which offers advantages over the prior art or which will at least provide the public with a useful choice.
All references, including any patents or patent applications cited in this specification are hereby incorporated by reference. No admission is made that any reference constitutes prior art. The discussion of the references states what their authors assert, and the applicants reserve the right to challenge the accuracy and pertinency of the cited documents. It will be clearly understood that, although a number of prior art publications are referred to herein, this reference does not constitute an admission that any of these documents form part of the common general knowledge in the art, in New Zealand or in any other country.
A reference to an “NFC” equipped device refers to a device which can communicate using a Near Field Communication protocol.
A reference to an “ERP” is a reference to an Enterprise Resource Planning system including at least an accounting system and a corporate travel planning system including itinerary planning and expenditure capability.
A reference herein to an itinerary “event” is a reference to a point at which there is a notable occurrence in the itinerary of a traveller. Such events may include points in space and time at which: a mode of transport changes (from aircraft to foot, from foot to taxi, from taxi to foot, from foot to rail); at which a payment is received, made or committed to (porters tip, meal expenditure, taxi charge, check out); at which a specific communication is received or made (aircraft gate check-in, phone initiated parking charge) or other occurrences which have relevance to the incurring of debt or the receiving of income as recorded in an ERP system.
SUMMARY OF THE INVENTION
In one exemplification the invention consists in a method of carrying out a financial transaction with a first NFC equipped device using a second device associated with a traveller which device is NFC equipped and has internet access, the second device receiving from or supplying to the first NFC device an invoice or receipt relating to one or more items, authorising a payment to or receiving a payment authorisation from the first device, thereby initiating a financial transaction, conveying from the second device to a remote ERP system information relating to the financial transaction, the remote ERP including the capability to allocate costs and payments against cost centres and having an itinerary for the traveller carrying the second device, the itinerary having one or more itinerary events in the itinerary, characterised in that at the remote ERP system the financial transaction is allocated against an itinerary event stored in the ERP system and the items of the financial transaction are allocated against cost centres in the ERP system.
Preferably the second device carries a replicate of the itinerary and itinerary events.
Preferably the itinerary events are identifiable events occurring during the progress of the itinerary and preferably at least some of the itinerary events are predicted to occur within a specific time frame.
Preferably the itinerary may be amended at the remote ERP system and replicated in the second device.
Preferably the second device has sufficient itinerary details to query expected item cost centres with the traveller.
Preferably the second device may allocate items to unexpected cost centres.
In a second embodiment the invention may consist in a system for the initiating of a financial transaction by a traveller travelling on an itinerary which itinerary has itinerary events,
the traveller travelling with a first device which is NFC equipped and remote communication capable and capable of initiating financial transactions with a second NFC equipped device; the first device interacting with a second NFC equipped device to carry out a financial transaction related to an itinerary event and to receive an invoice or receipt relating to items within that financial transaction; a remote ERP system storing the traveller itinerary and the expected itinerary events; the first device communicating with the remote ERP system upon completion of the transaction with information including details of the transaction and including the items within that transaction; characterised in the remote ERP system allocating the financial transaction against an itinerary event and allocating the items against cost centres in the ERP system.
These and other features of as well as advantages which characterise the present invention will be apparent upon reading of the following detailed description and review of the associated drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general illustrative view of the technology involved in the invention.
FIGS. 2 to 7 show drawing depicting the screen of a travellers mobile phone at various stages of the inventive process.
FIG. 8 is a flow diagram of one version of the flow process of the invention.
DESCRIPTION OF THE INVENTION
Referring now to FIG. 1 the inventive system predicates a traveller carried device which interacts with a remote ERP so that the combined system:
1) records in the travellers corporate ERP the travellers itinerary, and replicates a copy to the traveller carried device; 2) matches any change of the itinerary location to a one or more itinerary events occurring at specified times and places; 3) queries the itinerary event supplier or is queried by the itinerary event supplier for the required payment; 4) optionally queries the traveller for expense approval or authorisation; 5) initiates any approved financial transaction; 6) notifies the remote ERP of the expenditure or payment for the itinerary event as soon as this is possible; 7) notifies the remote ERP of the cost centres for the itinerary event.
FIG. 1 shows the travellers NFC equipped device 101 , typically a mobile phone, its internet connection 102 to a remote ERP system 103 which holds the original of the travellers itinerary, its local connections to payment initiating NFC devices at a hotel 104 , a taxi 105 or an airport 106 using the NFC NDEF protocol. Most itinerary items will have itinerary events associated with them, for instance an airport flight may have an associated entry in to a taxi, and exit from the taxi plus payment, a flight check in assuming there is baggage and a gate check in. Preferably each of these locations has an NFC identifying device which can serve to identify the traveller through the travellers NFC equipped device, and preferably where a financial transaction takes place at that location the NFC device can initiate a financial transaction with the travellers device if required.
Each of these locations occurs at a known itinerary event in the travellers itinerary and reporting back of these assists the corporate ERP in tracking the progress of the traveller and, by reporting back payments, recording the expenses of the traveller. The presence of the travellers device at a location can be estimated from location services using the location of found WiFi network names or phone cell locations or from a device GPS and failing this by the traveller manually activating an itinerary event.
The travellers phone may communicate with the remote ERP system via the internet or via any other available communication method when and where possible and the travellers itinerary may update the ERP system and be updated from the remote ERP system in this manner so that it carries a replica of the ERP itinerary. Typically the travellers phone will communicate with the ERP via WiFi rather than a telephone data link when outside of the home country in the interests of cost, and typically the WiFi connection will be only at selected locations.
The travellers device detects the occurrence of an itinerary event, for instance the passage of the phone past a checkout NFC device at a hotel at or near the time specified in the itinerary for checkout will be interpreted as an itinerary event for checkout, and retrieves from the checkout facility via NFC the expenditure incurred at the hotel. The traveller may authorise this for payment by NFC and the payment can then later be reported back to the remote ERP by a report conveyed from the travellers phone of the itemised invoice/receipt provided to the traveller by NFC.
In similar manner the traveller may take a taxi from the hotel to an airport. The taxi preferably has an identified transaction triggering NFC device and on leaving the taxi the device is queried, using the travellers device, for the required fare. Once the traveller authorises that fare a financial transaction will occur and again the transaction can be later reported through a WiFi connection or the travellers data connection to the corporate ERP.
FIG. 2 shows a display on an NFC equipped mobile phone 201 having control buttons 202 , 203 and screen icons 204 , 205 when the phone is passed by an NFC terminal in a hotel at a date and time which falls near to the expected check out time as recorded as an itinerary event in both the phone and the corporate ERP database. The monitoring application in the phone questions at 206 in message 207 whether checkout is required. Response icons 208 show the allowed responses and if the “YES” icon is touched the NFC connection queries the hotel for a checkout invoice.
This checkout invoice is parsed by the NFC transaction application and processed to show as at FIG. 3 the name of the billing centre at 301 , the total billed amount at 302 and the billing period at 303 . The latter may be broken down to the hotel cost centre items at 304 .
The phone application will have stored the predicted itinerary expenses and if this differs from the expected amount will raise a notification. This may produce a message 401 as seen in FIG. 4 on which the traveller can act before confirming the payment.
Similarly the phone application may provide for judging whether some of the expenses are corporate or personal expenses and presenting them differently to the remainder, for instance by coloration. It may also query the traveller as to whether such expenses should be assigned as to personal expenses as other than approved expenses as in FIG. 5 at 501 . If this is so the payment may be split so that the corporate part of the expenses is paid with the stored corporate credit card details and the personal part paid with the travellers own credit card.
Once all such queries have been answered the appropriate financial transaction or transactions will be performed with the hotel through the NFC connection and recorded by the travellers phone, either as data or as part of an uploadable webpage. Subsequently or simultaneously, depending on WiFi access, the phone application will transfer the itemised receipt to the remote ERP system together with details of the cost centres (corporate/personal, meals, accommodation, entertainment, etc).
Having checked out of the hotel the traveller may wish to take a taxi to the airport and hails a cab from outside the hotel. En route the traveller selects the cost centre menu 601 of FIG. 6 and selects the transportation “Taxi”. When the taxi arrives at the destination it is only necessary to pass the phone past the taxi NFC device and the invoice for the trip will be presented as at FIG. 7 . Typically the organization name appears at 701 , the currency type at 702 , the details of the completed trip at 703 and the item detail at 704 with a total at 705 . A confirmation touch on the screen will carry out the financial transaction leaving the travellers phone with transaction receipt details which will later be passed on to the remote ERP.
FIG. 8 shows a flowsheet of the phone and ERP process involved in carrying out the NFC connection and the transfer of data to the remote ERP. The left column relates to actions within the phone application of the traveller at 801 while the right column relates to actions at the remote ERP 802 . Initially the phone NFC device contacts at 803 another NFC device with which it can exchange data, preferably receiving an indication of the organisation providing the NFC device.
At 804 the application determines whether the NFC connection matches one of the itinerary events as to date and time. Typically each event will have an event start time and an event end time within which the event is expected to fall. For instance where the traveller is leaving the hotel to take an airline flight the end time will be the minimum cross town taxi time from the last possible check in time for the flight while the start time may be several hours beforehand.
Where the time matches that of an itinerary event the application will assume that the connection is correct for the event will show the event prompt at 805 asking the traveller whether to carry out the expected event, as in FIG. 2 . If not affirmed the NFC application then reverts to awaiting a new connection at 807 . If affirmed at 806 the application confirms that the itinerary event is taking place at 808 and if the event involves a financial transaction, as at 809 , retrieves from the connection the financial information as an invoice and presents it as in FIG. 3 . Whilst doing this the application will check at 810 that the amounts match those originally entered during the itinerary creation and if not raises an error as in FIG. 4 and typically allocates part of the expenses as personal and may pay these expenses using a personal account.
Where the expense of the itinerary event is small enough the mere detection of an NFC device for that itinerary event may be sufficient to allow the carrying out of the financial transaction.
The application may also check that all the items meet the cost centre amounts predicted by the itinerary for this event as in FIG. 5 and may prompt the traveller as to which cost centre amounts which have not been predicted should be allocated to.
If no other financial matters are raised the transaction or transactions are confirmed at 811 and takes place through the NFC connection. Following this the application checks at 812 if a connection to the remote ERP is available and if so provides an update of the receipt by internet data connection or some other method to the remote ERP, including an itinerary event identifier. If no connection is available the application returns to awaiting an NFC connection and also awaits an opportunistic connection to the remote ERP. The update is eventually received at 814 , the itinerary identified at 815 and the traveller concerned at 816 . The occurrence of the itinerary event is then logged at 817 . If the itinerary event was a financial event then the event is identified at 819 and the expected expense items retrieved from storage. At 820 the received update, whether invoice or receipt, is parsed to extract the items and the cost centres checked, noting that these should already have been allocated by the traveller as in FIG. 5 in the phone application. Where necessary any required amendments may be queried with the traveller and the recording of the itinerary event is then ended at 823 . Typically any discrepancies between the itinerary at the ERP and the replica at the travellers device will be corrected by uploading the updated itinerary from the remote ERP the next time the application connects to the ERP.
The travellers NFC equipped device may be used for purposes other than financial transactions, for instance the travellers bags may have RFID tags, and this allows the traveller to positively identify bags during travel, for instance at airport baggage claim.
It is to be understood that even though numerous characteristics and advantages of the various embodiments of the present invention have been set forth in the foregoing description, together with details of the structure and functioning of various embodiments of the invention, this disclosure is illustrative only, and changes may be made in detail so long as the functioning of the invention is not adversely affected. For example the invention is described in its application to an itinerary in which only expenses may be involved, but the invention is equally as applicable to an itinerary including the selling of items and may produce invoices for transfer to a participating NFC connection and receive an authorisation to transfer funds from that NFCs organisation. The invention may thus vary dependent on the particular application for which it is used without variation in the spirit and scope of the present invention.
In addition, although the preferred embodiments described herein are directed to the recording of itinerary events and their associated transactions in an ERP system, but it will be appreciated by those skilled in the art that variations and modifications are possible within the scope of the appended claims.
INDUSTRIAL APPLICABILITY
The method of the invention is used in the transfer and corellation of data between an invoice or receipt receiving device travelling on an itinerary and a corporate ERP system recording details of the itinerary, the transferred data relating to itinerary events and being recorded as financial transactions against cost centres in the ERP. The present invention is therefore industrially applicable. | A method of monitoring the expenses of a traveller during the progress of an itinerary utilises NFC for carrying out the financial transactions associated with the itinerary and updates a corporate ERP or similar financial database with the financial transactions as they occur allowing rapid allocation to cost centres. The itinerary may be laid out in terms of itinerary events, each of which may be tracked by an NFC connection with an NFC device at an expected location and date for the itinerary event. | 6 |
FIELD OF THE INVENTION
This invention relates to swivelling landing gears for aircraft and more particularly to nose landing gears comprising a casing and at least one wheel connected directly or indirectly to the casing through a rocker beam capable of being subjected to the action of a shock absorber.
BACKGROUND OF THE INVENTION
Generally, a nose landing gear of an aircraft includes a leg mounted in a casing, a rocker beam connected to one end of the leg through a swivel pin and supporting rolling means such as one or two wheels, a shock absorber of the type with a cylinder and a rod fixed on one side to the bottom of the leg or of the casing via a cardan joint and on the other side to the rocker beam.
It is in fact known that, firstly, when the aircraft is on the ground, it can move by rolling on the runway. In this case, the shock absorber must perform its function when it comes over rough spots on the runway for example. In addition, it is of course necessary for the aircraft to also be able to steer to go from one place to another. For this purpose, the leg is connected to a means allowing it to be turned so as to give the wheels the desired positioning. Taking into account all these parameters, it is noted that the cardan joint allows a rotation in a plane around a point of the shock absorber when it is compressed but also a rotation of this plane when the wheels undergo different orientations to steer the aircraft. These conditions are known and will not be described in further detail.
One thus also sees the utility of the cardan joint, which allows this rotation of the shock absorber around a point and within a solid angle having a value of a few degrees.
The cardan joints used in landing gears have been fully satisfactory from the viewpoint of reliability, but they exhibit at least one drawback. In fact, as they are placed at the back of the leg at one end of the shock absorber, access to them is very difficult, thus entailing relatively high maintenance costs. It is therefore an object of the present invention to overcome these drawbacks by providing a nose landing gear with a rocker beam subjected to the action of a shock absorber, of simple design and construction allowing very easy maintenance.
SUMMARY OF THE INVENTION
More precisely, it is the object of the present invention to provide a landing gear comprising a hollow casing, a leg with an open well, said leg being mounted in said hollow casing, a rocker beam mounted rotatably at one of its ends on one end of said leg, the other leg of said rocker beam supporting rolling means, a shock absorber comprising at least two elements, in this case a cylinder and a rod sliding in said cylinder, one end of one of the two elements being linked in rotation with said mechanisam and the other element being connected in said well of said leg to the casing by means for rotating around a point, characterized in that said means are constituted by the two ends of said element connected to the inside of said leg and to said casing, and shaped in convex spherical surface portions cooperating respectively with two complementary spherical concave surfaces linked respectively with the inside of said casing and the inside of said leg, said concave and convex spherical surfaces having substantially the same center of rotation.
According to a characteristic of the present invention, said center of curvature is located substantially on the axis of said well of the leg.
According to another characteristic of the present invention, said center of curvature is located as close as possible to the back end of said well so that the convexity of the spherical surfaces located at the back end of said well are larger than those of the other two spherical surfaces located toward the outside of said well.
BRIEF DESCRIPTION OF THE DRAWING
Other characteristics and advantages of the present invention will appear from the following description given with reference to the appended drawing in which the FIGURE represents schematically a section of an embodiment of a nose landing gear according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The landing gear shown schematically in cross section in the FIGURE comprises a leg 1 placed in a casing 2. This leg has a cylindrical form of revolution and a well 3 having an opening 4 at least at the lower end when the landing gear is raised on an aircraft represented by 5 in the FIGURE.
This leg is also connected to the casing 2 so that it can turn substantially about an axis 6 which is also that of the well 3 which preferably has a cylindrical form of revolution. The casing 2 is linked with the structure 5 of the aircraft and connected to the leg 1 by a rack 7 in a known manner, making it possible--taking for example a reference in relation to the casing--to rotate the leg with respect to the structure 5 of the aircraft and in particular with respect to the casing thanks to bearings 38.
Furthermore, the end 8 of the leg 1 has an elbow 9 in the form of a lateral extension carrying a swivel pin 10 which is off-centered in relation to the axis 6, pin 10 connecting one end 11 of a rocker beam 12 whose other end 13 carries rolling means such as one or two wheels 14. A shock absorber 15 comprising, in a simplified manner, a cylinder 16 in the upper position and a rod 17 sliding in the cylinder 16 through a piston 18 in the lower position. In this embodiment, the end 19 of the rod 17 is mounted rotatably at 24 on the rocker beam 12 relatively close to the end 11 connected in rotation to the leg 1 through the elbow 9.
On the other hand, the upper end 21 of the cylinder 16 penetrating into the well 3 of the leg emerges from the latter to cooperate by means of a bearing with a central part 20 of the hollow casing 2, this part 20 itself being fixed in relation to the structure 5 of the aircraft.
More precisely, this end 21 is shaped in a cap having a convex spherical surface 22 of sufficient convexity C1 so that the center of curvature 23 is as high as possible in the leg (i.e. the radius has a very small value). This surface cooperates by sliding with a concave spherical surface 25 complementary to the surface 22 formed on the central part 20 of the casing 2.
The end 21 of the cylinder 16 has two longitudinal grooves 26 and 27 substantially parallel to the axis 6 to cooperate with two lugs 28 and 29 integral with the part 20 so that the two surfaces can slide on each other such that the cylinder 16 can describe a solid angle having an apex 23 but the cylinder 16 cannot turn about itself.
To accomplish this, the two lugs 28 and 29 plunge radially respectively into grooves such that they are substantially directed toward the center 23 defined above.
The other end 42 of the cylinder, having the opening 30 through which penetrates the rod 17, is also shaped in a convex spherical surface 31 which cooperates by sliding on a complementary concave spherical surface. This concave surface 32 is made on the face of a ring 33 of annular form surrounding with a relatively large interval the rod 17 of the shock absorber 15 and is screwed for example in the well 3 of the leg 1 whose wall 34 near the opening 4 has a threading.
It is specified that the two spherical surfaces 31 and 32 have a fairly small convexity C2 and a center of curvature which coincides with the center 23 defined previously.
The landing gear just described above operates in the following manner:
First of all, it is assumed that the aircraft is rolling in a straight line on a runway having surface irregularities. Owing to their existence, the shock absorber plays its role and consequently the rod 17 penetrates into the cylinder 16. In this case, the attachment point 24 describes a circular arc 40 centered on the pin 10 so that the end 19 moves laterally by a certain value. This translation is possible owing to the existence of the spherical cap 22 with a small radius of curvature, which is in fact equivalent to compensating this relative translation of the end of the rod by a rotation of the shock absorber around the center 23 which is very far from this point 24, by the sliding of the two spherical surfaces 22 and 25 on each other. This is also possible by the fact that the two other spherical surfaces 31 and 32 of large radius are centered on the same point of rotation 23.
Hence, when the aircraft rolls in a straight line, it is observed that the rotation of the shock absorber takes place in a plane around the point 23. However, as it is well known, to steer an aircraft on the ground, the nose landing gear wheel is oriented. As described earlier, the orientation of the wheel 14 is obtained by actuating the rack 7 for example. As the rod 17 is connected to the rocker beam 12 around a pin 24 allowing only one degree of freedom, the rod 17 also turns in the cylinder 16.
It is also necessary that the cylinder should not turn about itself because the shock absorber has a means for bringing the wheel back into a given direction when the landing gear must be retracted into its well after the aircraft has taken off. This means has not been represented, in order to simplify the FIGURE, and also because it is known in itself.
However, it is pointed out that it is made up very schematically of a V-groove in the internal body of the cylinder cooperating with a finger on the rod, which follows the contour of this groove when the shock absorber is relieved upon the take-off of the aircraft, thereby bringing the wheel to a given position. It is then understood that in this case the cylinder must not swivel about itself on its axis of symmetry 6 because the position of the wheel would surely never be determined. Then, as stated previously, when the aircraft is moving on the ground it is necessary first of all for the shock absorber to be able to swivel as described above around the center 23 and secondly that the cylinder should not rotate about its axis defined substantially by the axis 6. This latter point is possible owing to the existence of two lugs 28 and 29 penetrating into the grooves 26 and 27 substantially in the direction of the center 23, because it is in this position that the relative movements between the lugs and the spherical cap are the greatest, considering that these lugs prevent the rotation of the cylinder about itself.
The landing gear just described above offers all the advantages of the cardan joint, but in addition it allows easy maintenance. In fact, to remove the shock absorber from inside the leg, it is sufficient to unscrew the ring 33, the entire shock absorber then coming out easily because the grooves 26 and 27 are open upwards respectively at 36 and 37.
The same applies to its installation. The shock absorber is introduced into the leg until the lugs 28 and 29 penetrate into the grooves 26 and 27 and the surface 22 comes into contact with the complementary surface 25. In this position, the ring 33 is introduced around the rod 17 and screwed into the leg 1. The end 19 is then fitted on its pin 24 to connect it to the rocker beam 12. | The invention concerns a landing gear. The landing gear is characterized essentially by the fact that it comprises at least one shock absorber (15), this shock absorber being mounted in the leg (1) and casing (2) assembly by means of two convex surfaces (22, 31) made on the cylinder (16) of the shock absorber (15) and cooperating with two concave surfaces (25, 32) integral respectively with the leg (1) and the casing (2). This landing gear finds an application as a nose gear of the rocker-beam type. | 5 |
CLAIM OF BENEFIT (35 U.S.C. § 119(e))
[0001] This Application claims the benefit of U.S. Provisional Application No. 60/398,493, filed Jul. 25, 2002.
FIELD OF THE INVENTION
[0002] The present invention relates generally to radio telephony, and more specifically to a system and method for efficient code division multiple access (CDMA) communication using wideband multi-carrier CDMA (MC-CDMA).
BACKGROUND OF THE INVENTION
[0003] The now ubiquitous telecommunication instruments commonly called cellular telephones (or simply “cell phones”) are actually mobile radios having a transmitter and a receiver, a power source, and some sort of user interface. They are referred to as cell phones because they are designed to operate within a cellular network. Despite being radios, they typically do not communicate directly with each other. Instead, these mobile telephones communicated over an air interface (radio link) with numerous base stations located throughout the network's coverage area. The network base stations are interconnected in order to route the calls to and from telephones operating within the network coverage area.
[0004] [0004]FIG. 1 is a simplified block diagram illustrating the configuration of a typical cellular network 100 . As may be apparent from its name, the network coverage area (only a portion of which is shown in FIG. 1) is divided into a number of cells, such as cells 10 through 15 delineated by broken lines in FIG. 1. Although only six cells are shown, there are typically a great many. In the illustrated network, each cell has associated with it a base transceiver station (BTS). Generally speaking, BTS 20 is for transmitting and receiving messages to and from any mobile stations (MSs) in cell 10 ; illustrated here as MS 31 , MS 32 , and MS 33 , via radio frequency (RF) links 35 , 36 , and 37 , respectively. Mobile stations MS 31 through MS 33 are usually (though not necessarily) mobile, and free to move in and out of cell 10 . Radio links 35 - 37 are therefore established only where necessary for communication. When the need for a particular radio link no longer exists, the associated radio channels are freed for use in other communications. (Certain channels, however, are dedicated for beacon transmissions and are therefore in continuous use.) BTS 21 through BTS 25 , located in cell 11 through cell 15 , respectively, are similarly equipped to establish radio contact with mobile stations in the cells they cover.
[0005] BTS 20 , BTS 21 , and BTS 22 operate under the direction of a base station controller (BSC) 26 , which also manages communication with the remainder of network 100 . Similarly, BTS 23 , BTS 24 , and BTS 25 are controlled by BSC 27 . In the network 100 of FIG. 1, BSC 26 and 27 are directly connected and may therefore route calls directly to each other. Not all BSCs in network 100 are so connected, however, and must therefore communicate through a central switch. To this end, BSC 20 is in communication with mobile switching center MSC 29 . MSC 29 is operable to route communication traffic throughout network 100 by sending it to other BSCs with which it is in communication, or to another MSC (not shown) of network 100 . Where appropriate, MSC 29 may also have the capability to route traffic to other networks, such as a packet data network 50 . Packet data network 50 may be the Internet, an intranet, a local area network (LAN), or any of numerous other communication networks that transfer data via a packet-switching protocol. Data passing from one network to another will typically though not necessarily pass through some type of gateway 49 , which not only provides a connection, but converts the data from one format to another, as appropriate.
[0006] Note that packet data network 50 is typically connected to the MSC 29 , as shown here, for low data rate applications. Where higher data rates are needed, such as in 1xEV-DO or 1xEV-DV networks, the packet data network 50 is connected directly to the BSCs ( 26 , 27 ), which in such networks are capable of processing the packet data. The downlink peak data rate for a 1xEV-DV system, for example, is 3.0912 Mbps.
[0007] The cellular network 100 of FIG. 1 has several advantages. As the cells are relatively small, the telephone transmitters do not need a great deal of power. This is particularly important where the power source, usually a battery, is housed and carried in the cell phone itself In addition, the use of low-power transmitters means that the mobile stations are less apt to interfere with others operating nearby. In some networks, this even enables frequency reuse, that is, the same communication frequencies can be used in non-adjacent cells at the same time without interference. This permits the addition of a larger number of network subscribers. In other systems, codes used for privacy or signal processing may be reused in a similar manner.
[0008] At this point, it should also be noted that as the terms for radio telephones, such as “cellular (or cell) phone” and “mobile phone” are often used interchangeably, they will be treated as equivalent herein. Both, however, are a sub-group of a larger family of devices that also includes, for example, certain computers and personal digital assistants (PDAs) that are also capable of wireless radio communication in a radio network. This family of devices will for convenience be referred to as “mobile stations” (regardless of whether a particular device is actually moved about in normal operation).
[0009] In addition to the cellular architecture itself, certain multiple access schemes may also be employed to increase the number of mobile stations that may operate at the same time in a given area. In frequency-division multiple access (FDMA), the available transmission bandwidth is divided into a number of channels, each for use by a different caller (or for a different non-traffic use). A disadvantage of FDMA, however, is that each frequency channel used for traffic is captured for the duration of each call and cannot be used for others. Time-division multiple access (TDMA) improves upon the FDMA scheme by dividing each frequency channel into time slots. Any given call is assigned one or more of these time slots on which to send information. More than one voice caller may therefore use each frequency channel. Although the channel is not continuously dedicated to them, the resulting discontinuity is usually imperceptible to the user. For data transmissions, of course, the discontinuity is not normally a factor.
[0010] Code-division multiple access (CDMA) operates somewhat differently. Rather than divide the available transmission bandwidth into individual channels, individual transmissions are spread by applying a unique spreading code. By spreading each transmission in a different way, each receiver (i.e. mobile station) processes only that information intended for it and ignores other transmissions. The number of mobile stations that can operate in a given area is therefore limited by the number of spreading sequences available, rather than the number of frequency bands. The operation of a CDMA network is normally performed in accordance with a protocol referred to as IS-95 (interim standard-95) or, increasingly, according to its third generation (3 G) successors, such as those sometimes referred to as 1xEV-DO and 1xEV-DV, the latter of which provides for the transport of both data and voice information.
[0011] [0011]FIG. 2 is a flow diagram illustrating the basic steps involved in sending a CDMA transmission according to the prior art. At START it is assumed that information from an information source (such as a caller's voice) is available and that a connection has been established with a receiving node. At step 205 , the audible voice information is sampled and digitally encoded. The encoded information is then organized into frames (step 210 ). Error detection bits are then added (step 215 ) so that the receiver can evaluate the integrity of the received data. The resulting signal is then convolutionally encoded (step 220 ). Block interleaving is then performed (step 225 ) on the resulting signal to further enhance the receiver's ability to reconstruct the bit stream with a minimum of error. The interleaved signal is then spread by a pseudonoise (PN) code (step 230 ), a long code is applied (step 235 ) and a Walsh code is used to spread the wave form and provide channelization (step 240 ). I and Q short codes are added (step 245 ) and the results filtered (step 250 ) before being combined and spread (step 255 ), then amplified (step 260 ) for transmission.
[0012] As alluded to above, mobile stations and the network they are a part of are presently being used to carry an increasingly large amount of traffic. Not only is the number of ordinary voice calls increasing, but so is the number of other uses to which mobile stations can be put. Short message service (SMS) messaging and instant messaging are becoming more popular, faxes and emails can be sent through mobile stations, and World Wide Web pages can be downloaded. Portable personal computers can be equipped to send through the network data files such as spreadsheets, word processing documents, and slide presentations. All of this information may enter and leave the network infrastructure through the air interface, which has a limited bandwidth by its nature and varying levels of interference and distortion. This means that more efficient methods of radio transmission offering higher data rates at satisfactory quality levels are increasingly in demand. The present invention presents a solution that addresses this growing need.
SUMMARY OF THE INVENTION
[0013] In one aspect, the present invention is a system for wireless communication using code division multiple access (CDMA), including an encoder for encoding information, a modulator for modulating the encoded information stream, and a transmitter for transmitting the modulated signal stream according to an orthogonal frequency division multiplexing (OFDM) scheme that allows for variation in one or more of a number of loading parameters such as the number of users, the coding rate and the data rate.
[0014] In another aspect, the present invention is a method of transmitting a CDMA signal, including the steps of encoding the information, modulating the encoded signal onto a carrier, dividing the modulated signal into a plurality of streams, spreading each of the plurality of streams with a spreading code, modulating the spread streams in an OFDM modulator, and determining whether to apply a variable loading parameter. This determination may be made according to predetermined factors relating to the location and expected use of the transmitter, and may be adjustable based on traffic conditions, channel interference, or similar factors.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] For a more complete understanding of the present invention, and the advantages thereof, reference is made to the following drawings in the detailed description below:
[0016] [0016]FIG. 1 is functional block diagram illustrating the relationship of selected components of a typical CDMA telecommunication network, such as one that might advantageously employ the system and method of the present invention.
[0017] [0017]FIG. 2 is a functional block diagram illustrating an exemplary process of transmitting and receiving a communication signal in the network of FIG. 1.
[0018] [0018]FIG. 3 is a functional block diagram illustrating the relationship of selected components of an MC-CDMA telecommunication system operable according to an embodiment of the present invention.
[0019] [0019]FIG. 4 is a functional block diagram illustrating selected components of an MC-CDMA transmitter operable according to an embodiment of the present invention.
[0020] [0020]FIG. 5 is a functional block diagram illustrating selected components of the receiver portion of an embodiment of the present invention.
[0021] [0021]FIG. 6 is a flow diagram illustrating a method of transmitting a radio signal according to an embodiment of the present invention.
[0022] [0022]FIG. 7 is a flow chart illustrating a method of receiving a radio signal according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0023] [0023]FIGS. 1 through 7, discussed herein, and the various embodiments used to describe the present invention are by way of illustration only, and should not be construed to limit the scope of the invention. Those skilled in the art will understand the principles of the present invention may be implemented in any similar radio telecommunication system, in addition to those specifically discussed herein.
[0024] The present invention is directed to a system and method for optimizing code division multiple access (CDMA) communication in a wireless communication system. As described above, in a conventional CDMA system, signals are spread in the time domain prior to transmission. In a multi-carrier CDMA (MC-CDMA) system, in contrast, spreading is done in the frequency domain.
[0025] [0025]FIG. 3 is a functional block diagram illustrating the relationship of selected components of an MC-CDMA telecommunication system 300 operable according to an embodiment of the present invention. System 300 has a transmit side 310 and a receive side 350 . Naturally, there could be any number of transmitters and receivers, but for simplicity only one of each is illustrated. Information, which could be voice or data, is first encoded in encoder 315 according to an encoding scheme such as that currently specified in the 1xEV-DV specification. Other encoding schemes may be acceptable, but it is preferred that the system of the present invention be backward compatible with established systems where feasible. In accordance with an embodiment of the present invention, the coding rate, however, may be varied to adjust for varying conditions, transmitter performance, or other design or environmental factors.
[0026] The encoded information is then provided to modulator 320 where it is modulated onto a carrier using, for example, a QPSK or 16QAM modulation scheme. The modulated signal is then provided to an MC-CDMA transmitter 325 for transmission over a selected air-interface channel. The signal transmitted by transmitter 325 is intended to be received by an MC-CDMA receiver 355 in the receiving instrument 350 , and the transmitted symbols are detected by detector 360 , and finally decoded in decoder 365 so that the transmitted information is recovered on the receiver side. A transmitter and a receiver according to an embodiment of the present invention are described in more detail below.
[0027] Note that the transmitter and receiver illustrated in FIG. 3 may be (and generally are) part of a much larger telecommunication system (see, for example, the system of FIG. 1), which uses for communication not only radio transmission, but often wire, optical fiber, and microwave channels as well. Information is frequently sent though the network, and between the network and other networks on such channels. Mobile stations, however, virtually always rely on radio communication to communicate with the rest of the network. This means that the air interface is an important and even indispensable part of the network. Unfortunately, it is generally speaking the most bandwidth limited channel, and the medium most subject to variable distortion, traffic, and interference effects. In this light, it is most advantageous to utilize radio transmitters and receivers that use optimum transmission methods that can be adjusted to these varying conditions, either by location, by individual transmitter, or from time to time as local conditions change.
[0028] As alluded to above, the transmitter 325 and receiver 355 are designed for use according to an MC-CDMA protocol, which differs in some respects from that used in a conventional CDMA system. FIG. 4 is a functional block diagram illustrating selected components of an MC-CDMA transmitter 425 operable according to an embodiment of the present invention. Initially, modulated symbols provided to the transmitter 425 (see, for example, the transmitter 325 of FIG. 3) are separated using serial-to-parallel converter 430 into K blocks of J streams. The number of streams in each block may be fixed, but in a preferred embodiment the number can be adjusted to account for varying transmission conditions (or other factors). Each of the J streams are spread using a spreading code, here numbered C 1 . . . C J . Naturally, the number of streams J is limited by the number of available unique spreading codes.
[0029] The spread streams are provided to a summer 435 (here illustrated as a summer for each block enumerated, respectively, 435 0 , 435 k , and 435 K−1 . The resulting symbol streams So through S K−1 are passed through S/P converter 440 0 , 440 k , and 440 K−1 and then provided to interleaver 445 where they are interleaved. The resulting streams are provided to an orthogonal frequency division multiplexing (OFDM) modulator 450 , which according to this embodiment of the invention applies an inverse fast Fourier transform (IFFT) to spread the symbols into frequency bins in the frequency domain. Note that in a preferred embodiment, the transmitter data rate can be varied to adjust for changing conditions. The signal from OFDM modulator 450 is filtered by pulse-shaping filter 455 before being transmitted via antenna 457 .
[0030] [0030]FIG. 5 is a functional block diagram illustrating selected components of the receiver portion 555 of an embodiment of the present invention. The receiver 555 receives a transmitted signal via antenna 558 , which provides it to a receive filter 560 . The filtered signal is then provided to an OFDM demodulator 565 and demodulated by application of a fast Fourier transform (FFT). The demodulated signal is then provided to an interleaver 570 , which deinterleaves the signal into reconstructed streams Ŝ 0 though Ŝ K−1 (each associate with a respective transmitted block). The streams Ŝ 0 though Ŝ K−1 will then be provided to a detector (see, for example, detector 360 in FIG. 3). In accordance with an embodiment of the present invention, the receiver 555 is operable to process signals transmitted by transmitter 425 (shown in FIG. 4), in which loading parameters such as coding rate, data rate, and streams per block are subject to variation.
[0031] [0031]FIG. 6 is a flow diagram illustrating a method 600 of transmitting a radio signal according to an embodiment of the present invention. At START, it is assumed that the required communications equipment, such as that described above in reference to FIGS. 2 - 5 . The method begins at step 605 where the information, such as data or voice information, is encoded using an encoding scheme such as one currently called out in the 1xEv-DV specification. The coding rate may be fixed but is preferably adjustable. The encoded information stream is then modulated onto a carrier (step 610 ) and the modulated signal provided to an MC-CDMA transmitter step 615 .
[0032] In the MC-CDMA transmitter, the modulated symbol stream is divided into a plurality of streams (step 620 ). If there are multiple users, then the modulated symbol streams of all users are divided into a plurality of blocks, with each block having a number of streams. In accordance with one embodiment of the present invention, the number of streams may be varied to account for varying conditions or for other reasons. The streams within each block are then each spread with a spreading code (step 625 ), preferably using a Walsh-Hadamard code of a predetermined length. The spread streams in each block are then summed (step 630 ) to form a single spread stream.
[0033] In the illustrated embodiment, the spread stream is one of a plurality of spread streams, each associated with a certain block. In this case, the spread stream associated with each block is provided to a serial to parallel (S/P) converter and divided (step 635 ). The resulting outputs are interleaved (step 640 ) and provided to an OFDM modulator where the interleaved signals are mapped to a plurality of frequency bins by applying an inverse fast Fourier transform (IFFT) (step 645 ). A cyclic prefix is then added (step 650 ) and the symbol stream is passed though a pulse shaping filter (step 655 ) before it is amplified for transmission (step 660 ).
[0034] The method described above has been found to provide comparable or superior communications when compared with conventional 1xEV-DV or other kinds of CDMA systems. In addition, it has been determined that using variable loading parameters in combination with the method described above provides further improvement in results. In a first embodiment of the present invention, the variable loading parameter is the number of spread streams into which the modulated symbol stream is divided prior to being spread with a spreading code (step 625 , described above). Significant reduction inter-symbol interference and a corresponding improvement in performance may be realized by adjusting the number of spread streams to an optimum level.
[0035] In another embodiment of the present invention the variable loading factor is the channel coding rate. By strengthening the channel coding rate the system in the MC-CDMA telecommunications system described above, the performance of the system in terms of evaluation factors such as bit error rate (BER) may be significantly improved without sacrificing communication capacity or data rate. In another embodiment, the code rate of the MC-CDMA system is increased such the data rate capability itself is increased.
[0036] In yet another embodiment of the present invention, application of one or more variable loading parameters may be combined, to the extent it is consistent to do so. The variable loading factors may also be dynamically adjustable to compensate for varying traffic loads, or for channel conditions such as noise level or fading state.
[0037] [0037]FIG. 7 is a flow diagram illustrating a method 700 of receiving a radio signal according to an embodiment of the present invention. At START is presumed that transmission from a compatible transmitter has already been made according to an embodiment of the present invention. The method begins with the reception of the transmitted signal (step 705 ). The receiver signal is filtered (step 710 ) and then the filtered signal is passed through an OFDM demodulator (step 715 ), which applies a fast Fourier transform (FFT). The demodulated signal is then deinterleaved (step 720 ) and provided to a parallel-to-serial (P/S) converter (step 725 ) where it is converted to a plurality of parallel spread streams. (Assuming the parallel spread streams form blocks) each block of spread streams is provided to a detector that attempts to detect the original encoded symbols (step 730 ). The symbols are then decoded (step 735 ) to reproduce the originally transmitted information.
[0038] The preferred descriptions are of preferred examples for implementing the invention, and the scope of the invention should not necessarily be limited by this description. Rather, the scope of the present invention is defined by the following claims. | A system and method for the efficient transmission of information in a code division multiple access (CDMA) wireless telecommunication system. The rate of reliable transmission is increased by implementing an orthogonal frequency-division multiplexing (OFDM) scheme in, for example, a direct-spread CDMA network, resulting in a multi-carrier CDMA (MC-CDMA) system. Information (such as voice and data), is encoded, divided, and spread across the frequency domain, rather than in the time domain as in traditional CDMA; the allowable transmission bandwidth is divided into a number of carriers. Using this scheme, a number of loading parameters such as code rate, data rate, and the number of streams into which the encoded data is divided may be varied to increase the performance of the system. Application of the variable loading parameter may be a function of channel quality, such as the presence of noise or the channel fading state. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a resin composition for no-flow underfill which can be formed into a film, a no-flow underfill film using the composition, and a manufacturing of the no-flow underfill film, more particularly, to a resin composition for no-flow underfill, which comprises a thermoplastic epoxy resin prepolymer, and thus can be formed into a film so as to make it possible to control the thickness and area of underfill, and to no-flow underfill film formed from the resin composition and a manufacturing method of the no-flow underfill film.
[0003] 2. Description of the Prior Art
[0004] In a flip chip package process, in order to solve the mismatch caused by the difference between the coefficients of thermal expansion (CTE) of a semiconductor chip, an interconnection material and a package substrate and to physically support the electrical connection between the package substrate and the semiconductor chip, a sealing material is filled in the gap between the semiconductor chip and the package substrate. This sealing material is known as “underfill” in the art, and the use of the underfill can increase the fatigue life of the solder joints.
[0005] As a process for underfilling semiconductor components, a capillary flow underfill process is being mainly used in which a liquid underfill material such as epoxy resin is dispensed between a semiconductor substrate and a package substrate and then cured. In conventional capillary flow underfill, the underfill dispensing and curing takes place after the metallic solder has been reflowed to form interconnections (a soldering process). When a predetermined amount of underfill material is dispensed along one or more peripheral sides of the package assembly, the underfill material is drawn inward by capillary action occurring in the gap between the semiconductor chip and the package substrate. The underfill material dispensed as described above is subsequently cured, thus completing the package assembly.
[0006] As a more effective process than that described above, a no-flow underfill process has been proposed. In the no-flow underfill process, underfill resin is applied to the assembly site before the semiconductor chip is placed. After the semiconductor chip is placed on the package substrate, it is soldered to the metal pad connections on the substrate by passing the full assembly, comprising the semiconductor chip, underfill and package substrate, through a reflow oven. During this process, the underfill fluxes the solder and metal pads, the solder joint ref lows, and the underfill cures. Thus, when the above-described no-flow underfill process is used, the separate steps of applying the flux and post-curing the underfill are eliminated.
[0007] As soldering and cure of the underfill occur during the same step of the process, maintaining the proper viscosity and cure rate of the underfill material is critical in the no-flow underfill process. The underfill must remain at a low viscosity to allow melting of the solder and the formation of the interconnections. It is also important that the cure of the underfill not be unduly delayed after the cure of the solder. It is desirable that the underfill in the no-flow underfill encapsulation process should not interfere with the melting of the solder and should cure rapidly after the melting of the solder. The underfill preferably has such a viscosity that it can be dispensed by a syringe.
[0008] However, the above-described no-flow underfill generally has the following problems. Because the underfill must remain at a low viscosity before cure thereof at the soldering process temperature so as to melt the solder thereby to facilitate the formation of the interconnections, it is generally manufactured as a paste type. If the no-flow underfill is manufactured as a paste type, the fluidity of the paste must be suitably adjusted to control the thickness and area of underfill applied. However, because the resin composition is in a paste state, it is difficult to accurately control the thickness of the paste. Also, because it is very difficult to uniformly treat an amount of the resin composition in the process of applying the composition, the paste type resin is disadvantageous for treating a large-area chip or treating several chips at the same time. Thus, these problems need to be solved.
[0009] Meanwhile, if the underfill is manufactured as a film type, it is possible to solve the above-described problems, but there is generally a problem in that it is difficult to form a film from the components of the no-flow underfill resin composition. It has been attempted to increase the film formability of the no-underfill resin composition by adding various thermoplastic resins as resin modifiers to the composition before applying the composition, but in this case, it is difficult to guarantee the stable heat resistance and electrical properties of the composition after the curing process. This is because the added modifiers adversely affect heat resistance and electrical properties compared to epoxy curing agents. Also, the modifiers act as binders in the resin composition to make it difficult to ensure low viscosity in the soldering process.
[0010] The present inventors have found that, when a thermoplastic epoxy resin prepolymer is obtained through a curing reaction between an epoxy and a low-temperature curing agent, which have an asymmetrically controlled equivalent ratio, and the obtained prepolymer is added to the formulation of the final resin composition, the film formability of the composition can be increased, thereby completing the present invention.
SUMMARY OF THE INVENTION
[0011] Accordingly, the present invention has been made in view of the problems occurring in the prior art, and it is an object of the present invention to provide a resin composition for no-flow underfill, which can be formed into a film so as to make it easy to control the thickness and area of underfill.
[0012] Another object of the present invention is to provide a no-flow underfill film formed from said resin composition.
[0013] Still another object of the present invention is to provide a manufacturing method of said no-flow underfill film.
[0014] The resin composition for no-flow underfill according to the present invention comprises a thermoplastic epoxy prepolymer, a high-temperature curing agent, a thermoplastic resin modifier and a fluxing agent.
[0015] The thermoplastic epoxy prepolymer is preferably obtained by allowing an epoxy resin to react with a low-temperature curing agent at a temperature of 80° C. or below.
[0016] The epoxy resin is preferably an aromatic epoxy resin which has at least two epoxy functional groups per molecule and an equivalent weight of 470 g/eq or less.
[0017] The low-temperature curing agent is preferably an aliphatic primary amine or aminosiloxane.
[0018] The equivalent ratio of the epoxy resin to the reactive hydrogen of the amine group of the low-temperature curing agent is preferably 2 to 10.
[0019] The thermoplastic epoxy prepolymer produced by the reaction of the low-temperature curing agent with the epoxy resin has a tertiary amine formed therein.
[0020] The resin composition for no-flow underfill may further comprise at least one additive selected from the group consisting of reactive monofunctional epoxy diluents, surfactants, adhesion promoters, inorganic fillers, flame retardants, and ion-trapping agents.
[0021] The no-flow underfill film according to the present invention has a layer formed by applying the resin composition for no-flow underfill to a base film.
[0022] The manufacturing method of the no-flow underfill film according to the present invention comprises the steps of: allowing an epoxy resin to react with a low-temperature curing agent at a temperature of 80° C. or below so as to obtain a thermoplastic epoxy prepolymer; preparing a resin composition for no-flow underfill by mixing the thermoplastic epoxy prepolymer with a high-temperature curing agent, a thermoplastic resin modifier and a fluxing agent to obtain; and applying the resin composition to a base film.
[0023] The resin composition for no-flow underfill has a viscosity higher than 500 cps which is suitable for coating on a film. Thus, the no-flow underfill composition can be manufactured into a laminatable film type without any additional additive. Accordingly, the resin composition makes it possible to accurately control the thickness and area of underfill, unlike the prior paste type composition.
DETAILED DESCRIPTION OF THE INVENTION
[0024] A resin composition for no-flow underfill according to the present invention comprises a thermoplastic epoxy prepolymer, a high-temperature curing agent, a thermoplastic resin modifier and a fluxing agent. Herein, the thermoplastic epoxy prepolymer is obtained by allowing an epoxy resin to react with a low-temperature curing agent at a temperature of 80° C. or below.
[0025] As used herein, the term “epoxy resin” which is used to obtain the thermoplastic epoxy prepolymer refers to an oligomeric compound having at least two epoxy functional groups per molecule. The epoxy resin is generally obtained, for example, by reacting epihalohydrin with a organic molecule having at least two —OH functional groups therein. Preferably, it is an aliphatic, alicyclic or aromatic epoxy resin of molecular weight of at least 200 which has a cyclic or linear main chain, in which the epoxy resin has at least two glycidyl groups per molecule. Examples of the epoxy resin include bisphenol-based epoxy resins, such as bisphenol A, F, AD or S, phenol, or cresol novolac type epoxy resins, alicyclic epoxy resins, aliphatic epoxy resins, naphthalene-based epoxy resins, fluorene-based epoxy resins, amide-based epoxy resins, glycidyl ester type epoxy resins, etc. These epoxy resins generally have a glycidyl group at the terminal end of the main chain, but may also be used in the form of epoxy resins obtained by allowing the main chain to react with resins or rubbers of other physical properties, such as epihalohydrin-modified epoxy resins, acryl-modified epoxy resins, vinyl-modified epoxy resins, elastomer-modified epoxy resins, or amine-modified epoxy resins. These epoxy resins may be used alone or in a mixture of two or more.
[0026] The epoxy resin preferably has an epoxy equivalent weight of 470 g/eq or less, and more preferably 300 g/eq or less, in order to ensure the glass transition temperature and mechanical strength of the composition after cure. In view of the preferred physical properties of the cured epoxy resin, an aromatic epoxy resin is preferable. As used herein, the term “aromatic epoxy resin” refers to an epoxy resin having an aromatic backbone in the molecule. The aromatic epoxy resin preferably has an equivalent weight of 470 g/eq or less and contains one or more epoxy groups per molecule. These epoxy resins may be used alone or in a mixture of two or more.
[0027] Specific examples of such epoxy resins include HP4032 series (Dainipppon Ink & Chemicals, Inc.), Epicoat 807 (Japan Epoxy Resin Co.), Epicoat 828 EL, Epicoat 152 and the like. Elastomer-modified liquid epoxy resins include TSR960 (Dainipppon Ink & Chemicals, Inc.; epoxy equivalent weight: 240; viscosity at 25° C.: 60,000-90,000 cp) and the like.
[0028] Meanwhile, the epoxy resin may contain non-glycidyl ether epoxides. Examples of the non-glycidyl ether epoxides include 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexane carboxylate, which has two epoxide groups which are part of the ring structures, and an ester linkage(ERL4221); vinylcyclohexene dioxide, which has two epoxide groups, one of which is part of a ring structure; 3,4-epoxy-6-methylcyclohexylmethyl-3,4-epoxycyclohexane carboxylate; and dicyclopentadiene dioxide. The non-glycidyl ether epoxide may be used in combination with the glycidylether epoxy.
[0029] The low-temperature curing agent which is used to obtain the thermoplastic epoxy prepolymer in the present invention serves to promote curing of the epoxy resin component. Examples of the low-temperature curing agent include aliphatic amines, aromatic amines and aminosiloxanes, which have a primary or secondary amine functional group. Among them, the aliphatic amines or aminosiloxanes are preferably used such that unhindered tertiary amines are easily formed after curing. Primary amines are more preferably used because they induce rapid curing of the composition. More specific examples of the low-temperature curing agent include 1-aminoisopropyl-3-aminopropyl-1,1,3,3-tetramethyldisiloxane.
[0030] When the epoxy resin and the low-temperature curing agent are used to synthesize the thermoplastic epoxy prepolymer, the equivalent ratio of the epoxy resin to the reactive hydrogen of the amine group of the low-temperature curing agent is preferably 2 to 10. If the epoxy equivalent ratio is less than 2, the viscosity of the thermoplastic epoxy prepolymer will be excessively increased due to a high degree of cure, and if the epoxy equivalent ratio exceeds 10, an excessively large amount of unreacted epoxy will remain in the thermoplastic epoxy prepolymer composition, and it will be difficult to impart film formability to the composition.
[0031] When the epoxy resin and the low-temperature curing agent are allowed to react at a temperature of 80° C. or below for at least 30 minutes, a thermoplastic resin will be produced through the reaction shown in Reaction Scheme 1 below. Reaction Scheme 1 is an example in which bisphenol A type epoxy resin is used.
[0000]
[0000] wherein R is an alkyl or siloxane group.
[0032] The high-temperature curing agent which is used as one component of the resin composition for no-flow underfill according to the present invention may be a conventional epoxy curing agent, such as an anhydride-based, amine-based or phenol-based curing agent. The high-temperature curing agent is preferably a curing agent which has a curing initiation temperature of 140° C. or above and is rapidly cured in the temperature range from 240 to 250° C. which is the maximum temperature range of the soldering process. Namely, it is preferable that the curing agent be completely cured at the temperature profile of a conventional soldering process. Also, the curing agent preferably has a long pot-life. Specific examples of the high-temperature curing agent include dicyandimides, aromatic diamines, anhydrides such as methylhexahydrophthalic anhydride, and phenol-based curing agents such as phenol novaolac resin or cresol novolac resin. In addition to the curing agent, at least one selected from the group consisting of organic phosphine compounds such as triphenylphosphine, imidazole-based compounds such as 2-ethyl-4-methylimidazole or 2-phenyl-4-methyl-5-hydroxymethylimidazole, and tertiary amines, may be added as a curing accelerator.
[0033] The content of the high-temperature curing agent and the curing accelerator is preferably 10-80 parts by weight based on 100 parts by weight of the thermoplastic epoxy prepolymer produced by the reaction of the epoxy rein with the low-temperature curing agent. If the content of the high-temperature curing agent is out of the above range, side reactions other than the curing reaction may occur in the resin composition due to unreacted epoxy or curing agent. Meanwhile, when the curing accelerator is used, it is preferably used in an amount of 0.05-2 parts by weight based on 100 parts by weight of the epoxy resin. If the curing accelerator is used in an amount of less than 0.05 parts by weight, it cannot accelerate the curing reaction, and if it exceeds 2 parts by weight, the curing reaction will rapidly occur, such that it can make it difficult to apply the no-flow underfill to the soldering process and the storage stability of the B-stage product falls down.
[0034] Meanwhile, the thermoplastic resin modifier functions to improve the brittle nature of the cured epoxy system so as to increase the fracture toughness of the composition and relax the internal stress. As the thermoplastic resin modifier, general-purpose resins, such as polyester polyol, acrylic rubber, acrylic rubber dispersed in epoxy resins, core-shell rubber, carboxy terminated butadiene nitrile (CTBN), acrylonitrile-butadiene-styrene, or polymethyl siloxane, may be used depending on the properties of the curable resin composition. Preferably, polyester polyol is used, and in this case, it is possible to impart flexibility to the cured composition layer and to increase the curing density of the composition through an additional curing reaction resulting from the hydroxyl group of polyol.
[0035] Core-shell rubber particles are rubber particles having a core layer and a shell layer, and examples thereof include: a two-layer structure comprising an outer shell layer made of a glassy polymer, and an inner core layer made of a rubbery polymer; and a three-layer structure comprising an outer shell layer made of a glassy polymer, a middle layer made of a rubbery polymer, and a core layer made of a glassy polymer. The glassy layer is made of, for example, a methyl methacrylate polymer, and the rubbery polymer layer is made of, for example, a butyl acrylate polymer. When the thermoplastic resin modifier is added, it is preferably used in an amount of 0.1-20 parts by weight based on 100 parts by weight of the thermoplastic epoxy prepolymer. If the thermoplastic resin modifier is used in an amount of less than 0.1 parts by weight, it will be difficult to achieve the purpose of increasing the fracture toughness of the resin composition and relaxing the internal stress of the composition, and if it exceeds 20 parts by weight, the content of the curable components in the resin composition can be excessively reduced, the mechanical and electrical reliability of the resin composition can be deteriorated after cure.
[0036] The fluxing agent functions to maintain the fluidity of the underfill resin composition at a high level, such that the cure of the resin composition and the electrical connection by a solder joint simultaneously occur in a no-flow underfill process. In addition, the fluxing agent must have a minimized adverse effect on the cure of the underfill composition and, at the same time, remove metal oxides generated in a copper pad on a package substrate during a soldering process and prevent a solder from melting by a re-oxidation reaction during a high-temperature process.
[0037] In general, in order to prevent boiling at high temperature, organic compounds having a terminal hydroxyl group, such as organic acids or alcohols, which have low vapor pressure at the soldering process temperature, may be used as the fluxing agent. However, because most organic acids can additionally participate in the curing reaction of the epoxy curing agent system, an organic acid having low reactivity must be selected. Specific examples of the fluxing agent include ethylene glycol, glycerol, 3-[bis(glycidyloxymethyl)methoxy]-1,2-propanediol, glutaric acid, trifluoroacetate and the like. The fluxing agent is preferably used in an amount of 1-10 parts by weight, and more preferably 2-8 parts by weight, based on 100 parts by weight of the total amount of the thermoplastic epoxy prepolymer, the high-temperature curing agent, the curing accelerator and the thermoplastic resin modifier. If the fluxing agent is used in an amount of less than 1 part by weight, it will be difficult to impart a fluidity suitable for a solder joint to the underfill resin composition, and if it is used in an amount of more than 10 parts by weight, it will interfere with the cure of the underfill resin composition, and unreacted fluxing agent can be volatilized during a soldering process.
[0038] In addition to the above-described components of the underfill resin composition, additional additives may be used if necessary. For example, when a monofunctional reactive diluent is used, it can delay the increase in the viscosity of the composition without adversely affecting the physical properties of the cured underfill. Examples of the diluent which can be used in the present invention include aliphatic glycidyl ether, allylglycidyl ether, glycerol diglycidyl ether, and mixtures thereof.
[0039] Meanwhile, various surfactants may be added in order to suppress the occurrence of voids during a flip-chip bonding process and a soldering process and to increase the fluidity of the underfill composition. Preferred examples of the surfactant include organic acrylic polymers, polymeric siloxanes such as polyol, and fluorine-based compounds such as FC-430 (3M). The surfactant is preferably added in an amount of 0.01-2 parts by weight of the total amount of the thermoplastic epoxy prepolymer, the high-temperature curing agent, the curing accelerator and the thermoplastic resin modifier.
[0040] Also, an adhesion promoter may be added to the underfill composition in order to improve the interfacial adhesion between a chip and a package substrate. Examples of the adhesion promoter which can be used in the present invention include imidazole, thiazole, trizole or silane coupling agents. The adhesion promoter is preferably used in an amount of 0.01-2 parts by weight based on 100 parts by weight of the thermoplastic epoxy prepolymer.
[0041] Moreover, inorganic filler such as silica, alumina, barium sulfate, talc, clay, aluminum hydroxide, magnesium hydroxide, silicon nitride or boron nitride may be added to the underfill composition in order to control the viscosity and fluidity properties of the underfill composition. In addition, a flame retardant, an ion-trapping agent or the like may be added depending on the intended use of the underfill composition.
[0042] According to the present invention, the thermoplastic epoxy prepolymer obtained as described above has formed therein a tertiary amine which can act as a catalyst in the esterification of epoxy. Accordingly, when the resin composition for no-flow underfill according to the present invention is cured at high temperature, the high-temperature curing agent and the epoxy react with each other, while the hydroxyl group and the epoxy is induced as shown in Reaction Scheme 2 below, thus increasing the curing density of the composition. As a result, it is possible to obtain higher heat resistance and mechanical strength.
[0000]
[0043] The manufacturing method of the no-flow underfill film according to the present invention comprises the steps of: allowing an epoxy resin to react with a low-temperature curing agent at a temperature of 80° C. or below so as to obtain a thermoplastic epoxy resin; preparing a resin composition for no-flow underfill by mixing the thermoplastic epoxy prepolymer with a high-temperature curing agent, a thermoplastic resin modifier and a fluxing agent; and applying the resin composition to a base film.
[0044] According to the present invention, a no-flow underfill film of B-stage is manufactured by applying the underfill resin composition of the present invention to a support base film to form a resin composition layer, and if necessary, drying the layer. In one embodiment, the epoxy resin and the low-temperature curing agent are stirred at a temperature of 80° C. or below for at least 30 minutes to obtain a varnish of a thermoplastic epoxy prepolymer. Then, the thermoplastic epoxy prepolymer varnish is mixed together with a high-temperature curing agent, a thermoplastic resin modifier, a fluxing agent and other necessary additives at room temperature for at least 4 hours to prepare a resin varnish for no-flow underfill.
[0045] In the steps of obtaining the thermoplastic epoxy prepolymer or in the process of preparing the resin varnish for no-flow underfill, an organic solvent may be used such that a blend of various components is easily obtained. Examples of the organic solvent which can be used in the present invention include conventional solvents, for example, ketones such as acetone, methyl ethyl ketone or cyclohexanone; acetic acid esters such as ethyl acetate, butyl acetate, cellosolve acetate or propylene glycol monomethyl ether acetate; and aromatic hydrocarbons such as toluene or xylene. These solvents may be used alone or in a mixture of two or more. The resin varnish for no-flow underfill is applied on a base film as a support, and then, if necessary, heated or dried to remove volatile matter such as water, which can result from moisture absorption, thereby forming a resin composition layer.
[0046] If necessary, the content of volatile matter which can result from, for example, moisture absorption, is preferably reduced to less than 0.2 wt %, and more preferably 0.15 wt %, through low-temperature aging after the coating process. The low-temperature aging condition is below 80° C., and more preferably below 60° C. The preferred volatile matter content may be achieved by pre-heating after laminating the no-flow underfill film on a package substrate. The pre-heating temperature and time can be controlled in consideration of the thickness and structure of the laminated no-flow underfill film and the package substrate. Preferably, the pre-heating is carried out at a temperature of 100° C. or below for 10 minutes or less.
[0047] Examples of the support base film of the no-flow underfill film according to the present invention include: polyolefin such as polyethylene or polyvinyl chloride; polyester such as polyethylene terephthalate; polycarbonate; and release paper. The thickness of the support base film is generally in the range from 10 μm to 150 μm. The support base film is treated by a mud process, a corona process or a release process.
[0048] The thickness of the no-flow underfill film according to the present invention can be controlled depending on the gap between a package substrate and a semiconductor chip and is generally in the range from 5 μm to 150 μm.
[0049] The inventive no-flow underfill film, which comprises the resin composition layer for no-flow underfill and the support base film, can be stored without further treatment or stored after depositing a protective film on the other surface of the resin composition and then winding the resultant structure. Examples of such a protective film include: polyolefin such as polyethylene or polyvinyl chloride; polyester such as polyethylene terephthalate; polycarbonate; and release paper. The thickness of the support base film is generally in the range from 10 μm to 150 μm.
[0050] The support base film can be satisfactorily treated by a mud process, a corona process and a release process. Because the resin of the resin composition for no-flow underfill leaks out in the laminating process, it is advantageous to place the uncoated portion (about 5 mm or longer) of the support base film on one or both sides of the roll, thereby preventing flow of the resin and facilitate the release of the protective film and the support base film.
[0051] Hereinafter, the present invention will be described in further detail with reference to examples. It is to be understood, however, that these examples are for illustrative purposes and are not to be construed to limit the scope of the present invention.
Example 1
1. Formulation of Resin Composition for No-Flow Underfill
[0052] (1) Obtaining thermoplastic epoxy prepolymer
[0053] a) Epoxy resin: 100 g of a 2:1 (wt/wt) blend of bisphenol F epoxy resin (liquid; epoxy equivalent weight: 190) and bisphenol A epoxy resin A (liquid; epoxy equivalent weight: 250).
[0054] b) Low-temperature curing agent: 6.0 g of 1-aminoisopropyl-3-aminopropyl-1,1,3,3-tetramethyldisiloxane.
[0055] The epoxy resin and the low-temperature curing agent were stirred at 70° C. for 2 hours to obtain a thermoplastic epoxy prepolymer. 100 g of the thermoplastic epoxy prepolymer was used to a resin composition for no-flow underfill.
[0056] (2) High-temperature curing agent and curing accelerator: 20.0 g of a 1000:1 (wt/wt) blend of methylhexahydrophthalic anhydride and 2-phenyl-4-methyl-5-hydroxymethylimidazole.
[0057] (3) Thermoplastic resin modifier: 10.0 g of polyester polyol.
[0058] (4) Fluxing agent: 5.0 g of glycerol.
[0059] (5) Additional additive: 0.2 g of FC4430 (3M, surfactant).
[0060] The thermoplastic epoxy prepolymer (1), the high-temperature curing agent and curing accelerator (2), the thermoplastic resin modifier (3), the fluxing agent (4) and the additional additive (5) were mixed at room temperature for 4 hours, thus preparing a resin composition for no-flow underfill films.
2. Assessment of Composition
[0061] 1) DSC Analysis
[0062] The above-described resin composition was stirred, and then cured by heating, while the curing initiation temperature, the curing peak temperature and the curing heat were measured by Differential Scanning calorimetry (DSC). The measurement was carried out using a DSC instrument (NETZSCH, Model DSC 200 F3 Maia) at a heating rate of 20° C./min.
[0063] 2) Measurement of Grass Transition Temperature, Coefficient of Thermal Expansion and Heat Resistance Properties
[0064] The glass transition temperature (Tg) and thermal expansion coefficient (CTE1 before Tg and CTE2 after Tg) of a sample obtained by curing the composition at 175° C. for 2 hours were measured using a thermal mechanical analyzer ((TA Instruments, Model TMA 2920). Also, a sample obtained by curing the composition in the same conditions as described above was measured for heat resistance properties (weight loss (%) at 300° C., and temperature at 5% weight loss) in a nitrogen atmosphere using a thermogravimetric analyzer (NETZSCH, Model TG 209 F3 Tarsus).
[0065] 3) Measuring Solderability
[0066] In order to examine whether the composition had the ability of a fluxing solder, 0.2 g of the composition was dispensed on a copper specimen, and solder balls (Sn/Ag/Cu; melting point: 217-219° C.) were dropped onto the composition. Then, a glass cover slide was placed on the composition, and the copper specimen was placed on a hot plate preheated to 145° C. After 2 minutes, the copper specimen was immediately transferred onto another hot plate preheated to 230-335° C. and maintained thereon for 2 minutes. Whether the lead-free solder was soldered to the copper specimen was observed with a microscope to evaluate the results of the fluxing test.
[0067] The results of the above assessments are summarized in Table 1 below.
[0000]
TABLE 1
Items analyzed
Results
Differential scanning
DSC initiation temperature (° C.)
145
calorimetric analysis
DSC peak temperature (° C.)
195
Solderability
Solder flux
Soldered
Thermal mechanical
Tg (° C.) of cured composition
120
analysis
CTE1 of cured composition(ppm)
85
CTE2 of cured composition(ppm)
170
Thermogravimetric
Weight loss at 300° C.
1.80
analysis
Temperature at 5% weight loss
352
[0068] As can be seen in Table 1 above, at a temperature lower than the soldering temperature, the cure of the composition was suppressed, whereas at the soldering process temperature, the curing reaction of the composition occurred. In addition, during the curing reaction, the composition was maintained at a low temperature such that it could be soldered.
3. Examination of Film Formability
[0069] A varnish resin obtained by mixing the resin composition of Example 1 had a viscosity of 15,000 cps, as measured with a Brookfield viscometer at room temperature. The resin was applied on a 38-μm-thick PET film by a roll coater such that the film thickness after drying was 60 μm. The applied resin was dried at 80° C. for 10 minutes, thus obtaining an adhesive film. As a result, it could be seen that the resin composition of Example 1 could provide a film having a smooth surface.
[0070] As described above, the no-flow underfill film can be used as a sealing material which is filled into the gap between a semiconductor chip and a package substrate.
[0071] Although the preferred embodiments of the present invention have been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. | Disclosed herein are a resin composition for no-flow underfill, which can be formed into a film, a no-flow underfill film formed from the composition and a manufacturing method of the no-flow underfill film. The resin composition for no-flow underfill has a viscosity higher than 500 cps which is suitable for coating on a film. Thus, the no-flow underfill composition can be manufactured into a laminatable film type without any additional additive. Accordingly, the resin composition makes it possible to accurately control the thickness and area of underfill, unlike the prior paste type composition. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates in general to lamps, and more specifically to a metal halide lamp which maximizes UV radiation in the desired useful range for curing chemical compositions.
It has long been a goal and objective in the field for a low wattage, long life, short arc gap lamp which could be used in a wide range of applications. Changing needs of the marketplace have identified the need for a short arc gap lamp in the range of 50 watts. Such an illumination source in one application could be used to irradiate small, light valves. This source would require a miniature source size, high radiance, good spectral properties, long life and low power. This goal was achieved with the development of a 50 watt arc lamp suitable for use as a projection lamp and is more fully described in U.S. Pat. No. 5,942,850.
When lamps of this type are attempted to be used in applications where UV radiation is required they are unsuitable in that even if operating conditions are modified to favorably promote UV radiation, lamp life or stability is compromised. Lamps of this type, therefore, do not satisfactorily operate to provide for enhanced radiation in the UV range, and as currently designed, are not candidates for applications where high UV response is essential.
It is therefore an object of the present invention to overcome the problems of the prior art described above.
It is a further object of the present invention to provide a high performance UV irradiation or light source which can be used as a curing light to initiate polymeric reactions in plastic and adhesive substrates.
It is a further object of the present invention to provide a high performance lamp for use in systems which require high UV radiation.
It is yet another object of the present invention to provide a compact lamp assembly which exhibits high radiance, long life, and good UV radiation.
SUMMARY OF THE INVENTION
The present invention is directed to a high performance miniature arc lamp. The lamp has a preferred use in curing chemical compositions which react to UV radiation. The lamp is used in an assembly that utilizes a dichroic coating on a reflector to concentrate UV light to the desired target or area.
It has been discovered that a unique metal halide mixture of individual compounds selected from the group of cesium iodide, indium iodide, scandium iodide, and sodium iodide provides a fill component which insures high lamp performance, and when used with a reflector having a suitable dichroic coating, is uniquely suited to providing an effective source of UV radiation.
A suitable mixture which accomplishes the objectives of the present invention comprises scandium iodide (or other suitable lanthanide), indium iodide, and alkali halides (sodium iodide and cesium iodide) in total amounts up to about 200 μg. The dichroic coating is selected to reflect UV radiation in a range from about 300 to 600 nm.
For use in the present invention it is essential that the lamp be of an acceptable miniature size, exhibit high radiance, long life and low power.
BRIEF DESCRIPTION OF THE DRAWING
For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description of a preferred mode of practicing the invention, read in connection with the accompanying drawings, in which:
FIG. 1 is a side sectional view of the light source of the present invention.
FIG. 1 a is an enlarged sectional view of the hermetically sealed chamber of the light source shown in FIG. 1 .
FIG. 2 is a side sectional view of a lamp containing the light source of FIG. 1 .
FIG. 2A is an enlarged sectional view taken through the sidewall of the reflector shown in FIG. 2 .
FIG. 3 is a rear view of the lamp shown in FIG. 1 .
FIG. 4 illustrates a plot of the UV output of the lamp of the present invention at three different apertures.
DETAILED DESCRIPTION OF THE INVENTION
The light source 10 of the present invention in the form of an elongated fused quartz envelope is shown in more detail in FIG. 1 as being a double ended structure having a pair of elongated electrodes 16 (cathode) and 18 (anode) disposed at opposite ends of neck sections 36 and 38 , respectively. The electrodes are separated from each other by a predetermined critical distance D or arc gap preferably in the range of about 0.8 mm to about 1.5 mm. The light source is in the shape of an elongated body having an overall length (L in FIG. 1) in the range of about 28 mm to about 32 mm having the neck sections with a diameter in the range of about 3 mm to about 5 mm, and has a generally ellipsoidal shaped central hermetically sealed chamber 2 having a volume 14 of about 130 mm 3 ±20 mm 3 . The wall thickness of chamber 2 s about 1 mm. The light source contains a critical fill mix which comprises an inert noble gas, mercury and metal halides which are formulated to enhance, UV output.
More specifically, the sealed chamber is designed to provide a unique UV spectral response for the lamp of the present invention as evidenced by the plot of spectral power in the UV range of about 300-600 nm as shown in FIG. 4 . The radiation illustrated in FIG. 4 is obtained from the lamp described herein operated at 50 W with a spectroradiometer traceable to NIST standards.
The volume of the chamber can be approximated to that of an ellipsoid of semi-major axis a and semi-minor axis b.
V =4/3 πb 2 ·a
The semi-major axis length (a in FIG. 1 a ) for the light source of the present invention is one half of the overall chamber length and in a range of about 4 to 6 mm. The semi-minor axis length (b in FIG. 1 a ) is one half of the chamber inner diameter and has a range of about 2 to 3 mm.
The preferred range of the chamber volume to yield optimal performance specifications is about 110 to 150 mm 3 . The lamp power divided by the chamber volume is known as the volume-power loading of the lamp. This number calculates out to be 0.4/mm 3 given the preferred range of design factors. This metric is significant because it relates to the amount of heat dissipated power unit size of the lamp and therefore influences the operating temperature of the lamp.
The appropriate volume of the chamber is determined in combination with other interrelated design factors, primarily the type and amount of fill materials and operating power.
Deviation from the optimal volume could lead to performance degradation as a result of either improper internal operating pressure or improper thermal operation as dictated by the volume-power loading.
The electrodes respectively consist of a shank portion the ends of which contain wrapped metal coils 20 and 22 , respectively. Proper thermal and electrical design of electrodes are required to achieve the desired performance. Coils, or wraps of wire, around the primary electrode shank can be added to properly balance the electrical and thermal requirements. Coils can serve the function of providing an additional thermal radiative surface to control the temperature of the electrode shank. The size and length of the coil can be designed to achieve optimal thermal performance. An additional function of coils is to provide the appropriate electrical field properties for efficient and reliable arc initiation, or lamp starting. In certain applications, the coil on the cathode is optional and is not required. The opposite end of the shank portions are respectively connected to one end of a foil member 28 and 30 respectively sealed in the opposite end of the neck portion. Typically, the foil members are made of molybdenum. The foil members have their other end respectively connected to relatively thicker outer lead wires 32 and 34 which in turn are respectively connected to the structural members shown more clearly in FIG. 2 .
FIG. 2 illustrates the miniature lamp 40 of the present invention which includes a reflector 42 containing the light source 10 having an insulating thermally resistant connector 44 having a pair of pins 46 and 48 suitable for connection to a suitable source of power. Structural members 35 , 37 and 39 are used to orient the light source in a substantial horizontal axis with respect to the reflector and form the electrical connections along with lead wire 32 . The reflector internal glass surface 43 further contains a coating of dichroic material 45 which function to transmit selected light, and reflect or direct UV radiation to a desired target or location. Suitable dichroic materials are combinations of silicon dioxide (S 1 O 2 ), aluminum oxide (Al 2 O 3 ), zirconium dioxide (ZrO 2 ), or tantalum oxide (Ta 2 O 5 ). Multiple coatings are applied in alternating layers. The dichroic coating is a submicron layer, typically about 0.005 to 0.010 microns thick. Multiple coatings (up to 100) of at least two different oxides are alternately formed on the inside surface of the reflector by a conventional vapor deposition technique.
In the present invention, a refractory insulating material is formed into an elongated envelope into which the following components are inserted and hermetically sealed:
a. a pair of refractory metal electrodes;
b. a quantity of metal halide material;
c. a quantity of metallic mercury; and
d. a quantity of an inert noble gas.
The electrodes are aligned in an axial manner facing each other. The light source is operating in a direct current (DC) mode at a low electrical power.
Refractory materials for the envelope can be fused silica or alumina oxide. The refractory materials for the electrodes typically are tungsten (with or without thorium) or molybdenum. The description of electrodes is defined in more detail below. The metal halide materials and quantity of mercury is also described below.
Preferably the envelope material is fused silica and the electrodes are tungsten. Fused silica is easier to handle and process, and tungsten allows for higher operating temperatures and increases light output and life.
The opposing electrodes are set apart and separated at a distance to provide optimal performances for projection display applications Maximum utilization of optical component light collection requires the light source to be as near to “point source” as possible.
The broad range of separation is 0.8 mm to 1.5 mm.
The preferred range of separation is 1.2 mm±0.2 mm.
Falling below the preferred range of separation will cause a corresponding loss in lamp luminous efficacy. Exceeding the preferred range will minimize the effectiveness of the lamp as a miniature source for projection optics.
In operating the light source in a DC mode, one electrode is identified as the anode, the other as the cathode, and each is sized appropriately for optimal operation for a given lamp power and current. The electrodes are constructed from known techniques that incorporate an overwound refractory metal coil attached to the metal shank. The optimal design is determined given the range of electrical power and current over which the source is intended to operate. The table below tabulates the electrode wire diameters and power and current ranges for the present invention.
Range of Wattage:
Preferred Wattage:
40 W-60 W
50 W ± 2 W
Range of Current:
Preferred Current:
0.5 A-1.5 A
0.9 A ± .2 A
Anode Shank
0.020 in. ± 0.008 in.
0.020 in. ± 0.001 in.
Anode Overwind Wire
0.010 in. ± 0.005 in.
0.010 in. ± 0.001 in.
Cathode Shank
0.014 in. ± 0.004 in.
0.014 in. ± 0.001 in.
Cathode Overwind
0.005 in. ± 0.005 in.
0.007 in. ± 0.001 in.
Wire
A mismatch between electrical operating characteristics and electrode design could be disastrous from a product performance standpoint. Generally, a design that permits too high of an operating temperature of the electrodes (high current/small electrodes) will result in rapid electrode erosion, darkening of the envelope, short life and low light output. Too low of an operating temperature of the electrode (low power/large electrodes) will result in an unstable or flickering arc.
In has been discovered that a unique metal halide mixture of individual compounds selected from the following group of scandium iodide, indium iodide, cesium iodide, and sodium iodide in conjunction with the other fill components results in a lamp which exhibits enhanced UV output. It is the specific dose of metal halide salts in combination with a reflector having a dichroic coating that concentrates only the desired UV radiation that is the key combination of components of the present invention.
The scandium iodide, or any other suitable lanthanide, provides a means of controlling undesired secondary processes within the lamp. The indium iodide contributes radiation emission in the blue to ultraviolet regions to enhance the total spectral output fundamental to this invention. The sodium iodides and cesium iodides are introduced in combination to provide the appropriate electrical, thermal, and convective characteristics of the plasma.
A suitable mixture, shown in the table below, which accomplishes the objectives of the present invention is a metal halide dose of 132 μg of material composed of (by mass percent). The operative concentration range which provides a combination that optimize stable electrical behavior is also listed in the table below:
Mass
Operative
Compound
Percent (Wt. %)
Range
ScI 3
10.9
5-25
μg
InI
5.0
3-15
μg
NaI
79.1
10-200
μg
CsI
5.0
10-200
μg
The quantity of mercury is added such that it will evaporate and enter the discharge in a gaseous state and regulate the electrical operational parameters.
The amount of mercury can range from 5 to 15 milligrams and is a function of the internal volume of the envelope.
The preferred amount being about 9 milligrams ±−10%.
Excess mercury will cause excess pressure within the bulb and could result in early failure. Too low of an amount of Hg could result in improper electrical operating characteristics, primarily thereby reducing luminous efficacy.
The fill inert gas is added to provide a gas that can be ionized to aid in the starting of the lamp. Suitable fill gasses include Ne, Ar, Kr, and Xe with cold fill pressures in the range of 0.5 atm to several atmospheres.
A preferred gas for use in the present invention is Ar at about 500 Torr±2%. Excess Ar would cause the required voltage to initiate the discharge to be very high and impose large costs on the electrical operating circuitry.
The above specification for the electrode arc gap, quantity of metal halide, mercury, and noble gas must be used in conjunction with an hermetically sealed chamber having a critical volume, which in the case of the present invention is about 130 mm 3 ±20 mm 3 .
The source size is dictated by the electrode separation (arc gap) in the range of 0.8 mm to 1.5 mm. The overall length of the envelope and associated structure being about 2 inches long. The service life exceeding 2,000 hrs.
The light source and lamp of the present invention has been particularly shown and described with reference to the preferred mode as illustrated in the drawing, it will be understood by one skilled in the art that various changes in detail may be effected therein without departing from the spirit and scope of the invention as defined by the claims. | An arc lamp assembly which includes in combination a reflector and a light source which is surrounded by said reflector. A dichroic coating on the reflector functions to reflect radiation in the range of about 300 to 600 nm. The light source is an arc lamp which contains a metal halide fill component which includes a mixture of scandium iodide, or other suitable lanthanide, indium iodide, sodium iodide and sodium iodide, whereby the lamp assembly emits effective amounts of WV radiation to cure selected chemical compositions. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to a technique for controlling access to file system resources using externally stored attributes. More specifically this invention describes a technique in which an externally stored attribute, such as an authorization security policy, uses a file system identifier to determine access to a file system resource associated to that file system identifier.
BACKGROUND OF THE INVENTION
[0002] File systems, in operating system environments, such as UNIX, have evolved into complex implementations with many features. These file systems present a hierarchical tree view of a file name space and support large amounts of data and numbers of objects at very high performance levels. Yet, one characteristic that has changed little is the authorization security models of these file systems. The fundamental problem is that, on operating systems such as UNIX, LINIX and even to some degree WINDOWS, the degree to which the native file systems do not support robust security models. For example, with UNIX, the security of an individual file may be specified is fairly limited in coarse grain. A user and a group owns the file. In this model, file access is based on a set of “mode” bits that grant permissions based on the file object's owning user and group. Some file systems support a more robust security model based on access control lists (ACLs) where more security is placed on a file to enable control of various users' access to files. The problem with this approach is that these models are very different across different versions of operating systems. This inconsistency leads to another problem that each system requires individual and separate administration of each system and each system requires a separate set of administration methods. When viewing the Information Technology (“IT”) infrastructures of large corporations and other entities, there is a growing need for stronger more granular security controls in file systems. This need is driven by large-scale commercial usage of these file systems, data sharing with Internet based applications, an increased focus on IT security, and the desire to control IT administration costs. From an IT cost perspective, there is a need to have enhanced security in an efficient way. This objective leads itself to being able to define the security rules and procedures centrally for all of an entity's systems that could be accessed so that there would be a central point of administration, control and verification of rules. The IT structures of today need better security and a more efficient way to implement the security. An efficient way to do that is to provide a file system security model that can be applied uniformly across a large number of systems using a centrally managed set of policies that is administered identically regardless of the target file system implementation or hardware platform.
[0003] Ideally, it would be desirable to add extended attributes describing properties such as authorization policy to the file system object's attributes. However, file systems, such as UNIX, are typically byte stream oriented and do not support mechanisms to add attributes beyond the classic UNIX attributes which are typically the object's owner, size, modification and access times, and mode bits.
[0004] A set of techniques is needed which allows unique identification of an accessed resource regardless of way in which it was accessed. In addition, the techniques must allow the specification of attributes in terms of an object's common path name in a manner that maps to the same unique file system resource regardless of the representation used at access time. These techniques should be efficient so they impose minimal impact the file system's native performance characteristics. They must allow for quick recognition and processing of attached attributes at access time. They must also accommodate changes in defined attributes and object changes in the file systems to which they are applied.
SUMMARY OF THE INVENTION
[0005] It is an objective of the present invention to provide a method for controlling access to named objects in a file system.
[0006] It is a second objective of the present invention to provide a method for associating external attributes defining authorization policy to named objects in a file system.
[0007] It is a third objective of the present invention to recognize the existence of an associated external file system authorization policy and provide for the evaluation and enforcement of that policy at the time of access to a file system object.
[0008] It is a fourth objective of the present invention to provide for the association, recognition, and processing of external attributes utilizing file system object file identifiers.
[0009] It is a fifth objective of the present invention to provide a means for the generation of object file identifiers when the native operating system for a particular file system does not provide these identifiers.
[0010] It is sixth objective of the present invention to allow for the processing of the externally defined policy by a resource manager based on associations to the original file name without requiring the resource manager to have knowledge of the underlying association and recognition techniques that utilize file identifiers (FIDs).
[0011] This invention describes a method for file system security through techniques that control access to the file system resources using externally stored attributes. This invention accomplishes the described objectives in file system security by creating an external database containing auxiliary attributes for objects in the file system. This solution incorporates techniques and algorithms for attribute attachment, storage and organization of the associations to these attributes, and subsequent recognition of attached attributes. In this approach, the attributes would define authorization policy for controlling access to objects in the file system. Such a solution would require techniques for associating the defined policy with file system objects, detecting accesses to the objects, locating the appropriate attributes at access time, and then processing the attributes to produce an access decision for granting or denying access to the accessed resource.
[0012] Administratively, the most convenient technique for defining authorization rules for a file system object is to associate the attributes with the object's fully qualified common name. This common name is also known as the path name to the file. UNIX file systems, for example, provide a hierarchical name space for constructing object names. For example, a file called mydata might have a fully qualified path of /home/john_doe/data_files/mydata. This path is the most recognizable representation of the object and the most convenient description for an administrator to use when defining new attributes for the object. Therefore the technique for associating (or attaching) attributes should support using the object's fully qualified pathname.
[0013] Recognizing and locating externally defined attributes for a file system object at the time of object access poses significant technical challenges. Accesses occur through a set of available programming Application Programming Interfaces (“APIs”) that provide several ways to identify the object being accessed. For many APIs, the name of the object is provided. However, this name is often not the full path name starting from the top or “root” of the file hierarchy. Instead, the name is relative to a “current directory” that is tracked for the calling application by the native operation system. UNIX file systems also commonly contain support for creating alternate names to an object using symbolic or hard links. This provides alias names to the same object. A symbolic link might allow /home/john_doe/data_files/mydata to be accessed as /u/jdoes_data/mydata. These variations make it difficult to locate the externally defined attributes using the provided name at the time of access. There are also APIs that do not take a pathname as input. Instead they take an integer number known as a file descriptor, which was obtained in an earlier name based function. It is desirable to intervene in and enforce policy on these APIs as well.
[0014] The present invention is described in the context of a resource manager embodying the techniques of the invention. The resource manager enforces authorization policy for file system resources. The policy resides external to the native operating system and is defined using full path names for the target file system resources to be protected. These names are referred to as protected object names or PONs. An example PON would be /home/john_doe/data_files/mydata. The policy can reside in a database on the system where the resources reside, or it could reside in a network of computers. The resource manager would be comprised of components for 1) retrieving the policy, 2) intervening in accesses to the objects to be protected, 3) collecting the access conditions such as the accessing user and the attempted action, and 4) producing an authorization decision based on the policy, the accessed object, and the access conditions. Those skilled in the art will recognize that systems with these characteristics can be constructed and that they could exist in many variations including a distributed application in a network of computing devices.
[0015] When the described resource manager starts, it first retrieves the authorization policy and then preprocesses the named protected files into their equivalent file identifier “FID” mappings. A FID is a binary representation that uniquely defines a physical file system object that resides in a file system. The manager then creates a database of FID to name mappings and potentially other properties that may facilitate processing at access time. For example, those properties could include the policy itself in the form of access control lists (ACLs) or hints about how the resource is protected. Potentially the resource manager could store the processed FID mappings and reuse them on subsequent starts instead of re-processing the name based authorization policy. The database of FID mappings could be organized in a variety of ways. The FID's numerical nature would allow for hashing techniques that would enable efficient searches using FID data as the search key.
[0016] When an object access is attempted through one of the access paths the resource manager will intervene. The resource manager uses available operating system services to process the API's provided description of the target file resource into its underlying data structure representation. This description could be the fully qualified path name, a relative path name, an alternate name such as a hard or symbolic line, or a non-name based description such as an integer UNIX file descriptor. Additional provided services or techniques are then used to produce a corresponding FID. The FID is then used to search the FID mapping database looking for a match. If a match is found, then the PON and any other included properties are provided to the decision-processing component of the resource manager to produce an access decision. The resulting decision is then enforced by the intervention component, which either permits or denies the resource access.
[0017] With these described techniques, the resource manager is able to efficiently associate defined policy with physical protected file system objects. It can then quickly recognize the existence of relevant policy at the time of object access regardless of how the object was accessed. Once recognized, the retrieved FID to PON mapping can by used to consult the decision component of the resource manager for an access decision that can then be enforced.
DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a flow diagram of the steps involved in processing an authorization policy record that is described using the objects fully qualified path name or PON.
[0019] [0019]FIG. 2 is a flow diagram of the steps to generate a FID for a provided access path to a file system object and determine if the accessed object is protected by authorization policy. If so, then an access decision is sought.
[0020] [0020]FIG. 3 is a flow diagram of the steps to search the FID to PON mapping database provided a search FID as the key.
[0021] [0021]FIG. 4 is a flow diagram of steps for generating a FID using provided file system services.
[0022] [0022]FIG. 5 is a flow diagram of steps for generating a FID in the absence of a provided file system service to do so.
[0023] [0023]FIG. 6 is a block diagram of the high-level architecture relationship between an example authorization manager, a file system, and techniques of the present invention.
[0024] [0024]FIG. 7 is a pictorial representation of data processing system which may be used in implementation of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The present invention is described in the context of a UNIX or UNIX type operating system. The invention describes a set of techniques and algorithms that achieve the objectives of file system object security through the use of a unique representation of a file system object known as a file identifier, or FID. A FID is a binary representation that uniquely defines a physical file system object that resides in a file system. The FID is typically a stream of bytes of arbitrary length that is commonly as small as eight to ten bytes in size. The contents of the FID bytes are often numerical in nature with the first set of bytes holding an index or “inode” number and the remaining bytes holding a generation or use instance of the inode. FIDs are used in present day operating systems for the implementation of network file sharing services. A file server process running on a file system server machine housing data will obtain a FID for a file when client machine on a network searches for the file by name. The server will then return the FID to the client. The client sends the FID in subsequent requests to the server to perform operations on the file such as reading or writing data. The server uses the FID to quickly find the file system object's data structure and perform the operation. Thus, in a network file system implementation, the FID acts as an alternate representation that can be quickly mapped to the object's defining data structure, which often is an inode/vnode. Inode and vnode are used synonymously in this description. The vnode is an in-memory object that usually has a short lifetime and is frequently recycled for use by other accessed file objects. However, the FID allows fast construction of a vnode for the unique physical file system object it describes.
[0026] The numerical nature, typically small size, and unique mapping to an individual file system object make the FID a powerful association tool. Given that the FID represents a single instantiation of an object, it also represents a unique mapping for any of the potential pathnames or alternate descriptors that can be used by an application to access the object. Thus, a FID can be used as an efficient bi-directional mapping equivalent of file system object and any of its names.
[0027] Different file systems use different techniques to create a FID that uniquely represents the object. Most implementations found on modern systems provide programming services to retrieve FIDs. For systems that do not provide these services, a technique can be used to generate an acceptable “pseudo” FID indirectly from other services and direct access to data structures. Such a technique is illustrated in FIG. 5 and discussed in this description. A common procedure for retrieving a FID for an object would first involve obtaining a file system object data structure based on how the object was accessed. On most UNIX systems, this data structure is commonly called a vnode. However, it could vary across implementations. For example, on Linux or some older systems it might be called an inode. If a resource is accessed by a full or partial name, a native kernel service is used which efficiently returns a vnode (or inode, etc.) from the name. That native system utilizes internal state and usually name based caches to quickly produce the vnode. In the case of non-name based access paths, there usually exists services or accessible data structures to obtain the vnode from an integer file descriptor. Once the vnode is obtained, the FID is retrieved or generated using services that operate on the vnode. This FID is then used to identify file objects being accessed.
[0028] Referring to the implementation of the invention in FIG. 1, described is the set of steps involved in processing an authorization policy record for the object's fully qualified path name or PON (the protected object name) which is the full path to the file. This process describes how one would take the protected object name and process it into the new database that maps the unique file identifiers (FIDs) back to the full name of the file and place that relationship into the mapping database. In step 10 , the file name is taken as an input. Step 11 retrieves a file identifier from the inputted file name, which corresponds to that file path name. This step produces a very unique definition or identifier (FID) for the file object that is described by that file name in step 10 . The step 11 is implemented using services provided by the native operating system or through techniques of this invention illustrated in FIG. 5 in the event the native operating system does not provide the services. Step 12 uses the obtained file identifier as a key to store a record of the FID and its associated file_path_name in a FID to protected object name (PON) mapping database. This database could be stored in memory, on disk or other storage mechanism. The result is that now there is a mapping for translation between this unique file identifier and this name that is stored in a master database of security rules. At this point, the procedure ends, step 13 .
[0029] [0029]FIG. 2 illustrates the process that occurs when an application attempts to access a file and some mechanism in the resource manager that enforces security on the file intercepts or detects that access attempt. As part of detecting that access attempt, the detecting mechanism wants to determine if that accessed file is actually protected by the resource manager. During the access, a name was used to identify the requested file. Step 15 begins the process of checking for a protected object name for the file being accessed. In step 16 , the process obtains a FID for that name used to access the file. As previously stated, this FID can be obtained through services provided by the native operating system of by techniques implemented when the operating system does not provide the services. After obtaining the FID, the next step in box 17 , is to use that FID as a key, to search the created mapping database to see if that FID actually exists in the mapping database. If the FID does exist in the database, the associated protected object name is extracted from that record. If the search does not produce a protected object name, then the access attempt is allowed as shown in step 18 . In this case, the external security manager does not protect the particular file being accessed. The access of the file is allowed to proceed. If the search in step 17 does produce a protected object name, the process proceeds to step 19 . This step makes a call to the decision-making component of the resource manager and obtains a security access decision for that PON. Because the decision-making component of the resource manager is connected to the master database, having the full name allows that security-making component to retrieve the specific protections for the file that an application is attempting to access. Once the decision-making component has the specific protections, it can make a decision whether to allow access to the file by the requesting application. If the security decision is to grant access, then to operation proceeds to step 18 . If the security decision were to deny access, the component that detected the access attempt would deny access in step 20 . The decision to allow access is based on the set of security rules defined in the external security database.
[0030] [0030]FIG. 3 is a more detailed illustration of step 17 , which shows a set of steps to search the FID to PON mapping database to determine if the file name requested is protected. In the first step, shown in step 21 , there would be an identification of the FD that would be used as the search key. In step 22 , the FID would be processed into a search hash bucket or list to find a FID match. A common practice in computing and software programming for databases is to take the information and process it into a list or index. For example, in the protection of thousands of objects, one means to speed up a search would be to divide those objects up into a hundred buckets. After this sorting exercise, some additional processing occurs to determine in which bucket one should initially search. The criteria for this decision could be based on any number of parameters.
[0031] The step 23 proceeds to search the list to determine if there is an entry that matches the desired FID. The process takes the first entry in the list and compares that entry to the object FID in step 24 . If the object FID matches the entry in the list, then there is a match and the PON for that FID in the list is returned as illustrated in step 25 . If in step 24 , the current entry does not match the object FID, the process moves to the next entry in the list, step 26 . The step 27 determines whether the end of the list has been reached, which would mean there was no next entry. If not, then the procedure returns to step 24 and there is a comparison of the next entry in the list with the object FID. If in step 27 , the end of the list is reached, then the search yielded no PON indicating the file resource represented by the provided FID has no external security policy. The operation then terminates, step 28 .
[0032] [0032]FIG. 4 is a flow diagram showing how to retrieve a file identifier (FID) for a given file path name using services that are provided by the native operating system. In step 30 , process starts with valid file resource name as input. The name could be any of the valid names for the resource, which may include a full path name, a name relative to the caller's current directory context. The step 31 gets an underlying object data pointer such as a vnode or inode using an operating system lookupname( ) service with the file path name used as the input. The UNIX operating systems that exist and the operating systems that are like UNIX (specifically LINIX) has the same “lookupname” capabilities. With this service, if the service is given a name associated with the file for which one is searching, the service will produce a reference to a data structure that is typically called a vnode or an inode. These data structures can contain a lot information about the files and access to a number of different operations one can perform on a file. It is necessary to take the name describing the desired file system resource and produce one of these data structures.
[0033] Once there is a data structure such as a vnode, one operation that can be performed with the vnode as input to the operating system is a request for a file identifier for the file resource that the vnode represents step 32 . In this request, the operating system interface VOP_FID( ) is called to retrieve a FID. The interface produces and returns a data structure that is a FID. The FID has as one of its members a field of the number of bytes in the FID and after that field is the number of bytes that is unique signature for that file. After obtaining the FID, the obtained FID is retained in step 33 .
[0034] [0034]FIG. 5 describes a method of producing a FID when the native operating does not provide a service generate a FID. In step 36 , the process begins by obtaining an underlying object data pointer. This data pointer could be a data structure known as a vnode or an inode. A feature of the native operating system called “lookupname” is a service that retrieves this object pointer based on the full path name of the file system object. With this technique there is an assumption that with a name one can always get some sort of data representation of the underlying file. Most if not all operating systems provide at least this amount of functionality. These lookupname services will typically provide a way to get a data structure for the requested file resource and a data structure that represents the parent directory in which that file resource resides. For example, there could be an inquiry about a file with a name such as /users/john/temp/myfile. The request would be for one of the data structure vnodes for the file called for “myfile” and for the service to give the data structure that represents the directory called “temp”. This directory is the directory location of the file called myfile. The retrieved information would be about the file (myfile) and the parent directory (temp). The two pieces of information are used in the next step 37 to obtain a physical file location.
[0035] The data structures that describe these files each have some physical trait about the file. Files are represented in operating systems one of one several ways: A very common piece of data is some address on the disk where the file is located such as a disk block address or a disk sector. In this representation, there will be some unique address information that is specific to the location of that file in the file system. In UNIX operating systems, this specific location information is a value called an inode or vnode index, which is just a number that starts at one and goes up to the number of objects in that file system. This number is an index to a series of disk block addresses with index one representing the first disk address in the sequence, which holds information representing an individual file resource. This number will be a field in that data structure.
[0036] Some operating systems have a data structure that does not contain an inode index number or have a data structure that is inadequate for the desired operations of this invention. These operating systems cannot provide an inode index for the location of the desired file. In this case, a programming interface called “get attributes” (getattr( )) is used to obtain specific file information. This programming interface will take the vnode or inode data structure as input for the file and return a data structure with a lot of attributes or properties of the file. One of those properties will be the file serial number. UNIX operating system file systems conform to a standard known as “POSIX” that governs programming interfaces. The premise for this POSIX standard is that for a given file resource that is being accessed, there must be some programmatic interface available in order to get a unique serial number for that file. This serial number is referred to as the POSIX serial number. Therefore, if the unique number information (inode) is not available in the data structure, then the operating system program interface is used to get a unique number (the serial number) for this file. No other file that currently exists in that file system will have that number. This serial number is usually in the form of a disk address or some value that relates to a disk address. Often, it is actually the inode or an equivalent that was not directly obtainable from a platform implementation's vnode or inode data structure.
[0037] The above obtained inode index, serial number, or disk address information tells of a location where the file resides in a file system. However this information alone is not a unique description of the resource and is not enough to construct a FID. The location information is only valid for the current instantiation of a named file resource. If the resource is deleted, the location becomes available for use by a subsequently created resource. If that resource has a different name, then the location no longer represents a resource with the name of the previously removed resource. If the previous resource is recreated with the same name, it may allocated another location.
[0038] The next portion of the technique, in FIG. 5, begins the process of getting the second piece of information that will make this definition very unique for that given instant of the file in the system. As long as that file resource stays on the system, this file identifier (FID) will be uniquely tied to that file. Now that there is a known file location number for that file resource, the way to make this file identifier unique is to couple this file location number with the name of the file resource. The identifier will have the name of the file and the physical location number where the file resides. In the example file path name, /users/john/temp/myfile, myfile is the name of the file. In practice, the information received may not be the full path name. For instance, the information may be a partial path file name or a file descriptor.
[0039] Referring to step 38 in order to get the file name, the vnode or inode data structure for the directory in which the file resides is used to open the directory in order to read information contained in that directory. The directory has a list of entries with locations where all file resources contained in that directory reside. Each directory entry will have the name of the particular resource and will have the inode index or the serial number for that entry's resource. Once the directory is opened, the next step in step 39 is to read the first directory entry for this directory to get the inode index or the POSIX serial number for the file location. Step 40 determines whether the inode index of the entry is equal to the inode index determined in step 37 . If the two inode indexes are equal, the next step is to retrieve the name of the resource out of the entry and the length of the name step 41 . In the previous example the name would be “myfile”. The length of the name is in that entry location or can be calculated by counting the number of characters in the name. With the name and name length, the next step 42 is the construct the file identifier for the file resource. In this construction, the file location information (inode index, serial number) is placed at the beginning of the file of bytes that will be the FID. The next step is to append the length for the name and the actual name to the FID bytes in step 43 . The FID can be viewed as an array of memory locations containing the serial number, the length of the name and the actual name located in consecutive memory locations at the beginning of the array. In the discussed example, the characters that spell “myfile” would be the name of the file placed after the name length. These three components comprise the stream of bytes for the FID. Step 44 sets the length parameter that is in the FID data structure to be equal to the length of the name plus the number of bytes it actually takes to write the serial number in the stream of bytes plus the number of bytes it actually takes to write the length of the name. This length is the total number of bytes that comprise the FID byte stream. The step writes that value into the length parameter of the Fid. This operation completes the construction of the FID. The FID is the returned to the caller in step 45 .
[0040] Returning to the question in step 40 of whether the inode index or serial number the entry is equal to the inode index or serial number determined in step 37 , if the answer is “No”, then the process moves to step 46 and sets the next entry in the directory. Step 47 , determines whether there are any more entries in the directory. If there are no more entries, then a FID can not be generated because there is not a directory entry for that resource, step 48 . If the answer in step 47 is “Yes”, then the procedure would return to step 39 read the next directory entry for this directory and repeat the process as described.
[0041] In summary, this technique described in FIG. 5 provides a way to generate a FID, when the native operating system does provide that service as described in FIG. 4. This FID construction combines a mostly-unique identification for the file usually in the form of a disk address or file system index and coupling that information with some unique information from the file, in this case the file name. Those two pieces of information together form a one-to-one relationship between that FID and the file resource that it represents. With this process, no other file resource in the system will have that representation. This representation will be the association mechanism for the external authorization policy.
[0042] [0042]FIG. 6 illustrates the high-level architecture relationship between an authorization manager, a file system, and techniques of the present invention. In the architecture, Box 50 contains the file identifier to protected object name (PON) mapping database. Relevant algorithms would be the ones that create a FID, get a FID and create a mapping to the PON and for a FID, provide it as input and return a PON to a caller. Box 51 contains the operation interceptor component of the authorization security manager that would intervene in operations accessing the file system resources that the security manager will protect. This component would examine the FID-to-PON mapping database and determine if that file system resource is protected, and if that resource has external authorization policy on it. If the resource does have external authorization policy defined on it, this operation interceptor would grant or deny access to the file system resource. Box 52 represents the applications that run on the system and users of the system that are accessing the protected file system resources. Box 53 is the database location where the authorization policy and security rules. This database location could be a variety of places such as on a network computer or on the same system that enforces the rules. Conceptually, there is some medium that actually holds all of the rules. Box 54 represents a security access system decision engine. In this decision engine, logic actually exist that would take the input information and other information related to the access request and determine whether to grant the access request. This authorization decision engine at the implementation level is application dependent.
[0043] In this invention, the technique allows the policy to be defined in terms of human readable names called PONs, full path names to files. Box 53 only pertains to security rules in terms of these file names, the name that describes something. The Box 50 takes those names and translates the names of files into very unique descriptions of these files as they exist on the system. Box 51 takes any route to a file and converts that into a unique physical description called a FID. Box 51 also takes this FID and maps it back to a real file name and determines that file that an application is attempting to access. Box 54 gets a name and information about the accessor and determines whether to grant access based on the security rules for these human generic file system names. Boxes 53 , 54 , and 55 do not necessarily know that they are protecting files or the details of how the file associations operate.
[0044] [0044]FIG. 7 depicts a pictorial representation of data processing system 60 which may be used in implementation of the present invention. As may be seen, data processing system 60 includes processor 61 that preferably includes a graphics processor, memory device and central processor (not shown). Coupled to processor 61 is video display 62 which may be implemented utilizing either a color or monochromatic monitor, in a manner well known in the art. Also coupled to processor 61 is keyboard 63 . Keyboard 63 preferably comprises a standard computer keyboard, which is coupled to the processor by means of cable 64 . Also coupled to processor 61 is a graphical pointing device, such as mouse 65 . Mouse 65 is coupled to processor 61 , in a manner well known in the art, via cable 66 . As is shown, mouse 65 may include left button 67 , and right button 18 , each of which may be depressed, or “clicked”, to provide command and control signals to data processing system 60 . While the disclosed embodiment of the present invention utilizes a mouse, those skilled in the art will appreciate that any graphical pointing device such as a light pen or touch sensitive screen may be utilized to implement the method and apparatus of the present invention. Upon reference to the foregoing, those skilled in the art will appreciate that data processing system 60 may be implemented utilizing a personal computer.
[0045] It is important to note that while the present invention has been described in the context of a fully functioning data processing system, those skilled in the art will appreciate that the processes of the present invention are capable of being distributed in the form of instructions in a computer readable medium and a variety of other forms, regardless of the particular type of medium used to carry out the distribution. Examples of computer readable media include media such as EPROM, ROM, tape, paper, floppy disc, hard disk drive, RAM, and CD-ROMs and transmission-type of media, such as digital and analog communications links. | The present invention is an algorithm that manages the ability of a user or software program to access certain protected file resources. This invention describes a method for file system security through techniques that control access to the file system resources using externally stored attributes. This invention accomplishes the described objectives in file system security by creating an external database containing auxiliary attributes for objects in the file system. During a file access attempt, an identifier of this file will be matched against a set of protected files in a security database. If that file is not in the database, there is not protection on the file and requester will be allowed to access the file. If a match does show that the file is protected there will be a determination as to whether the requester will be allowed access to the file. The basis for this access determination will be a set security rules defined in the external security attribute. This invention incorporates techniques and algorithms for attribute attachment, storage and organization of the associations to these attributes, and subsequent recognition of attached attributes. In this approach, the attributes would define authorization policy for controlling access to objects in the file system. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to U.S. patent application Ser. No. 10/792,778, entitled “METHOD OF MAKING PIEZOELECTRIC CANTILEVER PRESSURE SENSOR ARRAY” to Jun AMANO, et al.; and U.S. patent application Ser. No. 10/792,891, entitled “PIEZOELECTRIC CANTILEVER PRESSURE SENSOR ARRAY” to Jun AMANO, both applications of which are concurrently herewith being filed under separate covers, the subject matters of which are herein incorporated by reference in their entireties.
TECHNICAL FIELD
The technical field is pressure sensors and, in particular, piezoelectric cantilever pressure sensors.
BACKGROUND
Fingerprint identification involves the recognition of a pattern of ridges and valleys on the fingertips of a human hand. Fingerprint images can be captured by several types of methods. The oldest method is optical scanning. Most optical scanners use a charge coupled device (CCD) to capture the image of a fingertip that is placed on an illuminated plastic or glass platen. The CCD then converts the image into a digital signal. Optical fingerprint scanners are reliable and inexpensive, but they are fairly large and cannot be easily integrated into small devices.
In recent years, new approaches using non-optical technologies have been developed. One approach uses capacitance, or an object's ability to hold an electric charge, to capture fingerprint images. In this approach, the finger skin is one of the capacitor plates and a microelectrode is the other capacitor plate. The value of the capacitance is a function of the distance between the finger skin and the microelectrode. When the finger is placed on a microelectrode array, the capacitance variation pattern measured from electrode to electrode gives a mapping of the distance between the finger skin and the various microelectrodes underneath. The mapping corresponds to the ridge and valley structure on the finger tip. The capacitance is read using a integrated circuit fabricated on the same substrate as the microelectrode array.
A slightly different approach uses an active capacitive sensor array to capture the fingerprint image. The surface of each sensor is composed of two adjacent sensor plates. These sensor plates create a fringing capacitance between them whose field lines extend beyond the surface of the sensor. When live skin is brought in close proximity to the sensor plates, the skin interferes with field lines between the two plates and generate a “feedback” capacitance that is different from the original fringing capacitance. Because the fingerprint ridge and fingerprint valley generate different feedback capacitance, the entire fingerprint image may be captured by the array based on the feedback capacitance from each sensor. The capacitance sensors, however, are vulnerable to electric field and electrostatic discharge (ESD). The capacitance sensors also do not work with wet fingers. Moreover, the silicon-based sensor chip requires high power input (about 20 mA) and is expensive to manufacture.
Another approach employs thermal scanners to measure the differences in temperature between the ridges and the air caught in the valleys. The scanners typically use an array of thermal-electric sensors to capture the temperature difference. As the electrical charge generated within a sensor depends on the temperature change experienced by this sensor, a representation of the temperature field on the sensor array is obtained. This temperature field is directly related to the fingerprint structure. When a finger is initially placed on a thermal scanner, the temperature difference between the finger and the sensors in the array is usually large enough to be measurable and an image is created. However, it takes less than one-tenth of a second for the finger and the sensors to reach an equal temperature and the charge pattern representing the fingerprint will quickly fade away if the temperature change is not regularly refreshed.
Yet another approach is to use pressure sensors to detect the ridges and valleys of a fingerprint. The sensors typically include a compressible dielectric layer sandwiched between two electrodes. When pressure is applied to the top electrode, the inter-electrode distance changes, which modifies the capacitance associated with this structure. The higher the pressure applied, the larger the sensor capacitance gets. Arrays of such sensors combined with a read-out integrated circuit can be used for fingerprint acquisition. The pressure sensors may also be made of piezoelectric material. U.S. patent application Publication No. 20020053857 describes a piezoelectric film fingerprint scanner that contains an array of rod-like piezoelectric pressure sensors covered by a protective film. When a finger is brought into contact with such an array, the impedance of the pressure sensor changes under pressure. Fingerprint ridges correspond to the highest pressure point, while little pressure is applied at points associated with the fingerprint valleys. A range of intermediate pressures can be read for the transition zone between fingerprint ridge and valleys. The pattern of impedance changes, which is recorded by an impedance detector circuit, provides a representation of the fingerprint structure. The pressure sensing methods provide good recognition for wet fingers and are not susceptible to ESD. However, the major problem with the pressure based-detection method is the low sensor sensitivity. A certain amount of pressure is required for a sensor to generate a signal that is above the background noise. In order to reach this threshold pressure, the finger often needs to be pressed hard against the scanner to a point that the ridges and valleys are flattened under pressure, which may result in inaccurate fingerprint representation.
Thus, a need still exists for a fingerprint identification device that is accurate and sensitive, has a compact size, requires low power input, and can be manufactured at low cost.
SUMMARY
A piezoelectric cantilever pressure sensor is disclosed. The piezoelectric cantilever pressure sensor contains a substrate and an elongate piezoelectric cantilever mounted at one end to the substrate and extending over the cavity. The piezoelectric cantilever contains a first electrode, a second electrode, and a piezoelectric element that is located between the electrodes and is electrically connected both electrodes.
The piezoelectric cantilever pressure sensor can be manufactured at low cost and used in various applications including fingerprint identification devices.
BRIEF DESCRIPTION OF THE DRAWINGS
The detailed description will refer to the following drawings, in which like numerals refer to like elements, and in which:
FIGS. 1A and 1B are schematic cross-sectional views depicting a first embodiment of a piezoelectric cantilever pressure sensor in quiescent state and stressed state, respectively.
FIGS. 1C and 1D are schematic cross-sectional views depicting a second embodiment and a third embodiment, respectively, of a piezoelectric cantilever pressure sensor.
FIG. 2 is a cross-sectional view depicting a fourth embodiment of a piezoelectric cantilever pressure sensor.
FIG. 3A is a schematic representation of a piezoelectric cantilever pressure sensor array.
FIGS. 3B and 3C are schematic representations of a piezoelectric cantilever pressure sensor in on-state and off-state, respectively.
FIG. 3D is a schematic representation of a detection circuit for a piezoelectric cantilever sensor array.
FIGS. 4A–4F are schematic cross-sectional views depicting a first layer structure from which the first and second embodiments of the piezoelectric cantilever pressure sensor are fabricated at different stages of its manufacture.
FIGS. 5A and 5B are schematic top views of the layer structure before and after, respectively, the second etching in fabricating the first embodiment.
FIG. 5C shows a cross-sectional view of the partially completed piezoelectric cantilever along the line 5 C— 5 C in FIG. 5B .
FIG. 6A is a schematic top view of the layer structure after the third etching in fabricating the first embodiment.
FIG. 6B shows a cross-sectional view of the partially completed piezoelectric cantilever along the line 6 B— 6 B in FIG. 6A .
FIG. 7A is a schematic top view of the layer structure after the fourth etching in fabricating the first embodiment.
FIGS. 7B and 7C show cross-sectional views of the partially completed piezoelectric cantilever along the lines 7 B— 7 B and 7 C— 7 C in FIG. 7A .
FIG. 8A is a schematic top view of the layer structure after depositing the X-line metal layer in fabricating the first embodiment.
FIGS. 8B and 8C show cross-sectional views of the partially completed piezoelectric cantilever along the lines 8 B— 8 B and 8 C— 8 C in FIG. 8A .
FIG. 9A is a schematic top view of the layer structure after the fifth etching in fabricating the first embodiment.
FIGS. 9B and 9C are cross-sectional views of the partially completed piezoelectric cantilever along the lines 9 B— 9 B and 9 C— 9 C in FIG. 9A .
FIG. 10A is a schematic top view of the layer structure after formation of the second protective coating in fabricating the first embodiment.
FIG. 10B shows a cross-sectional view of the partially completed piezoelectric cantilever along the line 10 B— 10 B in FIG. 10A .
FIG. 11A is a schematic top view of the layer structure after the sixth etching in fabricating the first embodiment.
FIG. 11B shows a cross-sectional view of the piezoelectric cantilever along the line 11 B— 11 B in FIG. 11A .
FIG. 12 is a schematic top view of the layer structure after the seventh etching in fabricating the first embodiment.
FIG. 13A is a schematic top view of the layer structure in FIG. 4D after the second etching in fabricating the second embodiment.
FIG. 13B is a schematic cross-sectional view of the partially completed piezoelectric cantilever along the line 13 B— 13 B in FIG. 13A .
FIG. 14A is a schematic top view of the layer structure after the third etching in fabricating the second embodiment.
FIG. 14B is a schematic cross-sectional view of the partially completed piezoelectric cantilever along the line 14 B— 14 B in FIG. 14A .
FIG. 15A is a schematic top view of the layer structure after the fourth etching in fabricating the second embodiment.
FIGS. 15B and 15C are schematic cross-sectional views of the partially completed piezoelectric cantilever along the lines 15 B— 15 B and 15 C— 15 C in FIG. 15A .
FIG. 16A is a schematic top view of the layer structure after depositing the X-line metal layer in fabricating the second embodiment.
FIGS. 16B and 16C are schematic cross-sectional views of the partially completed piezoelectric cantilever along the lines 16 B— 16 B and 16 C— 16 C in FIG. 16A .
FIG. 17A is a schematic top view of the layer structure after the fifth etching in fabricating the second embodiment.
FIGS. 17B and 17C are schematic cross-sectional views of the partially completed piezoelectric cantilever along the lines 17 B— 17 B and 17 C— 17 C in FIG. 17A .
FIG. 18A is a schematic top view of the layer structure after the sixth etching in fabricating the second embodiment.
FIG. 18B is a schematic cross-sectional view of the completed piezoelectric cantilever along the line 18 B— 18 B in FIG. 18A .
FIG. 19A is a schematic top view of a layer structure after the formation of the second protective coating in fabricating the second embodiment.
FIG. 19B is a schematic cross-sectional view of the completed piezoelectric cantilever along the line 19 B— 19 B in FIG. 19A .
FIG. 20 is a schematic top view of the layer structure after the seventh etching in fabricating the second embodiment.
FIGS. 21A–21K are schematic cross-sectional views depicting a second layer structure at different stages of its manufacture in fabricating the third embodiment.
FIGS. 22A and 22B are schematic top views of the layer structure before and after the third etching, respectively, in fabricating the third embodiment.
FIG. 22C is a schematic cross-sectional view of the partially completed piezoelectric cantilever along the line 22 C— 22 C in FIG. 22B .
FIG. 23A is a schematic top view of the layer structure after the fourth etching in fabricating the third embodiment.
FIG. 23B is a schematic cross-sectional view of the partially completed piezoelectric cantilever along the line 23 B— 23 B in FIG. 23A .
FIG. 24A is a schematic top view of the layer structure after the fifth etching in fabricating the third embodiment.
FIGS. 24B and 24C are schematic cross-sectional views of the partially completed piezoelectric cantilever along the lines 24 B— 24 B and 24 C— 24 C in FIG. 24A .
FIG. 25A is a schematic top view of the layer structure after the deposition of the X-line metal layer in fabricating the third embodiment.
FIGS. 25B and 25C are schematic cross-sectional views of the partially completed piezoelectric cantilever along the lines 25 B— 25 B and 25 C— 25 C in FIG. 25A .
FIG. 26A is a schematic top view of the layer structure after the sixth etching in fabricating the third embodiment.
FIGS. 26B and 26C are schematic cross-sectional views of the partially completed piezoelectric cantilever along the lines 26 B— 26 B and 26 C— 26 C in FIG. 26A .
FIG. 27A is a schematic top view of the layer structure after the seventh etching in fabricating the third embodiment.
FIG. 27B is a schematic cross-sectional view of a completed piezoelectric cantilever along the line 27 B— 27 B in FIG. 27A .
FIG. 28A is schematic top view of the layer structure after the formation of the second protective layer in fabricating the third embodiment.
FIG. 28B is a schematic cross-sectional view of the completed piezoelectric cantilever along the line 28 B— 28 B in FIG. 28A .
FIG. 29 is a schematic top view of the layer structure after the eighth etching in fabricating the third embodiment.
FIG. 30 is a flow-chart of a process for manufacturing a piezoelectric cantilever pressure sensor array.
DETAILED DESCRIPTION
FIG. 1 shows a first embodiment of a piezoelectric cantilever pressure sensor 100 in its quiescent state. The piezoelectric cantilever pressure sensor 100 includes a piezoelectric cantilever 150 having a base portion 152 and a beam portion 154 , and an access transistor 160 having a gate contact 161 , a drain contact 163 , and a source contact 165 . The piezoelectric cantilever 150 further includes, from top to bottom, a top electrode 104 , a piezoelectric element 106 , a bottom electrode 108 , and an elastic element 110 . The electrodes 104 and 108 are electrically coupled to the piezoelectric element 106 . The bottom electrode 108 is also connected to the drain contact 163 of the access transistor 160 . The base portion 152 of the piezoelectric cantilever 150 is supported by a substrate 120 , while the beam portion 154 of the piezoelectric cantilever 150 is suspended above a cavity 130 .
In this first embodiment, the piezoelectric element 106 and the elastic element 110 form a asymmetrical piezoelectric bimorph, i.e., a two-layered structure having a piezoelectric element and a non-piezoelectric element. When the bimorph is bent, one element elongates and is under tensile stress while the other element contracts and is under compressive stress. In the quiescent, zero stress state of the piezoelectric cantilever pressure sensor 100 , there is no voltage difference between the electrodes 104 and 108 . When a finger touches the piezoelectric cantilever pressure sensor 100 , direct contact between a finger ridge and the beam portion 154 of the piezoelectric cantilever 150 (shown as arrow A in FIG. 1B ) will deflect the beam portion 154 of the piezoelectric cantilever 150 . This causes tensile stress in the piezoelectric element 106 and compressive stress in the elastic element 110 . The stress in the piezoelectric element 106 produces a proportional output voltage V between the electrodes 104 and 108 . The elastic element 110 offsets the neutral axis 140 of stress in the piezoelectric cantilever 150 so that strain produced by piezoelectric effect is translated into an output voltage in the piezoelectric element 106 . Typically, the piezoelectric cantilever pressure sensor 100 is capable of generating a voltage in the range of 100 mV to 1.0 V with a typical finger touch. A detailed description on the mathematical modeling of the piezoelectric cantilever 150 can be found, for example, in “Modeling and Optimal Design of Piezoelectric Cantilever Microactuators” (DeVoe and Pisano, IEEE J. Microelectromech. Syst., 6:266–270, 1997), which is incorporated herein by reference.
The material of substrate 120 is any etchable material. The material of substrate 120 is additionally selected based on its thermal stability, chemical inertness, specific coefficients of thermal expansion, and cost. In one embodiment, the material of the substrate is glass. Examples of glasses include, but are not limited to, borosilicate glasses, ceramic glasses, quartz and fused silica glasses, and soda lime glasses. The thickness of the substrate 120 may vary depending on the substrate material and the manufacturing process. In an embodiment, the material of the substrate 120 is a borosilicate glass and the substrate has a thickness of about 0.5 mm to about 1 mm. In this disclosure, the major surface of the substrate 120 on which the piezoelectric cantilever 150 is located will be called the top surface of the substrate and the major surface of the substrate opposite the top surface will be called the bottom surface.
The material of the piezoelectric element 106 is a piezoelectric material. Examples of the piezoelectric material include, but are not limited to, lead zirconate titanate (PZT), lead magnesium niobate-lead zirconate titanate (PMN-PZT), lead zirconate niobate-lead zirconate titanate (PZN-PZT), aluminum nitride (AlN), and zinc oxide (ZnO). The thickness of the piezoelectric element 106 depends on the piezoelectric material and the specific requirement of a particular application. In an embodiment, the piezoelectric element 106 has a thickness of about 0.5 μm to about 1 μm and is composed of PZT with a zirconium/titanium molar ratio of about 0.4 to about 0.6.
The electrodes 104 , 108 , and 112 are typically composed of one or more thin layers of a conducting material. The thickness of the electrodes is typically in the range of 20–200 nm. In one embodiment, at least one of the electrodes 104 , 108 , and 112 is composed of one or more layers of metal such as gold, silver, platinum, palladium, copper, aluminum or an alloy comprising one or more of such metals. In another embodiment, the top electrode 104 is composed of platinum and the bottom electrode 108 is composed of a layer of platinum and a layer of titanium or titanium oxide (TiO x ).
The elastic element 110 is typically composed of a silicon-based material. Examples include, but are not limited to, silicon, polycrystalline silicon (polysilicon), and silicon nitride (SiN x ). The thickness of the elastic element 110 is typically in the range of 0.2–1 μm. In an embodiment, the elastic element 110 is composed of silicon or silicon nitride and has a thickness of about 0.3–0.7 μm.
In all the embodiments described herein, the beam portion of the piezoelectric cantilever, e.g., the beam portion 154 of the piezoelectric cantilever 150 , is designed to have a rigidity that would allow a deflection large enough to generate a measurable voltage under the pressure from a finger. Typically, the load applied by an individual's finger on a fingerprint sensor surface is in the range of 100–500 g. A fingerprint sensor surface is approximately 15 mm×15 mm in dimensions. Assuming the fingerprint sensor has an array of piezoelectric cantilever pressure sensors with a standard pitch (i.e., distance between two neighboring sensors) of 50 μm, which corresponds to at least 500 dot per inch (dpi) specified by the Federal Bureau of Investigation, there will be a total of 90,000 sensors in the fingerprint area. As a first order approximation, one can assume that the area of the fingerprint ridges is equal to that of the fingerprint valleys. Accordingly, approximately 45,000 sensors will bear the applied load from the fingerprint. If one conservatively assumes an applied load of 90 grams from the fingerprint, then each beam portion 154 of the piezoelectric cantilever 150 bears a load of about 2 mg. Since the beam needs to fit within the array pitch dimensions of a maximum of 50 μm×50 μm, the length and width of the beam portion 154 of the piezoelectric cantilever 150 need to be less than the array pitch. Based on the length, width, thickness, and Young's Modulus for the beam material, the possible deflection of the beam portion 154 of the piezoelectric cantilever 150 under a given load and the voltage generated by the deflection can be determined. In an embodiment, the piezoelectric cantilever 150 is capable of producing a maximum voltage in the range of 500–1,000 mV under normal pressure from a finger.
The cavity 130 under the piezoelectric cantilever 150 is deep enough to allow maximum deflection of the cantilever 150 . In the first embodiment shown in FIGS. 1A and 1B , the cavity 130 extends through the thickness of the substrate 120 and is formed by etching from the bottom surface of the substrate 120 .
FIG. 1C shows a second embodiment of piezoelectric cantilever pressure sensor 100 in which the cavity 130 extends into the substrate 120 from the top surface of the substrate. Typically, the cavity 130 does not extend all the way to the bottom surface of the substrate 120 in this embodiment. In this embodiment, releasing holes 503 extend through the thickness of the beam portion 154 of the piezoelectric cantilever. The releasing holes permit etching of the cavity 130 from the top surface of the substrate to release the beam portion 154 of the piezoelectric cantilever from the substrate.
FIG. 1D shows a third embodiment of piezoelectric cantilever pressure sensor 100 in which the elastic element 110 is shaped to define a pedestal 111 that spaces the substrate-facing surface of the beam portion 154 of the piezoelectric cantilever 150 from the major surface of the substrate 120 . In this embodiment, the cavity 130 is located between the substrate-facing surface of the beam portion 154 and the top surface of the substrate 120 . The elastic element is shaped with the aid of a sacrificial mesa, as will be described in detail below.
The second and third embodiments shown in FIGS. 1C and 1D are otherwise similar to the first embodiment shown in FIGS. 1A and 1B , and will not be described further here. Exemplary methods that can be used to fabricate all three embodiments will be described below.
FIG. 2 shows a fourth embodiment of a piezoelectric cantilever pressure sensor 200 in which the piezoelectric cantilever incorporates a symmetrical piezoelectric bimorph. Piezoelectric cantilever pressure sensor 200 is based on the first embodiment of the piezoelectric cantilever pressure sensor described above with reference to FIGS. 1A and 1B . The second and third embodiments of the piezoelectric cantilever pressure sensor described above with reference to FIGS. 1C and 1D , respectively, may be similarly modified to incorporate a symmetrical piezoelectric bimorph.
The piezoelectric cantilever pressure sensor 200 includes a piezoelectric cantilever 250 having a base portion 252 and a beam portion 254 , and the access transistor 160 having the gate contact 161 , the drain contact 163 , and the source contact 165 . The piezoelectric cantilever 250 incorporates a symmetrical piezoelectric bimorph composed of, from top to bottom, the top electrode 104 , the piezoelectric element 106 , a middle electrode 112 , an additional piezoelectric element 107 , and the bottom electrode 108 , all of which are supported by the substrate 120 . The electrodes 104 and 112 are electrically coupled to the piezoelectric element 106 . The electrodes 112 and 104 are electrically coupled to the piezoelectric element 107 . The bottom electrode 108 is connected to the drain contact 163 of the access transistor 160 .
In this fourth embodiment, the piezoelectric elements 106 and 107 and their respective electrodes form a symmetrical piezoelectric bimorph that generates a measurable output voltage in response to finger pressure. When the bimorph structure is bent, the piezoelectric element 106 elongates and is under tensile stress while the piezoelectric element 107 contracts and is under compressive stress.
FIG. 3A shows a highly simplified example of a piezoelectric cantilever pressure sensor array 300 composed of four piezoelectric cantilever pressure sensors in a two-by-two matrix. In the example shown, the piezoelectric cantilever pressure sensors are the first embodiment of the piezoelectric cantilever pressure sensors 100 described above with reference to FIGS. 1A and 1B . However, the piezoelectric cantilever pressure sensor array 300 can incorporate any of the above-described piezoelectric cantilever pressure sensor embodiments. The piezoelectric cantilever pressure sensors 100 are connected to a grid of X-axis contact lines (X-lines) 302 and Y-axis contact lines (Y-lines) 304 . Each line 302 or 304 is connected to an exposed X-contact pad 306 (X-pad) or Y-contact pad (Y-pad) 308 , respectively. Specifically, the top electrodes of the piezoelectric cantilever pressure sensors 100 in each row of the array are connected to a respective X-line and the gates of the access transistors 160 of the piezoelectric cantilever pressure sensors 100 in each column of the array are connected to a respective Y-line. Additionally, the sources of the access transistors 160 of the piezoelectric cantilever pressure sensors 100 in each column of the array are connected to a respective reference voltage contact line (reference line) 312 . The reference lines 312 are connected to an exposed reference voltage contact pad (reference pad) 310 . Typically, the piezoelectric cantilever pressure sensor array 300 has a pitch of 50 μm and an array size of 300×300 or 256×360.
The state of each piezoelectric cantilever pressure sensor 100 in the piezoelectric cantilever pressure sensor array 300 is read out by the access transistor 160 connected to the piezoelectric cantilever 150 and typically located adjacent the base portion 152 of each piezoelectric cantilever 150 as shown in FIG. 1A . As shown in FIGS. 3B and 3C , the gate contact 161 of the access transistor 160 is connected to the Y-line, the drain contact 163 of the access transistor 160 is connected to the bottom electrode 108 of the piezoelectric cantilever 150 , and the source contact 165 of the access transistor 160 is connected to a reference voltage V ref by the reference line 312 shown in FIG. 3A . The piezoelectric cantilever 150 is accessed through the access transistor 160 by providing an activation signal on the Y-line and detecting the voltage signal output by the piezoelectric cantilever 150 on the X-line. The access signal causes the access transistor 160 to connect the bottom electrode 108 to the reference voltage, typically ground, applied to the reference pad 310 . The piezoelectric cantilever 150 bent by a fingerprint ridge will be said to be in an on state. A piezoelectric cantilever 150 in the on state delivers the output signal, typically in the range of 500–1000 mV, to the X-line ( FIG. 3B ), when the piezoelectric cantilever pressure sensor 100 is accessed through its access transistor 160 by the activation signal. On the other hand, the piezoelectric cantilever 150 under a fingerprint valley is not bent and will be said to be in an off state. A piezoelectric cantilever 150 in the off state generates no voltage difference between the electrodes 104 and 108 . Accordingly, when the piezoelectric cantilever pressure sensor 100 is accessed through its access transistor 160 by the activation signal, no output signal is generated on the X-line ( FIG. 3C ). A typical capacitance of the piezoelectric cantilever pressure sensor 100 is from 0.5 to 2 pF. The parasitic capacitance of the X-line is typically in the range of 1 to 5 pF and the sensing current in the X-line is in the order of 1–10 μA. The resistance of the X-line is in the order of few hundred Ohms, which results in a very fast operation of the piezoelectric cantilever pressure sensor 100 .
FIG. 3D shows a circuit 400 that serves to record the status of the sensors of the piezoelectric cantilever pressure sensor array 300 . Each piezoelectric cantilever pressure sensor 100 in the circuit 400 has a unique X-Y address based on its position in the X-line/Y-line matrix. The read-out circuits 170 scan the matrix by sequentially sending out activation signals to Y-lines. The status of each piezoelectric cantilever pressure sensor 100 is determined on the X-line to which it is connected based on its response to the activation signal. Typically, to distinguish between a real signal and an aberrant voltage fluctuation, the scan is repeated hundreds of times each second. Only signals detected for two or more scans are acted upon by the read-out circuits 170 . Such read-out circuits and the scanning mechanism are known in the art.
In addition to fingerprint detection, the piezoelectric cantilever pressure sensor array 300 has utility in many other applications. The piezoelectric cantilever pressure sensor array 300 may be used for tactile imaging of lumps in soft tissue in medical devices. For example, the piezoelectric cantilever pressure sensor array 300 can be used in ultrasound imaging devices to provide a three-dimensional image of breast cancer or as an electric “fingertip” in remote surgery. The piezoelectric cantilever pressure sensor array 300 may also be used to detect nano- or micro-movement. For example, the piezoelectric cantilever pressure sensor array 300 can be used in automobile electronics as a tire pressure sensor or an impact sensor and in microphones and micro-speakers as an acoustic sensor. The piezoelectric cantilever sensors can also be used as microactuators or nanopositioners by applying a drive voltage to them.
FIGS. 4A–4F , 5 A– 5 C, 6 A, 6 B, 7 A– 7 C, 8 A– 8 C, 9 A– 9 C, 10 A, 10 B, 11 A, 11 B, and 12 illustrate a first embodiment of a method of making an array of piezoelectric cantilever pressure sensors that incorporates piezoelectric cantilever pressure sensors 100 in accordance with the first embodiment described above with reference to FIGS. 1A and 1 B. The piezoelectric cantilever sensor array made by the method is otherwise similar to the array 300 described above with reference to FIGS. 3A and 3D .
The first embodiment of the method starts with the fabrication of a layer structure that can also be used in a second embodiment of the method, to be described below. The second embodiment of the method is for making an array of piezoelectric cantilever pressure sensors that incorporates piezoelectric cantilever pressure sensors 100 in accordance with the second embodiment shown in FIG. 1C .
FIGS. 4A–4F show the fabrication of a layer structure 180 by mounting prefabricated access transistors 160 on the top surface of the substrate 120 ( FIG. 4A ); forming the reference pad 310 ( FIG. 3A ) and reference lines 312 ( FIG. 3A ) connecting the reference pad (not shown in FIG. 4A ) to the source contacts 165 of the access transistors; depositing the elastic layer 410 on the substrate 120 ( FIG. 4B ); forming contact holes 171 and 173 extending through the elastic layer 410 to the gate contact 161 and drain contact 163 , respectively, of each access transistor 160 ( FIG. 4C ); depositing a bottom electrode layer 408 on the elastic layer 410 ( FIG. 4D ); depositing a piezoelectric layer 406 on the bottom electrode layer 408 ( FIG. 4E ); and depositing a top electrode layer 404 on the piezoelectric layer 106 ( FIG. 4F ).
The elastic layer 410 , the electrode layers 408 and 404 , and the piezoelectric layer 406 are deposited by a process such as sputtering, chemical vapor deposition (CVD), plasma CVD, physical vapor deposition (PVD) or the like. The contact holes 171 and 173 are formed by a first etching process that uses a first mask. The layer structure 180 fabricated as just described is shown in FIG. 4F . The layer structure 180 is then subject to additional processing to form the array of piezoelectric cantilever pressure sensors.
As described above, the thickness of each layer of the layer structure 180 depends on the specific requirements of a particular application. Either or both of the electrode layers 404 and 408 may also be a layer structure. In one embodiment, the substrate 120 is composed of borosilicate glass with a thickness of about 0.5 mm; the elastic layer 410 is composed of silicon nitride with a thickness of about 500 nm; the bottom electrode layer 408 has a two-layered structure composed of a platinum layer with a thickness of about 100 nm and a titanium oxide layer with a thickness of about 50 nm; the piezoelectric layer 406 has a thickness of about 500 nm to about 1,000 nm and is composed of PZT with a zirconium/titanium ratio of 0.4 to 0.6; the top electrode layer 404 has a thickness of about 100 nm and is composed of platinum.
Next, as shown in FIGS. 5A–5C , the layer structure 180 is subject to a second etching process that uses a second mask. FIG. 5A shows the layer structure 180 before the second etching process is performed. The locations on the surface of the substrate of the access transistors 160 , the reference lines 312 and the reference pad 310 are shown by broken lines. The second etching process defines partially completed piezoelectric cantilevers 501 in the top electrode layer 404 and the piezoelectric layer 406 . In an embodiment, the partially completed piezoelectric cantilever 501 has dimensions of 25 μm×10 μm (top view) to conform to the standard sensor pitch of 50 μm. As shown in FIGS. 5B and 5C , the second etching process removes part of the top electrode layer 404 and the piezoelectric layer 406 to define the top electrode 104 and the piezoelectric element 106 of the partially completed piezoelectric cantilevers in these layers, and additionally exposes part of the bottom electrode layer 408 for the next etching process.
After the second etching process, the layer structure 180 is subject to a third etching process that uses a third mask. As shown in FIGS. 6A and 6B , the third etching process removes the unmasked portion of the bottom electrode layer 408 to define the bottom electrodes 108 , the Y-lines 304 and Y-pads 308 , and the electrical connection between the bottom electrodes and the drains of the respective access transistors 160 . The third etching process additionally removes the unmasked portion of the elastic layer 410 to define the elastic element 110 and to expose the access transistors 160 , the prefabricated reference pad 310 and the reference lines 312 , which are connected to the source contacts 165 of the access transistors 160 . The Y-lines 304 are connected to the gate contacts 161 of the access transistors 160 . One of the Y-lines is shown as part of the bottom metal layer 408 on the gate contact 161 in FIG. 6B . The third etching process forms partially completed piezoelectric cantilevers 601 .
Next, the layer structure 180 is coated with a first protective layer 114 , as shown in FIGS. 7A and 7B , followed by a fourth etching process that uses a fourth mask. The protective layer 114 prevents hydrogen or water penetration. The protective layer 114 is composed of aluminum oxide or any other suitable material. The protective layer 114 is deposited by a process such as sputtering, CVD, plasma CVD, PVD or the like. The fourth etching process forms contact openings 703 in the protective layer 114 . As shown in FIGS. 7A and 7C , the contact openings expose part of the top electrodes 104 of the partially completed piezoelectric cantilevers 601 .
After the fourth etching process, an X-line metal layer 116 is deposited on the first protective layer 114 , as shown in FIGS. 8A and 8B . The X-line metal layer 116 is deposited by a process such as sputtering, CVD, plasma CVD, PVD or the like. The X-line metal layer 116 is typically composed of aluminum or an aluminum alloy. As shown in FIG. 8C , the X-line metal layer 116 fills the contact opening 703 in the first protective layer 114 and is thus electrically connected to the top electrode 104 of the partially completed piezoelectric cantilever 801 .
Next, a fifth etching process that uses a fifth mask is performed to define the X-lines 302 and X-pads 306 in the X-line metal layer 116 . As shown in FIGS. 9A–9C , the fifth etching process removes the unmasked portion of the X-line metal layer 116 to define the X-lines 302 and the X-pads 306 and additionally exposes the first protective layer 114 .
After the fifth etching process, a second protective layer 118 is deposited on the layer structure 180 by spin coating, as shown in FIGS. 10A and 10B . The second protective layer prevents direct contact between the fingertip and the X-lines 302 . The second protective layer 118 is composed of any material that meets the heat resistance, chemical resistance, and insulation requirement. The second protective layer 118 is also flexible enough to allow repeated deformation. In one embodiment, the second protective layer 118 is composed of polyimide and has a thickness of about 2–7 μm.
After the second protective layer 118 is deposited, the layer structure 180 is subject to a sixth etching process that uses a sixth mask. The sixth etching process is performed by applying the etchant to the bottom surface of the substrate 120 . The sixth etching process forms a cavity 130 that extends through the substrate 120 to the elastic element 110 of each completed piezoelectric cantilever 150 , as shown in FIGS. 11A and 11B . Forming the cavity 130 releases the beam portion 154 of each piezoelectric cantilever 150 from the substrate to complete the fabrication of the piezoelectric cantilevers.
Next, a seventh and final etching process that uses a seventh mask is performed. The seventh etching process removes portions of the first protective layer 114 and the second protective layer 118 to expose the X-pads 306 , the Y-pads 308 , and the reference pad 310 , as shown in FIG. 12 .
The method just described fabricates a piezoelectric cantilever pressure sensor arrays 300 with piezoelectric cantilever pressure sensors 100 in accordance with the first embodiment connected to the X-lines 302 , the Y-lines 304 , and the reference lines 312 , as shown in FIG. 12 . As is known in the art, the piezoelectric cantilevers 150 , the X-lines 302 and X-pads 306 , the Y-lines 304 and Y-pads 308 , the reference lines 312 and reference pad 310 , and the cavities 130 may differ in size, shape and layout from the example shown in the figures. For example, the shape of the cavities 130 can be round, oval, or rectangular.
Alternatively, the access transistors 160 can be fabricated after the piezoelectric cantilevers 150 have been defined in the layer structure 180 and the cavities 130 have been etched. The drain contacts 163 of the access transistors 160 are connected to the bottom electrodes 108 of the piezoelectric cantilevers 150 by a metallization process. The reference pad 310 and reference lines 312 are fabricated and connected to the gate contact 161 of the access transistor 160 by the same or another metallization process. The fabrication process for access transistors 160 is known in the art. For example, the process is described in detail in the book, “Thin Film Transistors” by C. R. Kagan and P. Andry, Marcel Dekker (New York, 2003), which is hereby incorporated by reference.
FIGS. 13A , 13 B, 14 A, 14 B, 15 A– 15 C, 16 A– 16 C, 17 A– 17 C, 18 A, 18 B, 19 A, 19 B, and 20 illustrate the above-mentioned second embodiment of a method of making an array of piezoelectric cantilever pressure sensors that incorporates piezoelectric cantilever pressure sensors 100 in accordance with the second embodiment described above with reference to FIG. 1C . The piezoelectric cantilever sensor array is otherwise similar to the array 300 described above with reference to FIGS. 3A and 3D . This second embodiment of the method fabricates the piezoelectric cantilever pressure sensor array using the layer structure 180 whose fabrication is described above with reference to FIGS. 4A–4F .
This second embodiment begins with the fabrication of the layer structure 180 as described above with reference to FIGS. 4A–4F . The layer structure 180 is then subject to a second etching process that uses a second mask. The second mask is similar to that used in the second etching process described above with reference to FIGS. 5A–5C except that it additionally defines releasing holes 503 in the beam portion 154 of each partially completed piezoelectric cantilever 1301 . The releasing holes are used later to facilitate etching part of the cavity under each beam portion.
As shown in FIG. 13B , the second etching process removes part of the top electrode layer 404 and the piezoelectric layer 406 to define the top electrode 104 and the piezoelectric element 106 of the partially completed piezoelectric cantilevers 1301 and to define the releasing holes 503 that extend through the top electrode layer and the piezoelectric layer. The second etching process additionally exposes part of the bottom electrode layer 408 for the next etching process.
After the second etching process, the layer structure 180 is subject to a third etching process that uses a third mask. As shown in FIGS. 14A and 14B , the third etching process removes the unmasked portion of the bottom electrode layer 408 to define the bottom electrodes 108 , the Y-lines 304 and Y-pads 308 and the electrical connection between the bottom electrodes and the drains of the respective access transistors 160 . The third etching process additionally removes the unmasked portion of the elastic layer 410 to define the elastic element 110 and to expose the prefabricated reference pad 310 and reference lines 312 , which are connected to the source contacts 165 of the access transistors 160 . The Y-lines 304 are connected to the gate contacts 161 of the access transistors 160 . One of the Y-lines 304 is shown as part of the bottom electrode layer 408 on the gate contact 161 in FIG. 14B . The third etching process forms a partially completed piezoelectric cantilever 1401 .
Next, the layer structure 180 is coated with a first protective layer 114 , as shown in FIGS. 15A and 15B , followed by a fourth etching process that uses a fourth mask. The protective layer 114 prevents hydrogen or water penetration. The protective layer 114 is composed of aluminum oxide or any other suitable material. The protective layer 114 is deposited by a process such as sputtering, CVD, plasma CVD, PVD or the like.
The fourth etching process forms in the protective layer 114 contact openings 703 and additionally forms a second set of releasing holes 705 around each partially completed piezoelectric cantilever 1501 . The fourth etching process also re-opens the releasing holes 503 that extend through the beam portion 154 of each partially completed piezoelectric cantilever 1501 . As shown in FIGS. 15A–15C , the contact openings 703 expose the top electrode layer 104 , while the releasing holes 503 and 705 expose the top surface of the substrate 120 . The interior wall 505 of the releasing holes 503 remains covered by the protective coating layer 114 after the fourth etching process.
Next, an X-line metal layer 116 is deposited on the first protective layer 114 , as shown in FIGS. 16A and 16B . The metal layer 116 is deposited by a process such as sputtering, CVD, plasma CVD, PVD or the like. The X-line metal layer 116 is typically composed of aluminum or an aluminum alloy. As shown in FIG. 16C , the X-line metal layer 116 fills the contact opening 703 in the first protective layer 114 and is thus electrically connected to the top electrode 104 of the partially completed piezoelectric cantilever 1601 .
Next, a fifth etching process that uses a fifth mask is performed to define the X-lines 302 and X-pads 306 in the X-line metal layer 116 . As shown in FIGS. 17A–17C , the fifth etching process removes the unmasked portion of the X-line metal layer 116 to define the X-lines and X-pads and exposes the first protective layer 114 . The fifth etching process additionally re-opens the releasing holes 503 and 705 , as shown in FIG. 17B .
After the fifth etching process, the layer structure 180 is subject to a sixth etching process that creates a cavity 130 under the beam portion 154 of each piezoelectric cantilever 150 , as shown in FIGS. 18A and 18B . The sixth etching process releases the beam portions 154 from the surface of the substrate 120 . No mask is needed for this etching process. Etchant flows through the releasing holes 503 and 705 shown in FIG. 18B to the portion of the top surface of the substrate 120 under the elastic element 110 and etches away this portion of the substrate to form the cavity 130 . Typically, the sixth etching process etches the cavity 130 to a depth that is larger than the maximum possible deflection of the piezoelectric cantilever 150 under the pressure from a fingertip, but is substantially less than the total thickness of the substrate 120 . Consequently, the sixth etching process is substantially shorter in duration than the etching process performed from the bottom surface of the substrate to form the cavity in the first embodiment of the method described above.
After the sixth etching process, a second protective layer 118 is deposited on the layer structure 180 by spin coating, as shown in FIGS. 19A and 19B . The second protective layer prevents direct contact between the fingertip and the X-lines 302 .
Finally, after the second protective layer 118 has been deposited, a seventh etching process that uses a seventh mask is performed. The seventh etching process removes portions of the first protective layer 114 and the second protective layer 118 to expose the X-pads 306 , the Y-pads 308 , and the reference pad 310 , as shown in FIG. 20 .
The method just described fabricates a piezoelectric cantilever pressure sensor array 300 with piezoelectric cantilever pressure sensors 100 in accordance with the second embodiment connected to the X-lines 302 , the Y-lines 304 , and the reference lines 312 , as shown in FIG. 20 . As is known in the art, the piezoelectric cantilevers 150 , the X-lines 302 and X-pads 306 , the Y-lines 304 and Y-pads 308 , the reference lines 312 and reference pad 310 , and the cavities 130 may differ in size, shape and layout from the example shown in the figures.
FIGS. 21A–21K , 22 A– 22 C, 23 A, 23 B, 24 A– 24 C, 25 A– 25 C, 26 A– 26 C, 27 A, 27 B, 28 A, 28 B and 29 illustrate a third embodiment of a method of making a piezoelectric cantilever sensor array that incorporates piezoelectric cantilever pressure sensors 100 in accordance with the third embodiment described above with reference to FIG. 1D . The piezoelectric cantilever sensor array made by the method is otherwise similar to the array 300 described above with reference to FIGS. 3A and 3D .
The third embodiment of the method starts with the fabrication of a layer structure 180 , as shown in FIGS. 21A–21K . The layer structure 180 is made by depositing the coating layer 122 on the top surface of the substrate 120 ( FIG. 21A ); mounting prefabricated access transistors 160 on the coating layer 122 and forming on the coating layer 122 the reference pad 310 and reference lines 312 connecting the reference pad 310 to the source contacts 165 of the access transistors 160 ( FIGS. 21B and 21C ); depositing a sacrificial layer 426 typically of phosphosilicate glass (PSG) on the coating layer 122 ( FIG. 21D ); etching the sacrificial layer 426 using a first mask to define a sacrificial mesa 126 adjacent each of the access transistors 160 and to expose the access transistors 160 , the reference pad 310 , the reference lines 312 , and the coating layer 122 ( FIGS. 21E and 21F ); depositing the elastic layer 410 ( FIG. 21G ); etching the elastic layer 410 using a second mask to create contact holes 171 and 173 extending through the elastic layer 410 to the gate contact 161 and drain contact 163 , respectively, of each access transistor 160 ( FIG. 21H ); depositing a bottom electrode layer 408 on the elastic layer 410 ( FIG. 21I ); depositing a piezoelectric layer 406 on the bottom electrode layer 408 ( FIG. 21J ); and depositing a top electrode layer 404 on the piezoelectric layer 406 ( FIG. 21K ). The coating layer 122 , sacrificial layer 124 , elastic layer 410 , electrode layers 408 and 404 , and the piezoelectric layer 406 are deposited by a process such as sputtering, chemical vapor deposition (CVD), plasma CVD, physical vapor deposition (PVD) or the like. The layer structure 180 fabricated as just described is shown in FIG. 21K . As will be described in the following paragraphs, the sacrificial mesas 126 will be etched away to form a cavity under the beam portion 154 of each piezoelectric cantilever 150 . Accordingly, the sacrificial mesas 126 typically have dimensions that are slightly larger than the dimensions of the beam portion 154 of the piezoelectric cantilever 150 , as shown in FIG. 5B . The thickness of the sacrificial mesas 126 is typically larger than the maximum possible deflection of the beam portion 154 of the piezoelectric cantilever 150 . In other words, the cavity created by etching away the sacrificial mesa 126 typically has a depth that accommodates the maximum possible deflection of the beam portion 154 of the piezoelectric cantilever 150 .
Next, as shown in FIGS. 22A–22C , the layer structure 180 is subject to a third etching process that uses a third mask. The third etching process partially define the piezoelectric cantilevers in the top electrode layer 404 and the piezoelectric layer 406 . FIG. 22A shows the layer structure 180 before the second etching process is performed. The locations on the surface of the substrate of the access transistors 160 , the reference lines 312 , the reference pad 310 , and the sacrificial mesas 126 are shown by broken lines. The third etching process defines partially completed piezoelectric cantilevers 2201 in the top electrode layer 404 and the piezoelectric layer 406 . As shown in FIGS. 22B and 22C , the third etching process removes part of the top electrode layer 404 and the piezoelectric layer 406 to define the top electrode 104 and the piezoelectric element 106 of the partially completed piezoelectric cantilevers in these layers, and additionally exposes part of the bottom electrode layer 408 for the next etching process.
After the third etching process, the layer structure 180 is subject to a fourth etching process that uses a fourth mask. As shown in FIGS. 23A and 23B , the fourth etching process removes the unmasked portion of the bottom electrode layer 408 to define the bottom electrodes 108 , the Y-lines 304 and Y-pads 308 , and the electrical connection between the bottom electrodes and the drains of the respective access transistors 160 . The fourth etching process additionally removes the unmasked portion of the elastic layer 410 to define the elastic element 110 and to expose the access transistors 160 , part of the sacrificial mesas 126 , the prefabricated reference pad 310 and reference lines 312 . The part of the elastic element 110 that later becomes part of the beam portion of the completed piezoelectric cantilever extends over the sacrificial mesa 126 . The reference lines are connected to the source contacts 165 of the access transistors 160 . The Y-lines 304 are electrically connected to the gate contact 161 of the access transistors 160 in each column. One of the Y-lines is shown as part of the bottom electrode layer 408 on the gate contact 161 in FIG. 23B . The fourth etching process forms partially completed piezoelectric cantilevers 2301 .
Next, the layer structure 180 is coated with a first protective layer 114 , as shown in FIGS. 24A and 24B , followed by a fifth etching process that uses a fifth mask. The protective layer 114 prevents hydrogen or water penetration. The protective layer 114 is composed of aluminum oxide or any other suitable material. The protective layer 114 is deposited by a process such as sputtering, CVD, plasma CVD, PVD or the like. The fifth etching process forms contact openings 703 in the protective layer 114 on each partially completed piezoelectric cantilever 2401 . The fifth etching process additionally forms release openings 707 around each partially completed piezoelectric cantilever 2401 , as shown in FIG. 24B . As shown in FIGS. 24B and 24C , the release openings 707 expose part of the sacrificial mesas 126 and the contact openings 703 expose the top electrodes 104 .
After the fifth etching process, an X-line metal layer 116 is deposited on the first protective layer 114 , as shown in FIGS. 25A and 25B . The X-line metal layer is deposited by a process such as sputtering, CVD, plasma CVD, PVD or the like. The X-line metal layer 116 is typically composed of aluminum or an aluminum alloy. As shown in FIG. 25C , the X-line metal layer 116 fills the contact opening 703 in the first protective layer 114 and is thus electrically connected to the top electrode 104 of the partially completed piezoelectric cantilever 2501 .
Next, a sixth etching process that uses a sixth mask is performed to define the X-lines 302 and X-pads 306 in the X-line metal layer 116 . The sixth etching process additionally reopens the release openings 707 . As shown in FIGS. 26A–26C , the sixth etching process removes the unmasked portion of the X-line metal layer 116 to define the X-lines 302 and X-pads 306 , and additionally exposes the first protective layer 114 and re-opens the release openings 707 to expose part of the sacrificial mesas 126 .
After the sixth etching process, a seventh etching process is performed to create the cavities 130 by removing the sacrificial mesas 126 , as shown in FIGS. 27A and 27B . No mask is used in the seventh etching process. The etchant flows through the release openings 707 and etches away the sacrificial mesa 126 from between the beam portion of each piezoelectric cantilever 150 and the top surface of the protective layer 122 . The seventh etching process releases the beam portion 154 from the substrate 120 .
Next, a second protective layer 118 is deposited on the layer structure 180 by spin coating, as shown in FIGS. 28A and 28B . The second protective layer prevents direct contact between the fingertip and the X-lines 302 .
Finally, an eighth and final etching process that uses a seventh mask is performed. The eighth etching process removes portions of the first protective layer 114 and the second protective layer 118 to expose the X-pads 306 , the Y-pads 308 , and the reference pad 310 , as shown in FIG. 29 .
The third embodiment of the method just described fabricates a piezoelectric cantilever pressure sensor array 300 with piezoelectric cantilever pressure sensors 100 in accordance with the third embodiment connected to the X-lines 302 , the Y-lines 304 , and the reference lines 312 , as shown in FIG. 29 . As is known in the art, the piezoelectric cantilevers 150 , the X-lines 302 and X-pads 306 , the Y-lines 304 and Y-pads 308 , the reference lines 312 and reference pad 310 , and the cavities 130 may differ in size, shape and layout from the example shown in the figures.
FIG. 30 shows a method 3000 for manufacturing the piezoelectric cantilever pressure sensor array 300 . In the method 3000 , there is formed ( 3001 ) a layer structure having, in order, a substrate, an elastic layer, a bottom electrode layer, a piezoelectric layer, and a top electrode layer, piezoelectric cantilevers are defined ( 3003 ) in the layer structure, Y-lines and Y-pads are defined ( 3005 ) in the bottom electrode layer, X-lines and X-pads are formed ( 3007 ), and a cavity is created ( 3009 ) under each piezoelectric cantilever.
In an embodiment, the layer structure additionally has a prefabricated access transistor adjacent each piezoelectric cantilever. Defining the piezoelectric cantilever forming an electrical connection between the bottom electrode of the piezoelectric cantilever and the drain of the access transistor.
In an embodiment, the cavity is created by etching the substrate from the bottom surface thereof. In another embodiment, the cavity is created by etching the substrate from the top surface thereof. In a third embodiment, the layer structure additionally has a sacrificial mesa and the piezoelectric cantilever partially overlaps the sacrificial mesa. In this embodiment, the cavity is created by removing the sacrificial mesa from under the piezoelectric cantilever.
In yet another embodiment, the process of forming X-lines and X-pads includes forming a first protective coating, creating contact openings in the first protective coating, depositing an X-line metal layer on the first protective coating, and defining the X-lines and X-pads in the X-line metal layer. In another embodiment, the layer structure is covered by a flexible protective layer.
Although preferred embodiments and their advantages have been described in detail, various changes, substitutions and alterations can be made herein without departing from the scope of the invention defined by the appended claims and their equivalents. | A piezoelectric cantilever pressure sensor has a substrate and a piezoelectric cantilever having a base portion attached to the substrate and a beam portion suspended over a cavity. The piezoelectric cantilever contains a piezoelectric layer sandwiched between two electrodes and generates a measurable voltage when deformed under pressure. The piezoelectric cantilever pressure sensor can be manufactured at low cost and used in various applications including fingerprint identification devices. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of manufacturing a multi-core optical fiber, as well as to a multi-core preform and a multi-core optical fiber obtained by performing the method.
2. Related Art
The term "multi-core optical fiber" refers to an optical fiber comprising a plurality of mutually parallel optical cores embedded in common optical cladding, the majority of the light rays conveyed by such a multi-core optical fiber being guided along its cores. Conventionally, each core of the multi-core fiber has a diameter of a few microns (in general, in the range 7 μm to 10 μm), and is disposed, for example, on a circle of radius approximately equal to 40 μm inside the optical cladding, which cladding has a standard outside diameter of 125 μm.
In order to provide the desired guiding properties, the optical cores are, in general, made of material based on silica that is doped so as to make its refractive index higher than that of pure silica, while the cladding is made of a material based on silica that is substantially pure, or that is slightly doped so as to make its refractive index lower than that of the core.
One of the main requirements when making multi-core optical fibers is that the cores must be positioned accurately relative to one another. Such accurate positioning makes it possible to effect reliable connections, and to avoid interference between the signals conveyed by the various cores (cross-talk). In particular, the various cores must be spaced apart by a minimum amount.
Spacing of about 40 μm is considered to be the lower limit below which cross-talk is no longer acceptable.
One of the methods currently being considered for manufacturing a multi-core optical fiber is described in Document EP-0 101 742. It consists in inserting into a glass tube a plurality of single-core optical fiber preforms, referred to as "single-core preforms", each of which comprises a core bar surrounded by a layer of cladding, so as to form a multi-core preform.
The multi-core preform is then mounted on a fiber-drawing installation, and it is drawn in the same way as a single-core fiber preform is drawn, at a temperature of about 2,000° C., while the air present in the interstices inside the tube, between said tube and the single-core preforms is evacuated via the top of the multi-core preform. In this way, the desired multi-core fiber is obtained.
That method is not satisfactory because the positioning of the single-core preforms inside the tube is not accurate, so that, in the resulting multi-core fiber, the cores are not positioned accurately relative to one another. Thus, for a multi-core fiber having 7 cores (one core in the center, and six peripheral cores), the core positioning error is approximately ±2kΔR, where ΔR is the difference between the real diameter and the nominal diameter of the single-core preforms, and k is the drawing ratio. Conventionally, where ΔR is equal to 0.33 mm and k is equal to 5.10 -3 , the core positioning error is approximately ±3 μm.
Another problem related to that method results from the use of a tube surrounding the set of single-core fibers. The tube increases the outside diameter of the multi-core preform. Since the multi-core fiber obtained by drawing down the multi-core preform must have a standard outside diameter of 125 μm, the tube results in spacing between the cores in the multi-core fiber that is less than the minimum required spacing, and this increases cross-talk problems.
SUMMARY OF THE INVENTION
An object of the invention is to remedy those problems by providing a method of manufacturing a multi-core optical fiber, which method makes it possible to have the cores positioned accurately relative to one another and to obtain the minimum required spacing therebetween.
To this end, the present invention provides a method of manufacturing a multi-core optical fiber, the method including the following steps:
assembling together a plurality of substantially identical single-core optical fiber preforms, referred to as "single-core preforms", each of which comprises a core bar surrounded by a layer of optical cladding, so as to form a "multi-core preform"; and
drawing down said multi-core preform so as to obtain said multi-core optical fiber;
said method being characterized in that the assembly step consists in securing said single-core preforms to one another by fusing them over their entire lengths or over portions thereof along their tangential lines of contact, without inserting said multi-core preform into a holding tube.
By securing said single-core preforms to one another in this way, it is possible to control the positioning of the single-core preforms relative to one another, and in particular, to control the positions of the axes of each of the single-core preforms relative to the axis of symmetry of the multi-core preform, so that the core positioning accuracy of the multi-core fiber is considerably better than in the prior art. The positioning error with the method of the invention is approximately +kΔR, i.e. in the numerical example given with respect to the prior art, ±1.5 μm. Thus, by means of the invention, it is possible to halve the positioning error of the cores in the multi-core fiber.
In addition, securing the single-core preforms to one another makes it unnecessary to use a holding tube, and therefore makes it possible for the required minimum spacing between the cores to be obtained in the drawn fiber, thereby avoiding cross-talk problems.
Advantageously, prior to being secured to one another, the single-core preforms are polished so as to adjust the centering of their cores. This further improves core positioning accuracy.
In an improved implementation, said multi-core preform is evacuated prior to being drawn, the evacuated preform being sealed off so as to maintain the vacuum during drawing.
Very advantageously, the multi-core preform may include a plurality of "outer" rods made of a vitreous material, each of said outer rods being fused between two adjacent single-core preforms situated at the periphery of the multi-core preform, so as to form bridges between the peripheral single-core preforms.
The diameter of the outer rods may be such that the diameter of the circumscribed circle of the multi-core preform does not exceed that of the circumscribed circle of the assembled-together single-core preforms.
Also advantageously, "inner" rods made of a vitreous material may be inserted into the interstices left empty between the single-core preforms.
A piece of glass serving as a drawing leader may extend one end of the multi-core preform. The leader may be constituted by a piece of glass secured to the end of the multi-core preform, or by an extension to one of the single-core preforms belonging to the multi-core preform.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
Other characteristics advantages of the present invention appear from the following description of an implementation of the method of the invention, given by way of non-limiting example and with reference to the accompanying drawing, in which:
FIG. 1 is a side view of an assembly comprising single-core preforms secured together according to the invention;
FIG. 2 is a section on line II--II of FIG. 1.
FIG. 3 is a side view of a multi-core preform of the invention ready to be drawn down; and
FIG. 4 is a cross-section view of a variant multi-core preform of the invention; and
FIG. 5 illustrates the drawing process.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In all of the figures, common elements are given the same references.
FIGS. 1 and 2 show an assembly 1 comprising seven assembled-together single-core preforms, in which assembly six "outer" preforms 2' surround a "central" preform 2". Each single-core preform 2', 2", e.g. obtained by performing modified chemical vapor deposition (MCVD), may, for example, be composed of a core bar 3, e.g. made of germanium-doped silica and having a diameter of 1.4 mm, surrounded by a layer of optical cladding 4, e.g. made of silica doped with fluorine so as to make its refractive index lower than that of the core bar 3. The diameter of each of the single-core preforms 2', 2" is 8 mm, and the length of each of them is at least 200 mm. The central preform 2" may be longer than the outer preforms 2' (e.g. it may have a length of 400 mm) so as to facilitate assembling them together, and so as to serve as a drawing leader (its end serving as a drawing leader is referenced 6 in FIG. 3).
The cores 3 of the single-core preforms 2', 2" constitute the cores of the multi-core fiber to be manufactured.
In order to facilitate subsequent drawing, one of the ends of each of the outer preforms 2' may be bevelled so that one end 1A of the assembly 1 is frustoconical in shape (see FIG. 1).
According to the invention, the six outer preforms 2' are secured to one another and to the central preform 2" by being fused, i.e. by being locally fused along portions of their tangential lines of contact T which are diagrammatically represented by respective dots in FIG. 2. For example, the fusion may be effected by means of a blowtorch or of a CO 2 laser (not shown) that moves along the tangential lines of contact T. In order to hold the preforms 2', 2" while they are being fused, it is possible, for example, to use a clamping chuck having three jaws (not shown), in which chuck each jaw has a V-shaped gripping portion.
The single-core preforms do not need to be secured to one another over the entire length of the assembly 1. For example, they may be secured together at the ends 1A and 1B of the assembly only.
By securing the preforms 2', 2" to one another, it is possible to ensure that they are accurately positioned relative to one another, by setting and checking the relative positions of the preforms 2', 2" prior to fusing. Such accurate positioning is simple to perform.
The resulting assembly 1 is referred to as a "multi-core preform", and it is referenced 10.
In order to ensure that the interstices left empty between the preforms 2' and 2" close properly during the subsequent drawing operation, so as to obtain a multi-core fiber that is compact and uniform, the interstices between the preforms 2' and 2" may be evacuated prior to drawing. To do this, a tube 7 is secured in gastight manner to one of the ends 10B of the preform 10, which tube is blind, i.e. it is closed off at its top end which is opposite from its end connected to the preform 10, and open to one side via a side tube 8 for connecting it to pumping means (not shown).
By connecting the pumping means to the side tube 8, a primary vacuum, close to 1 Pa is formed inside the preform 10, and the tube 8 is then sealed off (e.g. by means of a blow-torch) so as to maintain the vacuum in the preform 10.
Alternatively, it is possible to evacuate the preform 10 while it is being drawn. To do this, the pumping means are connected to the tube 8 while the preform is being drawn.
The assembly shown in FIG. 3 and comprising the multi-core preform 10, the leader 6, and the blind tube 7 can then be directly used in a fiber-drawing installation (not shown). It may be held therein by means of chucks (not shown) at a bottom section 6A belonging to the leader 6, and at a top section 7B belonging to the blind tube 7.
The preform is drawn down conventionally, with the drawing temperature being, for example, in the vicinity of 2,000° C., by drawing the bottom end 10A of the multi-core preform 10 until a multi-core fiber having the desired dimensions is obtained. See FIG. 5 which illustrates the drawing process.
In a very advantageous improved implementation of the invention, in order to provide good cohesion and good airtightness for the multi-core preform 10, an "outer" rod 13 (shown in dashed lines in FIG. 2) made of a vitreous material and of length in the vicinity of that of the single-core preforms 2', 2" may be disposed at the bottom of each curved V-shape 12 (see FIG. 2) defined between two adjacent outer preforms 2' of the multi-core preform 10, and the rods 13 may then be fused to the preforms 2' by being heated, so as to form bridges 14 between the peripheral preforms 2' (see FIG. 4). In this way, the outer rods 13 perform the holding function that is performed by the holding tube in the prior art, without giving rise to the problem related to that tube, namely a reduction in the spacing between the cores of the multi-core fiber, because the rods 13 can be chosen so that the diameter of the circumscribed circle of the multi-core preform 10 remains the same as that of the circumscribed circle of the set of assembled-together preforms 2'.
In a possible improved implementation, in order to reduce the volume left empty inside the preform 10 between the preforms 2', 2", the interstices left empty therebetween may be filled with inner filler rods 11 made of a vitreous material, as shown in FIG. 4.
The method of the invention makes it possible to position the single-core preforms relative to one another better than the prior art method consisting merely in disposing the single-core preforms in a tube.
Furthermore, to facilitate locating the cores of the resulting multi-core optical fiber, marking may be effected by inserting a filler rod that is, for example, colored.
Naturally, the present invention is not limited to the above-described implementation.
In particular, the number of single-core preforms making up the multi-core preform, and the dimensions of said single-core preforms are given merely by way of example, and said number and dimensions may be adapted to the characteristics of the desired multi-core fiber. In particular, a multi-core fiber having 3 or 4 cores may be manufactured according to the invention by starting with a multi-core preform comprising 3 or 4 single-core preforms. It is also possible, according to the invention, to manufacture a multi-core preform from n peripheral preforms disposed around a central bar that is made of a vitreous material and that is not necessarily a single-core preform. In which case the diameter φ of the central bar made of a vitreous material is given by the following formula:
φ=φ.sub.p (1/sin(π/n)-1)
where φ p is the outside diameter of the single-core preforms.
In order to hold the single-core preforms together while they are being fused, the single-core preforms may be pre-secured to one another at their ends by means of additional silica, instead of using clamping jaws.
If the tolerances on the outside diameter of the single-core preforms are not too tight, i.e. if the error on their diameter is greater than a tenth of a millimeter, it is possible to position the single-core preforms accurately relative to one another by means of a hole gauge, with the holes corresponding to the cores of the single-core preforms, the gauge being placed at the end of the assembly so that the cores of the single-core preforms are caused to coincide with the holes in the gauge, and inner rods then being inserted to take up the resulting clearance between the single-core preforms. The remainder of the method takes place as described above. When the tolerances on the outside diameter of the single-core preforms are tight, assembling them together compactly suffices to obtain the required positioning.
Furthermore, the inner rods may be secured by being fused to the single-core preforms. In which case, assembly must be effected in stages, i.e. the inner rods must be fused firstly with the inner preforms, and then secondly with the peripheral preforms.
That end of the central single-core preform which serves as the drawing leader may be replaced with a drawing leader in the form of a separate tube or bar fused to the end of the central single-core preform.
Finally, any means may be replaced by equivalent means without going beyond the ambit of the invention. | A method of manufacturing a multi-core optical fiber, the method including assembling together a plurality of substantially identical polished single-core optical fiber preforms (2', 2"), referred to as "single-core preforms", each of which includes a core bar (3) surrounded by a layer of optical cladding (4), so as to form a "multi-core preform" (10), and drawing down the multi-core preform (10) so as to obtain the multi-core optical fiber. The assembly step includes securing the single-core preforms (2', 2") to one another by fusing them over their entire lengths or over portions thereof along their tangential lines of contact (T), without inserting the multi-core preform (10) into a holding tube. A vacuum is maintained in the preform during the drawing step, the vacuum being formed before or during the drawing step. | 6 |
This is a continutation of application Ser. No. 08/439,874 filed May 12, 1995, now U.S. Pat. No. 5,644,057.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to novel substituted deazapurine derivatives which selectively bind to CRF receptors. More specifically, it relates to pyrrolo 3,2-d!pyrirnidin-4-amines, pyrrolo 3,2-b!pyridin-4-amines, and pyrrolo 3,2-b!pyridin-4-amines, and their use as antagonists of Corticotropin-Releasing Factor in the treatment of various disease states.
2. Description of the Related Art
Corticotropin-releasing factor (CRF) antagonists are mentioned in U.S. Pat. Nos. 4,605,642 and 5,063,245 referring to peptides and pyrazoline derivatives, respectively. The importance of CRF antagonists is described in the literature, for example, as discussed in U.S. Pat. No. 5,063,245, which is incorporated herein by reference in its entirety. CRF antagonists are considered effective in the treatment of a wide range of diseases including stress-related illnesses, such as stress-induced depression, anxiety, and headache. Other diseases considered treatable with CRF antagonists are discussed in U.S. Pat. No. 5,063,245 and Pharm. Rev., 43: 425-473 (1991).
International application WO 9413676 A1 discloses pyrrolo 2,3-d!pyrirnidines as having Corticotropin-Releasing Factor antagonist acitivity. J. Het. Chem. 9, 1077 (1972) describes the synthesis of 9-Phenyl-pyrrolo 3,2-d!pyrimidines.
SUMMARY OF THE INVENTION
This invention provides novel compounds of Formula I which interact with CRF receptors.
The invention provides pharmaceutical compositions comprising compounds of Formula I. It further relates to the use of such compounds in treating stress related disorders such as post trumatic stress disorder (PTSD) as well as depression, headache and anxiety. Accordingly, a broad embodiment of the invention is directed to a compound of Formula I: ##STR2## wherein Ar is phenyl, where the phenyl group is mono-, di-, or trisubstituted with halogen, hydroxy, lower alkyl, or lower alkoxy, with the proviso that at least one of the ortho positions of the phenyl group is substituted; or
Ar is 2-, 3-, or 4-pyridyl, 2- or 3- thienyl, 4- or 5-pyrimidyl, each of which is optionally mono-, di-, or trisubstituted with halogen, hydroxy, lower alkyl, or lower alkoxy, with the proviso that at least one of the ortho positions of the Ar substituent is substituted;
X is CH or nitrogen;
R 1 is lower alkyl;
R 2 is hydrogen, halogen, lower alkyl, lower alkoxy, or thioalkoxy; or
R 1 and R 2 taken together represent --(CH 2 ) n --A--(CH 2 ) m --,
where n is 2, 3 or 4, A is methylene, oxygen, sulfur or NR 6 , where R 6 is lower alkyl, and
m is 0, 1 or 2;
R 3 and R 4 are the same or different and represent hydrogen or lower alkyl; phenyl, 2-, 3-, or 4-pyridyl, 2-, or 3-thienyl, or 2-, 4-, or 5-pyrimidyl, each of which is optionally mono- or disubstituted with halogen, hydroxy, lower alkyld, or lower alkoxy; phenyl lower alkyl, 2-, 3-, or 4-pyridyl lower alkyl, 2- or 3-thienyl lower alkyl, or 2-, 4-, or 5-pyrimidyl lower alkyl; cycloalkyl having 3-8 carbon atoms or cycloalkyl lower alkyl where the cycloalkyl portion has 3-8 carbon atoms; 2-hydroxyethyl or 3-hydroxypropyl optionally mono or disubstituted with lower alkyl with the proviso that not both R 3 and R 4 are hydrogen; or
R 3 and R 4 taken together represent --(CH 2 ) n --A--(CH 2 ) m --
where n is 2, or 3,
A is methylene, 1,2 phenylene, oxygen, sulfur or NR 6 , wherein R 6 is lower alkyl, phenyl, 2-, 3-, or 4-pyridyl, 2-or 3-thienyl or 2-, 4-, or 5-pyrimidyl, phenyl lower alkyl, 2-, 3-, or 4-pyridyl lower alkyl, 2-or 3-thienyl lower alkyl, or 2-, 4-, or 5-pyrimidyl lower alkyl; and
m is 1, 2 or 3; and
R 5 is hydrogen, halogen, lower alkyl, lower alkoxy, or thioalkoxy.
These compounds, i.e., substituted deazapurine derivatives, are highly selective partial agonists or antagonists at CRF receptors and are useful in the diagnosis and treatment of stress related disorders such as post trumatic stress disorder (PTSD) as well as depression and anxiety.
Thus, the invention provides compounds, including pharmaceutically acceptable salts of the compounds of formula I, and pharmaceutical compositions for use in treating disease states associated with Corticotropin-releasing factor. The invention further provides methods including animal models relevant to the evaluation of the interaction of the compounds of the invention with CRF receptors. This interaction results in the pharmacological activities of these compounds.
DETAILED DESCRIPTION OF THE INVENTION
In this document, all temperatures will be stated in degrees Celsius. All amounts, ratios, concentrations, proportions and the like will be stated in weight units, unless otherwise stated, except for ratios of solvents, which are in volume units.
In addition to compounds of general formula I described above, the invention encompasses compounds of general formula IA: ##STR3## wherein Ar is phenyl, 2-, 3-, or 4-pyridyl, 2- or 3-thienyl, 4- or 5-pyrimidyl, each of which is mono-, di-, or trisubstituted with halogen, hydroxy, lower alkyl, or lower alkoxy, with the proviso that at least one of the ortho positions of the Ar substituent is substituted;
X is CH or nitrogen;
R 1 is lower alkyl;
R 2 is hydrogen, halogen, lower alkyl, lower alkoxy, or thioalkoxy; or
R 1 and R 2 taken together represent --(CH 2 ) n --A--(CH 2 ) m --,
where n is 2, 3 or 4, A is methylene, oxygen, sulfur or NR 6 , where R 6 is lower alkyl, and
m is 0, 1 or 2;
R 3 and R 4 are the same or different and represent
hydrogen or lower alkyl;
phenyl, 2-, 3-, or 4-pyridyl, 2-, or 3-thienyl, or 2-, 4-, or 5-pyrimidyl, each of which is mono- or disubstituted with halogen, hydroxy, lower alkyl, or lower alkoxy;
phenyl lower alkyl, 2-, 3-, or 4-pyridyl lower alkyl, 2- or 3-thienyl lower alkyl, or 2-, 4-, or 5-pyrimidyl lower alkyl;
cycloalkyl having 3-8 carbon atoms or cycloalkyl lower alkyl where the cycloalkyl portion has 3-8 carbon atoms;
2-hydroxyethyl or 3-hydroxypropyl optionally mono or disubstituted with lower alkyl with the proviso that not both R 3 and R 4 are hydrogen; or
R 3 and R 4 taken together represent --(CH 2 ) n --A--(CH 2 ) m --
where n is 2, or 3,
A is methylene, 1,2 phenylene, oxygen, sulfur or NR 6 , wherein R 6 is lower alkyl, phenyl, 2-, 3-, or 4-pyridyl, 2- or 3-thienyl or 2-, 4-, or 5-pyrimidyl, phenyl lower alkyl, 2-, 3-, or 4-pyridyl lower alkyl, 2- or 3-thienyl lower alkyl, or 2-, 4-, or 5-pyrimidyl lower alkyl, and
m is 1, 2 or 3; and
R 5 is hydrogen, halogen, lower alkyl, lower alkoxy, or thioalkoxy.
In the compounds of the invention, preferred NR 3 R 4 groups include the following: ##STR4##
Preferred compounds of formula I are those where R 1 is methyl, ethyl or propyl or isopropyl; R 2 is lower alkyl, halogen, or thio lower alkyl; R 5 is lower alkyl or halogen; and R 7 , R 8 , and R 9 represent methyl, ethyl, propyl or isopropyl.
The invention provides compounds of formula II ##STR5## wherein R 4 represents hydrogen or lower alkyl;
R 1 , R 7 , R 8 , and R 9 represent lower alkyl; and
R 3 represents lower alkyl, or cycloalkyl lower alkyl.
Preferred compounds of formula II are those where R 1 is methyl, ethyl or propyl or isopropyl; and R 7 , R 8 , and R 9 represent methyl, ethyl, propyl or isopropyl. Particularly preferred compounds of formula II are those where R 1 is methyl, and R 7 , R 8 , and R 9 represent methyl.
The invention provides compounds of formula III ##STR6## wherein R 4 represents hydrogen or lower alkyl;
R 1 , R 7 , R 8 , and R 9 represent lower alkyl; and
R 3 represents lower alkyl, or cycloalkyl lower alkyl; and
R 5 is lower alkyl, halogen, or thio lower alkyl.
Preferred compounds of formula III are those where R 1 is methyl, ethyl or propyl or isopropyl; R 5 is halogen or thio lower alkyl; and R 7 , R 8 , and R 9 represent methyl, ethyl, propyl or isopropyl. Particularly preferred compounds of formula III are those where R 1 is methyl; R 5 is halogen, thiomethyl; and R 7 , R 8 , and R 9 represent methyl, ethyl, propyl or isopropyl.
The invention provides compounds of formula IV ##STR7## wherein R 4 represents hydrogen or lower alkyl;
R 1 , R 7 , R 8 , and R 9 represent lower alkyl; and
R 3 represents lower alkyl, or cycloalkyl lower alkyl; and
R 5 is lower alkyl, halogen, or thio lower alkyl.
Preferred compounds of formula IV are those where R 1 is methyl, ethyl or propyl or isopropyl; R 5 is halogen or thio lower alkyl; and R 7 , R 8 , and R 9 represent methyl, ethyl, propyl or isopropyl. Particularly preferred compounds of formula IV are those where R 1 is methyl; R 5 is halogen, thiomethyl; and R 7 , R 8 , and R 9 represent methyl, ethyl, propyl or isopropyl.
The invention provides compounds of formula V ##STR8## wherein R 4 represents hydrogen or lower alkyl;
R 1 , R 7 , R 8 , and R 9 represent lower alkyl; and
R 3 represents lower alkyl, or cycloalkyl lower alkyl.
Preferred compounds of formula V are those where R 1 is methyl, ethyl or propyl or isopropyl; and R 7 , R 8 , and R 9 represent methyl, ethyl, propyl or isopropyl. Particularly preferred compounds of formula V are those where R 1 is methyl, and R 7 , R 8 , and R 9 represent methyl.
The invention provides compounds of formula VI ##STR9## wherein R 4 represents hydrogen or lower alkyl;
R 1 , R 7 , R 8 , and R 9 represent lower alkyl; and
R 3 represents lower alkyl, or cycloalkyl lower alkyl; and
R 5 is lower alkyl, halogen, or thio lower alkyl.
Preferred compounds of formula VI are those where R 1 is methyl, ethyl or propyl or isopropyl; R 5 is halogen or thio lower alkyl; and R 7 , R 8 , and R 9 represent methyl, ethyl, propyl or isopropyl. Particularly preferred compounds of formula VI are those where R 1 is methyl; R 5 is halogen, thiomethyl; and R 7 , R 8 , and R 9 represent methyl, ethyl, propyl or isopropyl.
The invention provides compounds of formula VII: ##STR10## wherein R 4 represents hydrogen or lower alkyl;
R 1 , R 7 , R 8 , and R 9 represent lower alkyl; and
R 3 represents lower alkyl, or cycloalkyl lower alkyl; and
R 5 is lower alkyl, halogen, or thio lower alkyl.
Preferred compounds of formula VII are those where R 1 is methyl, ethyl or propyl or isopropyl; R 5 is halogen or thio lower alkyl; and R 7 , R 8 , and R 9 represent methyl, ethyl, propyl or isopropyl. Particularly preferred compounds of formula VII are those where R 1 is methyl; R 5 is halogen, thiomethyl; and R 7 , R 8 , and R 9 represent methyl, ethyl, propyl or isopropyl.
In each of formulas II to VII, NR 3 R 4 optionally represents --(CH 2 ) n --A--(CH 2 ) m -- where m, n, and A are as defined above for formula I.
The invention also provides compounds of formula VIII: ##STR11## wherein Ar is phenyl, 2-, 3-, or 4-pyridyl, 2- or 3-thienyl, 4- or 5-pyrimidyl, each of which is mono-, di-, or trisubstituted with halogen, hydroxy, lower alkyl, or lower alkoxy, with the proviso that at least one of the ortho positions of the Ar substituent is substituted;
X is CH or nitrogen;
R 1 is lower alkyl;
R 2 is hydrogen, halogen, lower alkyl, lower alkoxy, or thioalkoxy; or
R 3 and R 4 are the same or different and represent hydrogen or lower alkyl; phenyl, 2-, 3-, or 4-pyridyl, 2-, or 3-thienyl, or 2-, 4-, or 5-pyrimidyl, each of which is mono- or disubstituted with halogen, hydroxy, lower alkyl, or lower alkoxy; phenyl lower alkyl, 2-, 3-, or 4-pyridyl lower alkyl, 2- or 3-thienyl lower alkyl, or 2-, 4-, or 5-pyrirnidyl lower alkyl; cycloalkyl having 3-8 carbon atoms or cycloalkyl lower alkyl where the cycloalkyl portion has 3-8 carbon atoms; 2-hydroxyethyl or 3-hydroxypropyl optionally mono or disubstituted with lower alkyl with the proviso that not both R 3 and R 4 are hydrogen;
R 3 and R 4 taken together represent --(CH 2 ) n --A--(CH 2 ) m --
where n is 2, or 3,
A is methylene, 1,2 phenylene, oxygen, sulfur or NR 6 , wherein R 6 is lower alkyl; and
m is 1, 2 or 3; and
R 5 is hydrogen, halogen, lower alkyl, lower alkoxy, or thioalkoxy.
In addition, the invention provides compounds of formula IX: ##STR12## wherein Ar is phenyl mono-, di-, or trisubstituted with halogen, hydroxy, lower alkyl, or lower alkoxy, with the proviso that at least one of the ortho positions of the Ar substituent is substituted;
X is nitrogen;
R 1 is lower alkyl;
R 2 is hydrogen, halogen, lower alkyl, lower alkoxy, or thioalkoxy; or
R 3 and R 4 are the same or different and represent
hydrogen or lower alkyl;
cycloalkyl having 3-8 carbon atoms or cycloalkyl lower alkyl where the cycloalkyl portion has 3-8 carbon atoms;
2-hydroxyethyl or 3-hydroxypropyl optionally mono or disubstituted with lower alkyl with the proviso that not both R 3 and R 4 are hydrogen; or
R 3 and R 4 taken together represent --(CH 2 ) n --A--(CH 2 ) m --
where n is 2, or 3,
A is methylene, 1,2 phenylene, oxygen, sulfur or NR 6 , wherein R 6 is lower alkyl; and
m is 1, 2 or 3;
R 5 is hydrogen, halogen, lower alkyl, lower alkoxy, or thioalkoxy.
Further, the invention provides compounds of formula X: ##STR13## wherein Ar is phenyl mono-, di-, or trisubstituted with halogen, hydroxy, lower alkyl, or lower alkoxy, with the proviso that at least one of the ortho positions of the Ar substituent is substituted;
R 1 is lower alkyl;
R 2 is hydrogen, halogen, lower alkyl, lower alkoxy, or thioalkoxy; or
R 3 and R 4 are the same or different and represent
hydrogen or lower alkyl;
cycloalkyl having 3-8 carbon atoms or cycloalkyl lower alkyl where the cycloalkyl portion has 3-8 carbon atoms;
2-hydroxyethyl or 3-hydroxypropyl optionally mono or disubstituted with lower alkyl with the proviso that not both R 3 and R 4 are hydrogen; or
R 3 and R 4 taken together represent --(CH 2 ) n --A--(CH 2 ) m --
where n is 2, or 3,
A is methylene, 1,2 phenylene, oxygen, sulfur or NR 6 , wherein R 6 is lower alkyl; and
m is 1, 2 or 3;
R 5 is hydrogen, halogen, lower alkyl, lower alkoxy, or thioalkoxy.
Representative compounds of the present invention, which are encompassed by Formula I, include, but are not limited to the compounds in FIG. I and their pharmaceutically acceptable salts. Non-toxic pharmaceutically acceptable salts include salts of acids such as hydrochloric, phosphoric, hydrobromic, sulfuric, sulfinic, formic, toluene sulfonic, hydroiodic, acetic and the like. Those skilled in the art will recognize a wide variety of non-toxic pharmaceutically acceptable addition salts.
The present invention also encompasses the acylated prodrugs of the compounds of Formula I. Those skilled in the art will recognize various synthetic methodologies which may be employed to prepare non-toxic pharmaceutically acceptable addition salts and acylated prodrugs of the compounds encompassed by Formula I.
By aryl or "Ar" is meant an aromatic carbocyclic group having a single ring (e.g., phenyl), multiple rings (e.g., biphenyl), or multiple condensed rings in which at least one is aromatic, (e.g., 1,2,3,4-tetrahydronaphthyl, naphthyl, anthryl, or phenanthryl), which is optionally mono-, di-, or trisubstituted with, e.g., halogen, lower alkyl, lower alkoxy, lower alkylthio, trifluoromethyl, lower acyloxy, aryl, heteroaryl, and hydroxy.
By aryl or "Ar" is also meant heteroaryl groups where heteroaryl is defined as 5, 6, or 7 membered aromatic ring systems having at least one hetero atom selected from the group consisting of nitrogen, oxygen and sulfur. Examples of heteroaryl groups are pyridyl, pyrimidinyl, pyrrolyl, pyrazolyl, pyrazinyl, pyridazinyl, oxazolyl, furanyl, quinolinyl, isoquinolinyl, thiazolyl, and thienyl, which can optionally be substituted with, e.g., halogen, lower alkyl, lower alkoxy, lower alkylthio, trifluoromethyl, lower acyloxy, aryl, heteroaryl, and hydroxy.
By alkyl and lower alkyl is meant straight and branched chain alkyl groups having from 1-6 carbon atoms. Specific examples of alkyl groups are methyl, ethyl, propyl, isopropyl, n-butyl, isobutyl, tert-butyl, sec-butyl, neopentyl and n-pentyl.
By lower alkoxy and alkoxy is meant straight and branched chain alkoxy groups having from 1-6 carbon atoms.
By thioalkoxy is meant a straight or branched chain alkoxy group having from 1-6 carbon atoms and a terminal sulfhydryl, i.e., --SH, moiety.
By thio lower alkyl as used herein is meant a lower alkyl group having a terminal sulfhydryl, i.e., --SH, group.
By halogen is meant fluorine, chlorine, bromine and iodine.
Representative examples of pyrrolo 3,2-d!pyrimidines according to the invention are shown in Table 1 below.
TABLE 1.sup.1______________________________________ ##STR14## 1 ##STR15## 2 ##STR16## 3 ##STR17## 4 ##STR18## 5 ##STR19## 6 ##STR20## 7 ##STR21## 8 ##STR22## 9 ##STR23## 10 ##STR24## 11 ##STR25## 12 ##STR26## 13 ##STR27## 14 ##STR28## 15 ##STR29## 16 ##STR30## 17 ##STR31## 18 ##STR32## 19 ##STR33## 20 ##STR34## 21______________________________________ .sup.1 The number below each compound is its compound number.
The pharmaceutical utility of compounds of this invention is indicated by the following assay for CRF receptor activity.
Assay for CRF Receptor Binding Activity
CRF receptor binding was performed using a modified version of the assay described by Grigoriadis and De Souza (Biochemical, Pharmnacological, and Autoradiographic Methods to Study Corticotropin-Releasing Factor Receptors. Methods in Netirosciences, Vol. 5, 1991). Membrane pellets containing CRF receptors were resuspended in 50 mM Tris buffer pH 7.7 containing 10 mM MgCl 2 and 2mM EGTA and centrifuged for 10 minutes at 48000 g. Membranes were washed again and brought to a final concentration of 1500 μg/ml in binding buffer (Tris buffer above with 0.1% BSA, 0.15 mM bacitracin and 0.01 mg/ml aprotinin.). For the binding assay, 100 μl of the membrane preparation was added to 96 well microtube plates containing 100 μl of 125 I-CRF (SA 2200 Ci/mmol, final concentration of 100 pM) and 50 μl of drug. Binding was carried out at room temperature for 2 hours. Plates were then harvested on a Brandel 96 well cell harvester and filters were counted for gamma emissions on a Wallac 1205 Betaplate liquid scintillation counter. Non specific binding was defined by 1 μM cold CRF. IC 50 values were calculated with the non-linear curve fitting program RS/1 (BBN Software Products Corp., Cambridge, Mass.). The binding characteristics for examples from this patent are shown in Table 2.
TABLE 2______________________________________Compound Number.sup.2 IC.sub.50 (uM)______________________________________1 0.1105 0.500______________________________________ .sup.2 Compound numbers relate to compounds shown above in Table 1.
Compounds 1 and 5 are particularly preferred embodiments of the present invention because of their potency in binding to CRF receptors.
The compounds of general formula I may be administered orally, topically, parenterally, by inhalation or spray or rectally in dosage unit formulations containing conventional non-toxic pharmaceutically acceptable carriers, adjuvants and vehicles. The term parenteral as used herein includes subcutaneous injections, intravenous, intramuscular, intrasternal injection or infusion techniques. In addition, there is provided a pharmaceutical formulation comprising a compound of general formula I and a pharmaceutically acceptable carrier. One or more compounds of general formula I may be present in association with one or more non-toxic pharmaceutically acceptable carriers and/or diluents and/or adjuvants and if desired other active ingredients. The pharmaceutical compositions containing compounds of general formula I may be in a form suitable for oral use, for example, as tablets, troches, lozenges, aqueous or oily suspensions, dispersible powders or granules, emulsion, hard or soft capsules, or syrups or elixirs.
Compositions intended for oral use may be prepared according to any method known to the art for the manufacture of pharmaceutical compositions and such compositions may contain one or more agents selected from the group consisting of sweetening agents, flavoring agents, coloring agents and preserving agents in order to provide pharmaceutically elegant and palatable preparations. Tablets contain the active ingredient in admixture with non-toxic pharmaceutically acceptable excipients which are suitable for the manufacture of tablets. These excipients may be for example, inert diluents, such as calcium carbonate, sodium carbonate, lactose, calcium phosphate or sodium phosphate; granulating and disintegrating agents, for example, corn starch, or alginic acid; binding agents, for example starch, gelatin or acacia, and lubricating agents, for example magnesium stearate, stearic acid or talc. The tablets may be uncoated or they may be coated by known techniques to delay disintegration and absorption in the gastrointestinal tract and thereby provide a sustained action over a longer period. For example, a time delay material such as glyceryl monosterate or glyceryl distearate may be employed.
Formulations for oral use may also be presented as hard gelatin capsules wherein the active ingredient is mixed with an inert solid diluent, for example, calcium carbonate, calcium phosphate or kaolin, or as soft gelatin capsules wherein the active ingredient is mixed with water or an oil medium, for example peanut oil, liquid paraffin or olive oil.
Aqueous suspensions contain the active materials in admixture with excipients suitable for the manufacture of aqueous suspensions. Such excipients are suspending agents, for example sodium carboxymethylcellulose, methylcellulose, hydropropylmethylcellulose, sodium alginate, polyvinylpyrrolidone, gum tragacanth and gum acacia; dispersing or wetting agents may be a naturally-occurring phosphatide, for example, lecithin, or condensation products of an alkylene oxide with fatty acids, for example polyoxyethylene stearate, or condensation products of ethylene oxide with long chain aliphatic alcohols, for example heptadecaethyleneoxycetanol, or condensation products of ethylene oxide with partial esters derived from fatty acids and a hexitol such as polyoxyethylene sorbitol monooleate, or condensation products of ethylene oxide with partial esters derived from fatty acids and hexitol anhydrides, for example polyethylene sorbitan monooleate. The aqueous suspensions may also contain one or more preservatives, for example ethyl, or n-propyl p-hydroxybenzoate, one or more coloring agents, one or more flavoring agents, and one or more sweetening agents, such as sucrose or saccharin.
Oily suspensions may be formulated by suspending the active ingredients in a vegetable oil, for example arachis oil, olive oil, sesame oil or coconut oil, or in a mineral oil such as liquid paraffin. The oily suspensions may contain a thickening agent, for example beeswax, hard paraffin or cetyl alcohol. Sweetening agents such as those set forth above, and flavoring agents may be added to provide palatable oral preparations. These compositions may be preserved by the addition of an anti-oxidant such as ascorbic acid.
Dispersible powders and granules suitable for preparation of an aqueous suspension by the addition of water provide the active ingredient in admixture with a dispersing or wetting agent, suspending agent and one or more preservatives. Suitable dispersing or wetting agents and suspending agents are exemplified by those already mentioned above. Additional excipients, for example sweetening, flavoring and coloring agents, may also be present.
Pharmaceutical compositions of the invention may also be in the torn of oil-in-water emulsions. The oily phase may be a vegetable oil, for example olive oil or arachis oil, or a mineral oil, for example liquid paraffin or mixtures of these. Suitable emulsifying agents may be naturally-occuring gums, for example gum acacia or gum tragacanth, naturally-occurring phosphatides, for example soy bean, lecithin, and esters or partial esters derived from fatty acids and hexitol, anhydrides, for example sorbitan monoleate, and condensation products of the said partial esters with ethylene oxide, for example polyoxyethylene sorbitan monoleate. The emulsions may also contain sweetening and flavoring agents.
Syrups and elixirs may be formulated with sweetening agents, for example glycerol, propylene glycol, sorbitol or sucrose. Such formulations may also contain a demulcent, a preservative and flavoring and coloring agents. The pharmaceutical compositions may be in the form of a sterile injectable aqueous or oleaginous suspension. This suspension may be formulated according to the known art using those suitable dispersing or wetting agents and suspending agents which have been mentioned above. The sterile injectable preparation may also be sterile injectable solution or suspension in a non-toxic parentally acceptable diluent or solvent, for example as a solution in 1,3-butanediol. Among the acceptable vehicles and solvents that may be employed are water, Ringer's solution and isotonic sodium chloride solution. In addition, sterile. fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil may be employed including synthetic mono- or diglycerides. In addition, fatty acids such as oleic acid find use in the preparation of injectables.
The compounds of general formula I may also be administered in the form of suppositories for rectal administration of the drug. These compositions can be prepared by mixing the drug with a suitable non-irritating excipient which is solid at ordinary temperatures but liquid at the rectal temperature and will therefore melt in the rectum to release the drug. Such materials are cocoa butter and polyethylene glycols.
Compounds of general formula I may be administered parenterally in a sterile medium. The drug, depending on the vehicle and concentration used, can either be suspended or dissolved in the vehicle. Advantageously, adjuvants such as local anaesthetics, preservatives and buffering agents can be dissolved in the vehicle.
Dosage levels of the order of from about 0.1 mg to about 140 mg per kilogram of body weight per day are useful in the treatment of the above-indicated conditions (about 0.5 mg to about 7 g per patient per day). The amount of active ingredient that may be combined with the carrier materials to produce a single dosage form will vary depending upon the host treated and the particular mode of administration. Dosage unit forms will generally contain between from about 1 mg to about 500 mg of an active ingredient.
It will be understood, however, that the specific dose level for any particular patient will depend upon a variety of factors including the activity of the specific compound employed, the age, body weight, general health, sex, diet, time of administration, route of administration, and rate of excretion, drug combination and the severity of the particular disease undergoing therapy.
A representative illustration of methods suitable for the preparation of compounds of the present invention is shown in Schemes I and II. Those having skill in the art will recognize that the starting materials may be varied and additional steps employed to produce compounds encompassed by the present invention. ##STR35## wherein Ar, R 1 , R 2 , R 3 , R 4 , and R 5 are as defined above for formula I. ##STR36## where Ar, n, m, and A are as defined above for formula I.
The disclosures in this application of all articles and references, including patents, are incorporated herein by reference.
The invention is illustrated further by the following examples which are not to be construed as limiting the invention in scope or spirit to the specific procedures and compounds described in them.
EXAMPLE IA ##STR37##
To a stirred mixture of sodium methoxide (2.78 g, 51 mmol) and ethyl formate (4.0 g, 54 mmol) in 100 mL of benzene was added 2,4,6 trimethylphenylacetonitrile (8.0 g, 50 mmol) over 5 min. After stirring for an additional hour it was treated with water (100 mL) and the layers were separated. The aqueous layer was separated and acidified with 10% HCl and extracted with ethyl acetate. After drying the solvent was removed in vacuo to afford a-formyl-2,4,6-trimethylphenylacetonitrile as colorless crystals melting at 120°-122° C. ##STR38##
EXAMPLE IB
A mixture of a-formyl-2,4,6 trimethylphenylacetonitrile (4.5 g, 24 mmol) and sarcosine ethyl ester hydrochloride (3.7 g, 24 mmol) in 100 mL of benzene was refluxed in a Dean-Stark apparatus for 16 h. The solvent was removed in vacuo to afford N-Methyl-N- 2-(2,4,6-trimethylphenyl)-2-cyanovinyl!-glycine ethyl ester as a pale yellow oil.
EXAMPLE IC ##STR39##
A solution of N-Methyl-N- 2-(2,4,6-trimethylphenyl)-2-cyanovinyl!-glycine ethyl ester (6.8 g, 24 mmol) in 0.28M ethanolic sodium ethoxide (100 mL) was heated at 70° C. for 6 h. The reaction was cooled and evaporated in vacuo. The residue was treated with water and neutralized with acetic acid and the product was extracted with ethyl acetate. After drying the solvent was removed in vacuo to afford 3-Amino-2-ethoxycarbonyl-2-methyl-4-(2,4,6-trimethylphenyl)-1H-pyrrole as a yellow oil.
EXAMPLE ID ##STR40##
A solution of 3-Amino-2-ethoxycarbonyl-1-methyl-4-(2,4,6-trimethylphenyl)-1H-pyrrole (2.0 g, 7 mmol) in 20 mL of formamide was heated at 140° C. for 12 h. After cooling the mixture was poured into water and the resulting solid was collected and washed with more water and dried to afford 5-Methyl-7-(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2-d!pyrimidin-4-ol as a tan solid melting at 230°-232° C.
EXAMPLE IE ##STR41##
A mixture of 5-Methyl-7-(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2-d!pyrimidin-4-ol (100 mg) and phosphorous oxychloride (0.5 mL) was heated at reflux for 3 hours. Excess reagent was removed in vacuo and the residual 4-chloro compound was treated with N-propylcyclopropylmethylamine (100 mg) and triethylamine (100 mg) in xylene (2 mL) and the mixture was refluxed for 8 hours.
After diluting the reaction mixture with ethyl acetate and washing with dilute bicarbonate solution, the organic layer was dried and the solvent removed in vacuo. The residue was chromatagraphed on silica gel to afford N-cyclopropylmethyl-N-propyl-5-methyl-7-(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2-d!pyrimidin-4-amine (Compound 1) as an oil. The HCl salt from ethyl acetate/HCl melted at 205°-207° C.
EXAMPLE II
The following compounds are prepared essentially according to the procedures described in Examples IA-E above.
a) N,N-Dipropyl-5-methyl-7-(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2-d!pyrimidin-4-amine (Compound 2) melting at 116°-118° C.
b) N,N-Diethyl-5-methyl-7-(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2-d!pyrimidin-4-amine (Compound 3).
c) N,N-Dimethyl-5-methyl-7-(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2-d!pyrimidin-4-amine (Compound 4).
d) N-Butyl-N-Ethyl-5-methyl-7-(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2-d!pyrinidin-4-amine (Compound 5) melting at 126°-128° C.
e) N-(2-Hydroxyethyl)-N-Ethyl-5-methyl-7-(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2-d!pyrimidin-4-amine (Compound 6).
f) 4-(1-Homopiperdinyl)-5-methyl-7-(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2-d!pyrimidine(Compound 7) melting at 140°-142° C.
g) N-(1-Ethylpropyl)-5-methyl-7-(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2d!pyrimidin-4-amine (Compound 8).
h) N-(1-Hydroxymethylpropyl)-1-methyl-7-(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2d!pyrimidin-4-amine (Compound 9) melting at 118°-120° C.
i) N,N-Dipropyl-5,6-dimethyl7-(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2-d!pyrimidin-4-amine (Compound 10).
j) N-(1-Hydroxymethylpropyl)-5,6-dimethyl-7-(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2d!pyrimidin-4-amine (Compound 11).
k) N-(1-Hydroxymethylpropyl)-2,5-dimethyl-7-(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2d!pyrimidin-4-amine (Compound 12).
l) N,N-Dipropyl-2,5-dimethyl-7-(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2-d!pyrimidin-4-amine (Compound 13).
m) N-Cyclopropylmethyl-N-propyl-6-chloro-5-methyl-7-(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2-d!pyrimidin-4-amine (Compound 14).
n) N-Cyclopropylmethyl-N-propyl-2-choro-5-methyl-7-(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2-d!pyrimidin-4-amine (Compound 15).
o) N-Cyclopropylmethyl-N-propyl-6-bromo-5-methyl-7-(2,4,6-trimethvlphenyl)-5H-pyrrolo 3,2-d!pyrimidin-4-amine (Compound 16).
p) N-Cyclopropylmethyl-N-propyl-6-thiomethyl-5-methyl-7-(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2-d!pyrimidin-4-amine (Compound 17).
q) N-Cyclopropylmethyl-N-propyl-2-thiomethyl-5-methyl-7-(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2-d!pyrimidin-4-amine (Compound 18).
r) N-Cyclopropyl methyl-N-propyl-2-chloro-5-methyl-7 -(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2-bpyridin-4-amine (Compound 19).
s) N-Cyclopropylmethyl-N-propyl-5-methyl-7-(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2-bpyridin-4-amine (Compound 20).
t) N-(1-Hdroxymethylpropyl)-5-methyl-7-(2,4,6-trimethylphenyl)-5H-pyrrolo 3,2bpyridin-4-amine (Compound 21).
u) N-Cyclopropylmethyl-N-propyl-5-amino-9-(2,4,6-trimethylphenyl)-1,2-dihydro-3H-pyrimido 5,4-e!pyrrolizine (Compound 22).
v) N-(1-Hydroxymethylpropyl)-5-amino-9-(2,4,6-trimethylphenyl)-1,2-dihydro-3H-pyrimido 5,4-e!pyrrolizine (Compound 23).
w) N-Cyclopropylmethyl-N-propyl-5-amino-7-methyl-9-(2,4,6-trimethylphenyl)-1,2-dihydro-3H-pyrimido 5,4-e!pyrrolizine (Compound 24).
x) N-Cyclopropylmethyl-N-propyl-5-amino-9-(2,4-dichlorophenyl)-1,2-dihydro-3H-pyrimido 5,4-e!pyrrolizine (Compound 25).
y) N,N-Dipropyl-5-methyl-7-(2,4-dichlorophenyl)-5H-pyrrolo 3,2-d!pyrimidin-4-amine (Compound 26).
z) N-Cyclopropylmethyl-N-propyl-5-amino-9-(2,4,6-trimethylphenyl)-1,2-dihydro-3H-pyrido 2,3-e!pyrrolizine (Compound 27).
The invention and the manner and process of making and using it, are now described in such full, clear, concise and exact terms as to enable any person skilled in the art to which it pertains, to make and use the same. It is to be understood that the foregoing describes preferred embodiments of the present invention and that modifications may be made therein without departing from the spirit or scope of the present invention as set forth in the claims. To particularly point out and distinctly claim the subject matter regarded as invention, the following claims conclude this specification. | Disclosed are compounds of the formula ##STR1## wherein Ar represents an aryl or heteroaryl group; and
R 1 , R 2 , R 3 , R 4 , and R 5 represent organic or inorganic substituents, which compounds are highly selective partial agonists or antagonists at human CRF1 receptors and, thus, are useful in the diagnosis and treatment of treating stress related disorders such as post trumatic stress disorder (PTSD) as well as depression, headache and anxiety. | 2 |
This invention was made with Government support under Contract No. F30602-95-2-0004 awarded by the United States Department of the Air Force, Rome Laboratory. The Government has certain rights in this invention.
FIELD OF THE INVENTION
The present invention relates generally to methods of rotating the plane of incident light polarization, and more particularly, to the use of right-angle prisms to accomplish this rotation.
BACKGROUND OF THE INVENTION
It is often desirable to have an optical component which enables one to rotate the plane of polarization of a light beam by one-quarter turn, i.e., 90°. For example, consider a disk-shaped optical storage medium having spiral or concentric grooves. A manufacturer of the optical discs may use an optical media tester to evaluate the disk with polarizations that are parallel and perpendicular to the grooves. This test indicates the dependence of data and servo signals upon the incident light polarization.
Although half wave length (1/2λ) retardation plates have been used to rotate the plane of polarization of the light from a tester incident upon an optical disk, there are at least four disadvantages to using a 1/2λ plate. First, the wavefront distortion of most commercially available wave plates is generally fairly large (typically λ/4 at 633 nm), which reduces the quality of the focused spot. Second, the wave plate itself must be chosen for the precise laser wavelength, otherwise it will introduce a spurious phase shift into the light polarization, converting it to elliptical polarization. This not only limits the accuracy of the test results, but can also mismatch the phase shift in the medium to that of the tester read channel. Both of these effects (wavefront distortion and spurious phase shift) reduce the measured carrier-to-noise ratio (CNR) of the medium in the tester. A third problem with a half wave plate is that multiple wave plates must be purchased for a media tester designed to operate at multiple laser wavelengths. This can be very expensive. While there are half wave retarders advertised to exhibit approximately half wave retardation over a range of wavelengths (e.g., Fresnel rhombs), their actual retardation deviates significantly from half wave over any substantial wavelength range, making them unsuitable for this use in a media tester. The fourth problem is that half wave plates must be carefully aligned in their angular orientation, and their face must be perpendicular to the incident beam. Otherwise, the retardation of the wave plate will be incorrect for rotating the polarization without introducing ellipticity.
Another application for an optical component capable of rotating the plane of polarization by 90° is in the area of polarizing interferometers. An achromatic polarization-rotating retroreflector is a key component of a polarizing, i.e., Martin-Puplett, interferometer. Presently, such interferometers are useful only for spectroscopy in the far infrared. At the extremely long far infrared wavelengths, metallic mirrors act essentially as perfect mirrors without significantly depolarizing the incident light. As a result, a simple roof mirror oriented at a 45° angle to the plane of polarization of the incident beam is sufficient to rotate the polarization by 90° and retroreflect the beam. Michelson (nonpolarizing) interferometers are now standard commercial products for Fourier transform spectroscopy from the mid infrared through the visible because interferometers often have advantages over monochromators in spectroscopic applications in throughput, multiplexing capability, and resolution. However, the significant depolarizing effects of metallic mirrors at the shorter visible and near infrared wavelengths preclude the use of roof mirrors in polarizing interferometers at these wavelengths.
SUMMARY OF THE INVENTION
It would be desirable to have a polarization-rotating optical element in which the exiting beam does not travel in the opposite direction from the entering beam, but rather travels perpendicular to (i.e., at 90°) and undisplaced from the entering beam. This is advantageous because it allows one to use the optical element interchangeably with a mirror oriented at 45° to the entering beam so that the optical element and mirror may each be used to evaluate an optical disk with polarizations that are both parallel (e.g., with the optical element) and perpendicular (e.g., with the mirror) to the grooves on the disk. Because the optical element must be interchangeable with the mirror, it is essential that the beam exiting the optical element not be displaced from the entering beam.
It would also be desirable to have a polarization rotating element in which the exiting beam continues along in the same direction and undisplaced from the entering beam. This is advantageous because it allows one to evaluate an optical disk with polarizations that are both parallel and perpendicular to the grooves on the disk simply by placing the optical element in the path of the beam (for one polarization) and removing the optical element from the path of the beam (for the other polarization). Because the beam must travel along the same path regardless of whether the optical element is present or not, it is essential that the optical element not displace the exiting beam from the beam's original path.
In either of the cases discussed above (i.e., where the orientation of the beam is rotated 90° or continues along its original path), it would be desirable that the optical element perform its function independent of the orientation of the optical element with respect to the entering beam. (Although the optical element may function even though rotated through 360°, the entering beam should be perpendicular to the face of the optical element that it must enter.) This greatly simplifies the installation and alignment of the optical element. The present invention also provides an achromatic polarization rotator which maintains strict linear polarization at all wavelengths.
One embodiment of the present invention includes the pair of prisms shown in FIGS. 2 and 3 as well as a second pair of right-angle isosceles prisms as shown, for example, in FIG. 1. The first pair of prisms includes one prism having a length a with sides having a width b and a second prism having a length b with sides having a width a. The base of the second prism is on top of and coextensive with a side of the first prism.
The second pair of prisms (see FIG. 1) includes a prism (the "third" prism) having a length b with sides having a width a/2. The other prism (the "fourth" prism) has a length a/2 with sides having a width b. The third prism is adjacent the first prism such that a side of the third prism is coextensive with the half of the side of the first prism that is not coextensive with the second prism. The apex of the third prism is coextensive with one end of the first prism. The fourth prism is adjacent the first prism such that a side of the fourth prism is coextensive with the remaining half of the side of the first prism which is coextensive with the third prism. The apex of the fourth prism is coextensive with an edge of said side of the first prism opposite the apex of the first prism.
The present invention also includes a method of rotating the plane of polarization of an electric field, E, of an incident beam by 90° while altering the direction of the beam by 90°. The method includes providing a first pair of prisms as described above for FIGS. 2 and 3. A beam having a plane of polarization of an electric field, E, travels in an initial ("first") direction toward a first portion of one side of the first prism which is not coextensive with the second prism so that the incident beam is normal to that side of the first prism. The plane of polarization of E is oriented at an angle θ with respect to a plane ("the first plane") which is defined as bisecting the prism assembly through the apex of the second prism. The plane of polarization of E is reflected across the first plane by an angle of -θ. The plane of polarization of E is reflected across another plane ("the second plane") which is oriented at an angle of 45° with respect to the first plane. The direction of travel of the beam is altered 90° so that it emerges traveling at an angle of 90° from its initial angle. Thus, the plane of polarization is rotated 90° from its original orientation and the direction of travel of the beam is also altered 90° from its initial direction. (See FIG. 1.)
Ease of alignment of the optical elements is insured by arranging the reflections such that the vertical, V, and horizontal, H, components of E undergo an equal number of s-polarized reflections and undergo an equal number of p-polarized reflections. In the embodiment of the invention shown in FIG. 1, the number of s-polarizations for H and V is three each, and the number of p-polarizations for H and V is also three each. The steps of reflecting the polarization across the second plane and rotating the first direction of travel of the beam may be accomplished by providing the third and fourth prisms discussed above and shown as prisms 70 and 80 in FIG. 1.
The present invention also includes a method of rotating the plane of polarization of E of an incident beam by 90° while allowing the beam to continue along undisplaced and in the same direction of travel. One version of this method (see FIG. 6) includes the prism assembly described above and shown in FIGS. 2 and 3. The beam has a plane of polarization of E and travels in a first direction toward and normal to the side of the first prism which is not coextensive with the second prism. The plane of polarization of E is oriented at an angle θ with respect to a plane ("the first plane") which bisects the prism assembly (assembly 10) through the apex (44) of the second prism (40). The plane of polarization of E is reflected across the first plane to an angle -θ.
The beam undergoes three separate displacements which result in a net displacement of zero. (See FIGS. 7A-C.) One displacement moves the beam in one direction, e.g., horizontally, by a distance of a/(22), where a is the length of the first prism (prism 20 in FIGS. 2 and 3). The beam undergoes another displacement in a perpendicular direction, e.g., vertically, by an equal distance, i.e., a/(22). The beam undergoes a third displacement in a direction equal and opposite to the sum of the other two displacements, i.e., at an angle of -135° (180°-45°), and a distance of a/2, since ##EQU1##
Thus, the net displacement is zero.
The beam also undergoes two retroreflections, the sum of which allow the beam to continue on in its original direction. At the first retroreflection, the plane of polarization is reflected across a first plane. At the second retroreflection, the plane of polarization is reflected across a second plane which is at 45° to the first plane. Two reflections are equivalent to a rotation at twice the angle between the planes, or 90°. As was the case above, V and H undergo an equal number of s-polarized reflections and undergo an equal number of p-polarized reflections. In the embodiment shown in FIG. 6, the number of s-polarizations for H and V is four each, and the number of p-polarizations for H and V is also four each.
Another method for rotating the plane of polarization of E of an incident beam by 90° while allowing the beam to continue along undisplaced and in the same direction includes the following steps. The beam is directed toward a portion of an optical assembly (e.g., as shown in FIG. 6). The plane of polarization of E is reflected across a first plane which bisects H and V. H and V each undergo two s-polarized and two p-polarized reflections. The plane of polarization of E is then reflected across a second plane which is oriented at 45° with respect to the first plane. H and V each undergo two s-polarized and two p-polarized reflections. The beam is retroreflected two times so that the beam continues along in its original direction. The total number of s-polarized reflections is the same for V and H, and the total number of p-polarized reflections is also the same for V and H, thereby maintaining the linear polarization of the incident beam. In one embodiment, the method includes displacing the beam in a direction ("the second direction") perpendicular to its direction of travel by a distance x. The beam also is displaced by a distance x in a direction ("the third direction") perpendicular to the direction of travel and the second direction. The beam is also displaced in a direction ("the fourth direction") which bisects the second and third directions by a distance -2x, so that the net effect of the three displacements is zero.
The present invention includes yet another method for rotating the plane of polarization of E while allowing the beam to continue undisplaced. The beam travels in a first direction toward and normal to a portion of an optical assembly (e.g., FIGS. 8 or 11). The beam is reflected to a second direction which is perpendicular to the first direction and is then reflected to a third direction which is normal to a plane defined by the first two directions. H and V each undergo one s-polarized and one p-polarized reflection. The beam is retroreflected from a third to a fourth (opposite) direction and the plane of polarization of E is reflected across a plane which bisects H and V. H and V each undergo two s-polarized and two p-polarized reflections. The beam is then reflected to a fifth direction opposite the second direction and then reflected back along the first direction. H and V each undergo one s-polarized and one p-polarized reflection. In one embodiment, the beam is displaced by a distance x in the second direction and also by a distance x in the fifth direction, so that there is no net displacement of the beam.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an isometric view of one embodiment of the present invention for rotating the plane of polarization by 90° while altering the direction of the incident light beam by 90°.
FIG. 2 is an isometric view of an assembly of two right-angle prisms for rotating the plane of polarization of incident light by 90°.
FIG. 3 shows the path of a light ray through the assembly shown in FIG. 2.
FIGS. 4 and 5 are isometric views showing the path of a light ray through two optical components of the assembly of FIG. 6.
FIG. 6 shows an isometric view of an assembly of the optical components of FIGS. 4 and 5 according to one embodiment of the present invention for rotating the plane of polarization by 90° with no redirection or displacement of the incident light ray.
FIGS. 7A-C show the relative dimensions of the optical components of the assembly of FIG. 6.
FIG. 8 shows an isometric view of an assembly of optical components according to yet another embodiment of the present invention for rotating the plane of polarization by 90° with no redirection or displacement of the incident light ray.
FIG. 9 shows an isometric view of one of the optical components of FIG. 8.
FIG. 10 is an exploded isometric view of the path of a light ray through the assembly shown in FIG. 8.
FIG. 11 is an isometric view of an alternative embodiment of the assembly of optical components shown in FIG. 8.
DETAILED DESCRIPTION
One embodiment of the present invention rotates the plane of polarization of an incident beam by 90° and alters the direction of the beam by 90°. This is shown in FIG. 1 as assembly 60 which is comprised of assembly 10 and right angle isosceles prisms 70 and 80.
As shown in FIGS. 2 and 3, prism assembly 10 comprises first right-angle isosceles prism 20 and second right-angle isosceles prism 40. Prism 20 has a rectangular base 22 opposite angle α at the apex 24 of the prism. Because prism 20 is a right-angle prism, angle α=90°. Prism 20 has rectangular sides 26 and 28, which are perpendicular to each other, since the prism is a right-angle prism, and which each form an angle β of 45° with respect to base 22, since the prism is an isosceles prism. Prism 20 has opposite, parallel, right-angle isosceles triangle ends 32 and 34.
Second prism 40 has a rectangular base 42 opposite angle α at apex 44 of the prism. Because prism 40 is also a right-angle prism, angle α=90°. Prism 40 has rectangular sides 46 and 48, which are perpendicular to each other, since the prism is a right-angle prism, and which each form an angle β of 45° with respect to base 42, since the prism is an isosceles prism. Prism 40 has opposite, parallel, right-angle isosceles triangle ends 52 and 54.
Prism 40 is placed on top of prism 20 so that base 42 of prism 40 is coextensive with side 28 of prism 20. Thus, the length of side 28 of prism 20, designated as a, is equal to the width of base 42 of prism 40. Similarly, the width of side 28 of prism 20, designated as b, is equal to the length of base 42 of prism 40. Thus, by simple geometry, base 22 of prism 20 has a width of 2 b and prism 20 has a height of (2/2) b. Similarly, sides 46 and 48 of prism 40 have widths of a and prism 40 has a height of a/2.
Assembly 10 is preferably made of the same materials as those typically used for prisms, e.g., polycarbonate, plastic, or glass. Assembly 10 may be formed as a single piece from the materials described above, or it may be formed by assembling two separate prisms 20 and 40 as shown in FIGS. 2 and 3. If two separate prisms are used, the two prisms should be optically adhered together by a transparent, refractive index-matching adhesive to minimize the possibility of internal reflections at the interface between the two prisms.
The manner in which assembly 10 can be used to rotate the polarization of a beam of incident light by 90° will now be described with reference to a light ray A shown in FIG. 3. Ray A has a polarization field E having a vertical component V, pointing up, and a horizontal component H pointing to the right, as shown in FIG. 3. Assembly 10 should be oriented with respect to ray A such that the plane of polarization of ray A is at a 45° angle with respect to the bottom edge of prism 20. Light ray A enters side 26 of prism 20 toward the right side of side 26, i.e., to the right of apex 44 of prism 40, as shown in FIG. 3. Ray A enters side 26 of prism 20 at an angle normal (i.e., 90°) to the surface of side 26. Ray A proceeds through prism 20 until it is reflected 90° at base 22 (due to total internal reflection and an angle of incidence of 45°). As a result of this first reflection, the vertical component, V, of Ray A experiences a p-polarized reflection and no change in the orientation of V, since light rays having a polarization parallel to the plane of incidence are defined as "p-polarized" and light rays having a polarization perpendicular to the plane of incidence are "s-polarized." (The horizontal component, H, will be discussed later.)
Ray A then passes out of side 28 of prism 20 and thus enters base 42 of prism 40. Ray A proceeds through prism 40 until it is reflected 90° at side 46. As a result of this second reflection, the vertical component, V, of Ray A experiences an s-polarized reflection with no change in the orientation of the vertical component. Ray A then passes through prism 40 until it is reflected 90° at the other side 48 of prism 40, whereupon V experiences a second s-polarized reflection with no change in the orientation of V. Ray A then passes back through base 42 of prism 40 and thus enters prism 20 via side 28. Ray A proceeds through prism 20 until it is reflected 90° at base 22 of prism 20, whereupon V experiences a second p-polarized reflection with no change in the orientation of V. (Please note that the reflected angle is always 90° since α=90°, β=45°, and light ray A enters prism 20 normal to side 26.) Ray A then passes out of prism 20 via side 26 at an angle normal to the surface of side 26.
Thus, as a result of the four reflections, the vertical component, V, of the polarization field E has undergone two p-polarization phase shifts and two s-polarization phase shifts, while the orientation of the vertical component has not been affected.
The four reflections of light ray A discussed above for the vertical component of Ray A will now be discussed with respect to the horizontal component, H, of Ray A. The horizontal component of Ray A is initially oriented toward the right, as shown in FIG. 3. At the first reflection (at base 22 of prism 20), Ray A experiences an s-polarized reflection with no change in the orientation of the horizontal component, H. At the second reflection (at side 46 of prism 40), Ray A experiences a p-polarized reflection and the orientation of H is rotated 90° clockwise (or to the right), so that it points downward. At the third reflection (at side 48 of prism 40), Ray A experiences a second p-polarized reflection and the orientation of H is rotated clockwise by another 90° so that the horizontal component points to the left. At the fourth reflection (at base 22 of prism 20), Ray A experiences a second s-polarized reflection with no change in the orientation of H.
Thus, as a result of the four reflections, the horizontal component, H, of E has undergone two p-polarization phase shifts and two s-polarization phase shifts and the orientation of the horizontal component has shifted 180° from right-pointing to left-pointing.
Because both the vertical and horizontal components of the plane of polarization of the electric field E were each subjected to two s- and two p-polarization phase shifts, no net phase shift between the two components is introduced by prism assembly 10 for any wavelength. Second, because the horizontal component H, of E is reversed (180° change) and the vertical component is not changed, the effect of the prism assembly 10 is to reflect the incident polarization E about the vertical plane. Third, the exiting beam is (a) traveling in the opposite direction from the entering beam, and (b) is displaced from the entering beam (since ray A must be reflected off both sides 46 and 48).
As shown in FIG. 1, prism 70 is optically attached to prism 20 so that side 78 of prism 70 is attached to side 26 of prism 20. Prism 70 is oriented on prism 20 such that apex 74 of prism 70 is aligned with end 32 of prism 20. Thus, side 78 of prism 70 has a length of b (equal to the width of side 26 of prism 20) and a width of a/2 (i.e., equal to one half the length of side 26 of prism 20).
Prism 80 is oriented at an angle of 90° with respect to prism 70 and is positioned on side 26 of prism 20 next to prism 70. Apex 84 of prism 80 is aligned with the edge of side 26 of prism 20 opposite apex 24 of prism 20. Triangular end 89 of prism 80 is aligned with end 34 of prism 20. Thus, side 88 of prism 80 has a length of a/2 (equal to one half the length of side 26 of prism 20) and a width of b (equal to the width of side 26 of prism 20).
The manner in which assembly 60 can be used to rotate the polarization of a beam of incident light by 90° while also altering the direction of the beam by 90° will now be described with reference to a light ray B, as shown in FIG. 1. Ray B has an electric field E' having a vertical component V', pointing up, and a horizontal component H' pointing to the right, as shown in FIG. 1. Ray B enters side 76 of prism 70 at an angle normal (i.e., 90°) to the surface of side 76. Ray B proceeds through prism 70 until it is reflected 90° at base 72 (due to total internal reflection at an angle of incidence of 45°). As a result of this first reflection, the vertical component, V', of Ray B undergoes a p-polarized reflection, and the horizontal component, H', of Ray B undergoes an s-polarized reflection.
Ray B then passes through side 78 of prism 70 and enters prism 20 via side 26 at an angle normal to the surface of side 26. Ray B then undergoes the four reflections within assembly 10 described in FIG. 3. Ray B then passes out of prism 20 via side 26 at an angle normal to side 26 and enters prism 80 via side 88. Ray B proceeds through prism 80 until it is reflected 90° at a base 82. As a result of this last reflection, V' of Ray B undergoes an s-polarized reflection and H' undergoes a p-polarized reflection. Ray B then exits prism 80 via side 86 at an angle normal to side 86.
Thus, as a result of the six reflections, H' and V' have both undergone 3 p-polarization phase shifts and 3 s-polarization phase shifts, V' has rotated 90° and H' has rotated 90°. Because these are orthogonal vectors, both rotated 90° in the same direction, any other vector will also be rotated 90°. Because the number of p- and s-polarized reflections are equal for both V' and H', the light remains linearly polarized.
Although base 82 of prism 80 is shown as facing out of the page on FIG. 1, prism 80 may be rotated 180° so that the base faces into the page, i.e., apex 84 of prism 80 could be aligned with apex 24 of prism 20. In this case, Ray B would exit assembly 60 via prism 80 in the opposite direction (i.e., rotated 180°) from that shown in FIG. 1, although the direction of travel exiting Ray B would still be rotated by 90° (actually, -90° or 270°) from the direction of travel of Ray B prior to entering assembly 60.
Prism assembly 10 can also be combined with other optical elements to allow an optical assembly to, in addition to rotating the plane of polarization of an incident light beam by 90°, allow the reemerging beam to continue on in the same direction as and undisplaced from the original beam. Such an arrangement is shown as optical assembly 100 in FIG. 6. Optical assembly 100 is comprised of prism assembly 10 and beam redirection assembly 120.
Beam redirection assembly 120 is shown in FIG. 4, with the exception of rectilinear beam conduit 170, which has been omitted. Beam conduit 170 will be discussed later. Assembly 120 is comprised of a right angle isosceles prism 130 and a rhomboid, or a parallelogram-shaped, beam guide 150.
Rhomboid 150 has interior angles of 45° and 135° for angles γ and δ as shown in FIGS. 4 and 6. Thus, sides 156 and 158 of rhomboid 150 are parallel to each other, ends 162 and 164 are parallel to each other, and top and bottom 154 and 152 are parallel to each other. Sides 156 and 158 are oriented at 45° to ends 162 and 164. As shown in FIG. 4, the surface of end 164 of rhomboid 150 contacts the lower half of base 132 of prism 130,
The relative sizes of rhomboid 150, prism 130, and assembly 10 are shown in FIGS. 7A-C. As shown in FIG. 7A, prism 20 of assembly 10 has a length of a (and thus base 42 of prism 40 has a width of a). The entrance and exit points of Ray C are shown on side 26 of prism 20 and are separated by a distance a/2. An overhead plan view of rhomboid 150 is shown in FIG. 7B. Rhomboid 150 has a width of a/(22), and a length, perpendicular to the width, also equal to a/(22). The path of travel of Ray C within rhomboid 150 is shown in dashed lines. As shown in FIG. 7C, base 132 of prism 130 has a width of a/(22). The entrance and exit points of Ray C at base 132 are shown in FIG. 7C and are separated by a distance a/2.
Prism assembly 10 is positioned with respect to beam redirection assembly 120 as shown in FIG. 6. A portion of side 26 of prism 20 is in optically intimate contact with base 132 of prism 130 to allow Ray C exiting prism 130 to enter prism assembly 10. Prism assembly 10 does not contact rhomboid 150. In order to provide the proper orientation of prism assembly 10, as shown in FIG. 6, it is necessary to use an optical connector 170, e.g., having a rectangular (e.g., square) cross-section, to allow Ray C to pass from a rhomboid 150 to prism 130. The ends of optical connector 170 are preferably perpendicular to its length so that the interfaces between the connector and prism 130 and the connector and rhomboid 150 do not affect the transmission, direction, or polarization of Ray C. The orientation of prism assembly 10 with respect to beam redirection assembly 120 should be such that apex 24 of prism 20 is at a 45° angle with respect to apex 134 of prism 130. Prism assembly 10 should also be positioned with respect to prism 130 such that Ray C exiting prism 130 will enter prism assembly 10 and can be reflected as shown in the ray diagram of FIG. 5 and so that Ray C exits prism assembly 10 in the same direction as and along the same line as the original Ray C prior to entering rhomboid 150. This results from the fact that the horizontal displacement of the central light ray by rhomboid 150 and prism assembly 10 cancel each other out, while the vertical displacement of prism 130 and prism assembly 10 also cancel each other out.
The manner in which assembly 100 can be used to rotate the polarization of a light beam by 90° while allowing the re-emerging beam to continue on in the same direction as and undisplaced from the original beam is described as follows. Ray C has a polarization field E" having a vertical component V", pointing up, and a horizontal component, H", pointing to the right, as shown in FIG. 6.
Ray C enters end 162 of rhomboid 150 normal to the surface of end 162. Ray C is then reflected at a 90° angle at side 156 of rhomboid 150 (due to total internal reflection at an angle of incidence of 45°) and is then reflected 90° again at opposite side 158, as shown in FIG. 7B. As a result of these first two reflections, V" undergoes two p-polarized reflections, while H" undergoes two s-polarized reflections.
Ray C then exits rhomboid 150, passes through optical connector 170, and enters prism 130, as shown in FIGS. 4, 6, and 7C. Ray C undergoes two 90° reflections at both sides of prism 130. As a result of these two reflections, V" undergoes two p-polarized reflections, while H" undergoes two s-polarized reflections. V" now points downward, while H" still points to the right. The effect of beam redirection assembly 120 therefore is to retroreflect the incident beam direction, while reflecting the incident polarization about the horizontal plane.
Ray C then exits prism 130 via base 132 and enters assembly 10 via side 26 of prism 20. Ray C then undergoes the four reflections within assembly 10 described for FIG. 3. Ray C then exits prism 20 via side 26 and continues on along the same line as Ray C traveled prior to entering assembly 100, i.e., in the same direction as and undisplaced from the original beam. As previously discussed, prism assembly 10 rotates V" to point to the left, while it rotates H" to point upward. Both V" and H" have been rotated 90° in the same direction, so any other ray will also be rotated by 90°. Both rays undergo a total of 4 p-polarized and 4 s-polarized reflections. Therefore, the light remains linearly polarized.
Another embodiment according to the present invention for rotating the plane of polarization by 90° while allowing the light beam to proceed on in the same direction and undisplaced is shown as optical assembly 200 in FIG. 8. Optical assembly 200 is comprised of optical subassembly 210 and beam redirection assembly 120.
As shown in FIG. 9, optical subassembly 210 is comprised of prism 20 and right-angle isosceles prisms 220 and 230. Prisms 220 and 230 are optically attached to side 26 of prism 20 so that apex 224 of prism 220 shares an edge with end 32 of prism 20 and apex 234 of prism 230 shares an edge with end 34 of prism 20. Thus, prisms 220 and 230 each have a length b (equal to the width of side 26 of prism 20) and have sides 228 and 238, respectively, having widths of a/2 (equal to half the length of side 26 of prism 20).
Beam redirection assembly 120 is shown in FIG. 4. Assembly 120 is optically attached to optical subassembly 210 as shown in FIGS. 8 and 10. In order to minimize disruptions caused by air-optical element interfaces between base 132 of prism 130 and side 26 of prism 20, it is recommended that a cube 250 be provided between side 26 of prism 20 and that portion (usually half) of base 132 of prism 130 which is not occupied by rhomboid 150. Thus, cube 250 has dimensions of one-half of the width of prism 130 as shown in FIGS. 8 and 10. A portion of rhomboid 150 is in contact with cube 250, although this fact is of no significance to the function of beam redirection assembly 120.
Beam redirecting assembly 120 and cube 250 should be positioned on optical subassembly 210 such that V-portion 260 formed by the faces of cube 250 and rhomboid 150 is vertically displaced from an oriented at the same angle (45° with respect to faces 32 and 226) as the V-portion 206 formed by bases 222 and 232 of prisms 220 and 230, respectively.
The manner in which assembly 200 can be used to rotate the polarization of an incident light beam by 90° while allowing the light beam to proceed on in the same direction and undisplaced will now be described with reference to a light Ray D, as shown in FIG. 10. Ray D enters prism 220 normal to the surface of side 226. It undergoes one reflection at base 222 of prism 220 and then enters prism 20. It reflects from base 22 of prism 20 and then enters beam redirection assembly 120. Ray D has a polarization field with vertical component V"' and horizontal component H"'. As a result of these two reflections, V"' is rotated to point left and H"' is rotated to point downwards, V"' first undergoes a p-polarized reflection, then an s-polarized reflection, while H"' undergoes first an s-polarized reflection, then a p-polarized reflection.
As discussed previously for beam redirection assembly 120, V"' is rotated to point downwards while H"' is rotated to point to the left. The number of s- and p-polarized reflections is balanced for both V"' and H"' in assembly 120. Ray D then exits assembly 120 and re-enters prism 20 of subassembly 210. It undergoes two more reflections at base 22 of prism 20 and at base 232 of prism 230 and exits prism 230 normal to side 236. For these two reflections, V"' is rotated to point left and H"' is rotated to point down. Both polarization components undergo one p-polarized reflection and one s-polarized reflection.
When ray D exits prism assembly 210, both V"' and H"' have been rotated in the same direction by 90° and they have both undergone an equal number of sand p-polarized reflections. Therefore, any entering polarization field will be rotated by 90° and will remain linearly polarized.
In an alternative embodiment, subassemblies 120 and 210 could be arranged as shown in FIG. 11. The performance of this embodiment would be similar to that described with respect to FIG. 10. | An achromatic polarization-rotating right-angle prism system for rotating the plane of polarization of an electric field, E, by 90° while maintaining strict linear polarization at all wavelengths. The direction of travel of the beam may be altered by 90° or the beam may continue on in the same direction and along the same line of travel. One embodiment includes two pairs of right-angle isosceles prisms. The horizontal, H, and vertical components, V, of E each undergo an equal number of s- and p-polarized reflections. | 6 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to the field of golf and, more particularly, to golf club heads.
[0002] Each club must enable a player to impart to the ball a long, precise trajectory. The distance traveled by the ball increases as the dynamic loft of the club head becomes greater, and trajectory accuracy improves as a function of head stability at the moment of impact on the ball. For this reason, manufacturers seek to improve the mechanical inertia of the heads.
[0003] Traditionally, golf club heads possessed homogeneous density; that is, they were made of solid wood or metal. These heads were difficult to use because of their low mechanical inertia. When a stroke was poorly aligned, the ball traveled substantially off-line.
[0004] Next appeared hollow heads made of metal or composite materials. These heads provided greater mechanical inertia for a given weight, thereby improving the golfers' performance.
[0005] However, despite the various prior art solutions to achieve optimal distribution of the weight of the head, many golfers still had difficulty hitting their shots properly.
[0006] Current heads do not make it possible to obtain ball trajectories that are simultaneously long and precise. In other words, present-day heads do not incorporate weight distribution capable of providing at the same time good dynamic loft and good stability upon impact.
SUMMARY OF THE INVENTION
[0007] The invention attempts to solve these problems by proposing a golf club head whose volume is delimited by the upper face, or crown, and a lower face, or sole plate, separated by a belt and a front, or hitting, surface, junction points of the belt and the hitting surface delimiting a heel and a toe.
[0008] According to the invention, the belt comprises at least one arc-shaped portion constituting a visible layer of the belt while extending along the belt between the heel and the toe, the arc-shaped portion being a peripheral mass made of a high-density material.
[0009] This structure makes it possible to increase maximally the mechanical inertia of the head as regards dynamic loft and stability upon impact. It follows, advantageously, that ball trajectories are both long and accurate.
[0010] According to a first embodiment, the head according to the invention comprises a single arc-shaped portion which is continuous along the belt from the heel to the toe. This structure facilitates manufacture and allows use of new, economical processes.
[0011] According to a first variant of the first embodiment, the head according to the invention comprises at least three parts, i.e., a first, upper part incorporating the crown, the hitting surface, and an upper portion of the belt; a lower part including the sole-plate and a lower portion of the belt; and an intermediate part constituted by the arc-shaped portion. This structure allows the use of materials of different kinds.
[0012] According to this first variant, the upper part, the lower part, and the intermediate part of the head are screwed together into one assembly.
[0013] This assembly method facilitates the attachment and detachment of the head. It advantageously allows adjustment and maintenance of the head.
[0014] According to a second variant of the first embodiment, the head comprises two parts, i.e., the arc-shaped portion and a block incorporating at least the crown, the belt, the sole-plate, and the hitting surface.
[0015] In this instance, it is easy to manufacture an impermeable block that can advantageously prevent the risks of dirt accumulation and heaviness of the head.
[0016] According to this second variant, the arc-shaped portion of the head is made of a metallic copper alloy, and the block is made of a titanium-based metal alloy. This arrangement makes it possible to optimize weight distribution and the inertial properties of the head, without impairing the impact-resistance thereof.
[0017] According to the second variant, the arc-shaped portion and the block are welded together. This structure produces a more pleasant sound on impact and, consequently, allows the golfer to remain focused.
[0018] According to the first and second variants of the first embodiment of the invention, the total weight of the head is between 185 and 205 grams, the weight of the arc-shaped portion is between 40 and 60 grams, and the volume of the head is between 250 and 270 cm 3 .
[0019] These parameters impart to the head the size which is most reassuring to golfers, since it is neither too small nor too large and thus instills confidence in them.
[0020] According to a second embodiment, the head according to the invention comprises two arc-shaped portions. In this case, when considered together, the arc-shaped portions extend over at least 60% of the length of the belt, between the heel and the toe. This arrangement makes it possible to adjust weight distribution specifically for an individual golfer.
[0021] According to this second embodiment, the head comprises at least three parts, i.e., the two arc-shaped portions and a block incorporating at least the crown, the belt, the sole-plate, and the hitting surface. This structure allows selection of at least two different materials for manufacture of the head. Furthermore, the two arc-shaped portions may possess different densities. Accordingly, weight distribution specific to an individual golfer is further refined.
[0022] According to the second embodiment, the arc-shaped portions of the head are made of a metallic copper alloy and the block is made of a titanium-based metal alloy. In this case, the arc-shaped portions and the block are welded together, the total weight of the head is between 185 and 205 grams, the weight of each arc-shaped portion is between 16 and 34 grams, and the volume of the head is between 250 and 270 cm 3 .
[0023] The structure disclosed by the second embodiment allows weight to be balanced in a manner suited to the game of an amateur player.
[0024] The invention also relates to a process for producing a head possessing the characteristics previously mentioned.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Other features and advantages of the invention will be better understood from the following description provided with reference to the attached drawings illustrating, by means of examples, how the invention can be produced, and in which:
[0026] [0026]FIG. 1 is a perspective view of a head according to a first variant of a first embodiment of the invention;
[0027] [0027]FIG. 2 is a perspective view from another angle of the head in FIG. 1;
[0028] [0028]FIG. 3 shows a method for assembly of the head in FIGS. 1 and 2;
[0029] [0029]FIG. 4 is a second variant of the first embodiment;
[0030] [0030]FIG. 5 is a view similar to FIG. 4; and
[0031] [0031]FIG. 6 is a perspective view of a head according to a second embodiment of the invention.
DETAILED DESCRIPTION
[0032] According to a first variant of a first embodiment, a head 1 according to the invention is illustrated in perspective in FIG. 1 , from an angle making it possible to distinguish a front, or hitting, surface 2 , and upper face, or crown, 3 , a belt 4 , and a hosel 5 . The belt 4 in turn comprises an upper portion 6 and a lower portion 7 separated by a strip 8 whose function will be explained below. Two ends of the hitting surface 2 form a heel 9 and a toe 10 at the spot where they connect with the belt 4 .
[0033] A view of the head 1 from another angle as illustrated in FIG. 2 shows that a lower face, or sole-plate 11 , is attached to the belt 4 . The entire group of faces, including the hitting surface 2 , the crown 3 , the belt 4 , and the sole-plate 11 , form the jacket of a head 1 , in this case the head of a metal-wood.
[0034] The head 1 is made of three main elements, as illustrated in an exploded view in FIG. 3:
[0035] a first, or upper, part 12 formed by the combination of the crown 3 , the hitting surface 2 , the hosel 5 , and the upper portion 6 of the belt 4 ;
[0036] a second, or lower part 13 formed by the combination of the sole-plate 11 and the lower portion 7 of the center strip 4 ;
[0037] an intermediate part formed by the peripheral strip 8 .
[0038] The upper part 12 is preferably produced using casting techniques and a metal which may have a low density. For example, it is possible to use a titanium- or aluminum-based alloy. A steel could prove suitable, however, if the thickness of the faces is sufficiently thin, the goal being to produce a part 12 which is light in relation to the weight of the head 1 .
[0039] The upper part 12 comprises means for connecting and positioning the peripheral strip 8 , which take the form, for example, of a peripheral edge 14 of the upper portion 6 and eyes 15 , 16 , 17 , 18 in the upper part 12 , which are spaced along the peripheral edge 14 .
[0040] The peripheral edge 14 may be produced directly by casting, or it may be machined. It functions as a surface supporting the peripheral strip 8 , which serves as a weight extending along the peripheral edge 14 , substantially from the heel 9 to the toe 10 .
[0041] The peripheral strip, or weight, 8 preferably has a shape matching that of the peripheral edge 14 and of the eyes 15 , 16 , 17 , 18 . To this end, it comprises an arch 19 and projections 20 , 21 , 22 , 23 .
[0042] The weight 8 acts to add weight to the head 1 at the spot where it is located, i.e., substantially on the sides and to the rear of the head 1 , but not on the front portion.
[0043] It is preferably made of a high-density material, e.g., an alloy containing copper, tin, or other metal. A steel weight 8 may be suitable if it has sufficient thickness.
[0044] The lower part 13 is preferably supported both on the weight 8 and on an inner side 24 of the hitting surface 2 , so as to complete the jacket of the head 1 . It is preferably made of a metal, in order to be both light and wear-resistant. In fact, it is the weight 8 which must govern the dynamic performance of the head 1 , while the sole-plate 11 must resist friction on the ground.
[0045] Assembly means, for example screws 25 , 26 , 27 , 28 , are provided to hold together the upper part 12 , the weight 8 , and the lower part 13 .
[0046] The screws 25 , 26 , 27 , 28 extend simultaneously through the holes in the lower portion 7 of the belt 4 and through the holes in the projections 20 , 21 , 22 , 23 belonging to the weight 8 , before being housed in the eyes 15 , 16 , 17 , 18 in the upper portion 12 . Thus, when the screws 25 , 26 , 27 , 28 are tightened, the head 1 is assembled and ready for use.
[0047] The structure of the head 1 makes it possible to position the weight 8 with great precision, in order to impart to the head 1 good mechanical properties. In fact, the lateral portions of the weight 8 adjoining the heel 9 and the toe 10 create a stabilizing effect during rotation of the head 1 in relation to a vertical axis at the moment of impact on a ball. As a result, ball trajectories are more accurate.
[0048] The rear portion of the weight 8 allows the head 1 to pivot around a substantially horizontal axis, by virtue of an inertial phenomenon called dynamic loft. This phenomenon occurs as a result of club shaft flection during the swing and helps accentuate the original angle of inclination of the hitting surface 2 . As a result, the balls climb higher into the air and travel farther.
[0049] Surprisingly, the continuous extension of the weight 8 along the belt 4 makes it possible to combine the effect of stabilization during rotation and the dynamic loft phenomenon in order to achieve optimal effectiveness.
[0050] The head 1 is thus advantageously accurate and capable of producing long strokes.
[0051] Moreover, this structure facilitates manufacture enormously as compared with traditional methods. In fact, it is not necessary to use complex cored molds comprising multiple parts, nor is it necessary to carry out welding, sanding, or heat treatment operations. Production costs and time are thus advantageously reduced.
[0052] The head 1 produced is a hollow volume that can be filled with a light material capable of damping vibrations generated by impacts with the ball. As one example, a plastic foam is highly effective.
[0053] The head 1 may be produced in accordance with other variants, such as that illustrated in FIG. 4.
[0054] For reasons of convenience, identical references are used to designate the same components.
[0055] The head 1 according to this variant comprises a block formed by assembling the hitting surface 2 , the crown 3 , the sole-plate 11 , the belt 4 , and the hosel 5 . A recess 36 in the belt 4 and extending along the belt 4 substantially from the heel 9 to the toe 10 is provided to house an arc-shaped portion 32 made of a high-density material, the other parts of the head 1 being made of a material possessing lower density. For example, the portion 32 is made of a copper-based metal alloy, while the rest of the head 1 is made of a titanium-based metal alloy. The arc-shaped portion 32 is assembled with the block of the head 1 and is positioned in the recess 36 , preferably in such a way that the volume of the recess 36 is entirely filled by the arc-shaped portion 32 . As a result, the volume of the head 1 remains unchanged despite the presence of the arc-shaped portion 32 . Any means of attaching the block and the arc-shaped portion 32 can be used. For example, the portion 32 can be welded to the block, with or without adding material in the form, for example, of a brazed seam, an electric spot weld, etc.
[0056] The two elements can also be-glued, screwed together, riveted, etc.
[0057] Another variant of the head 1 according to this embodiment is illustrated in FIG. 5. It differs from the variant in FIG. 4 only by virtue of the fact that the shape of the arc-shaped portion and the housing recess do not have uniform width. The arc-shaped portion 33 incorporates three extensions 29 , 30 , 31 located respectively on the toe 10 side, to the rear, and on the heel 9 side. These extensions 29 , 30 , 31 of the arc-shaped portion 33 further improve the dynamic performance of the head 1 while increasing its total weight, but without exceeding the values which would make the golf swing difficult to perform.
[0058] Moreover, by virtue of their shape, these extensions 29 , 30 , 31 combine with the sole-plate 11 to facilitate the movement of the head 1 in the grass or in gravel. In fact, the shape of the sole-plate 11 corresponds to the areas of heaviest friction and wear. Now, the harder material used to manufacture the sole-plate 11 is relatively expensive. Consequently, savings are achieved by combining the extensions 29 , 30 , 31 of the arc-shaped portion 33 with the shape of the sole-plate 11 .
[0059] [0059]FIG. 6 illustrates a second embodiment of a head 1 according to the invention. This head 1 comprises two arc-shaped portions 34 , 35 intended to be made integral with a block incorporating, in particular, the hitting surface 2 , the sole-plate 11 , the crown 3 , the peripheral strip 4 , and the hosel 5 . In this instance, the arc-shaped portions 34 , 35 partially fill cavities 37 , 38 in the head 1 and are attached to the head 1 , as was previously described.
[0060] The cavities 37 , 38 are open, but do not prevent the block from retaining a volume substantially identical to that of the variants of the previous embodiment.
[0061] On the other hand, the shape of the arc-shaped portions 34 , 35 of the cavities 37 , 38 and of the sole-plate 11 are combined so as to ensure simultaneously good dynamic equilibrium of the head 1 and the enhanced capacity to describe a line tangent to the ground during the swing.
[0062] In all of the variants and according to all of the embodiments of the invention, the head is distinguished from all other existing club heads on the market by the fact that, for a given volume, inertial properties are enhanced, since they are greater in magnitude.
[0063] Knowing that the golf market requires wood-type heads having a volume of approximately 260 cm 3 , the invention can be compared to existing heads using the table below, in which:
[0064] each volume is given in cm 3 ,
[0065] 13 is the mechanical inertia of the head in relation to a vertical axis passing through the center of gravity when the head 1 is in the ball-address position, in g/mm 2 ,
[0066] weights are expressed in grams.
VOLUME 13 WEIGHT steel head currently sold 220 280 185-205 titanium head currently sold 260 290 to 310 185-205 head according to the 260 310 to 340 185-205 invention
[0067] Preferably, the arc-shaped portion 8 , 32 , 33 weighs approximately 50 grams and is between 40 and 60 grams. The arc-shaped portions 34 , 35 preferably weigh between 16 and 34 grams.
[0068] Furthermore, this type of construction can be used for all of the heads in a set of clubs. | A golf club head ( 1 ) whose volume is delimited by a crown ( 3 ), a sole-plate ( 11 ), a belt ( 4 ), and a hitting surface ( 2 ), junctions between the belt ( 4 ) and the hitting surface ( 2 ) delimiting a heel ( 9 ) and a toe ( 10 ). The belt ( 4 ) comprises at least one arc-shaped portion ( 8, 32, 33, 34, 35 ) which forms a visible layer of the belt ( 4 ), while extending along the belt ( 4 ) between the heel ( 9 ) and the tip ( 10 ), the arc-shaped portion ( 8, 32, 33, 34, 35 ) being a peripheral weight made of a high-density material. | 0 |
BACKGROUND OF THE INVENTION
In respirator treatment, a patient is connected to a respirator, which aids the patient in breathing. The respirator typically comprise a means of mixing and forming a breathing gas having a predetermined ratio of one or more gases, the pressurized sources for which are connected to the respirator. The gas mixture has to contain a sufficient amount of oxygen. For this reason, one of the gases is always O 2 , or alternatively, in the most simplified one gas source devices, is air. The other gas or gases to be mixed with O 2 comprise most typically air, N 2 O, and sometimes also He or Xe.
To perform the mixing function, each of the gas flow paths has a regulating means, typically a valve, to regulate the gas flow. In current state of the art, these regulating means are driven by a microprocessor control unit according to the information the control unit receives from various pressure, flow, and/or position sensors to regulate to predetermined control parameter values.
The control parameters include a plurality of various criteria defining the respiration pattern. These parameters are e.g. inspiration and expiration times, respiration rate, tidal volume (the volume of one breath), inspiratory flow, inspiration pressure, and positive end expiratory pressure. Modern respirator treatment encourages the patient to breathe by himself. State of the art respirators are thus equipped to both support the spontaneous breath trials by the patient and to provide pressure to assist or carry out breathing when necessary.
The patient is connected to the respirator through a breathing circuit comprising an inspiratory limb, expiratory limb, and a patient limb terminating in an endotracheal tube or breathing mask. These elements are connected together at a Y-piece connector. The inspiratory limb is connected to the respirator at the outlet for the breathing gas mixture and to the inlet of the Y-piece connector. The expiratory limb is connected to the outlet of the Y-piece connector and to a expiration valve, normally also included in the respirator. The patient is connected to the breathing circuit through the patient limb to the endotracheal tube or breathing mask.
When the patient is inspiring, the expiration valve is closed. The breathing gas is supplied with overpressure through the inspiratory limb to endotracheal tube or breathing mask and further to the lungs of the patient. During expiration, an inspiratory valve also included in the respirator is closed, and the expiration valve is opened, releasing the pressure within the lungs. This relief is based on the tension and elasticity of the lungs.
Tidal volumes range from a few tens of milliliters for the smallest babies to more than one liter for adults. The respiration rates also vary from tens/minute down to a few/minute. Typical breathing gas flow rates extend from the level of one liter/min up to 10 liters/min, but may even exceed these. The volume of breathing gas is delivered during the inspiration phase, representing typically one third of the respiration cycle. Thus the peak inspiratory flow may easily exceed 30 liters/min and reach momentarily 100 liters/min in inspiratory regulation based on a preset inspiration pressure.
During respirator treatment, for diagnostic and therapeutic purposes, a need for completing the breathing gas with a special gas exists. Typical special gases are nitric oxide (NO) for improvement of lung perfusion and thus patient O 2 uptake raising the blood oxygen saturation, SF 6 (sulfur hexa fluoride) for measuring the lung functional residual volume (FRC) and nitrous oxide (N 2 O) for measuring the lung capillary blood flow. The gases may even be combined into a single gas reservoir for multiple action behavior as shown e.g. in EP 640357.
A special problem arises from the supply of, or dosing, NO due to the extremely small amounts of gas to be regulated. The usual levels start from 0.1 ppm (part per million) up to some tens of ppm. To facilitate the regulation, the NO gas is diluted to a ratio about 100 ppm-1000 ppm in N 2 in the pressure container from which the gas is delivered. Another problem is the reactivity of the NO. Together with O 2 an extremely toxic end product, nitrogen dioxide (NO 2 ), will be produced from the NO. To minimize this production, it is advantageous to design the delivery system to minimize the exposure time the NO and O 2 have to react with each other.
A further requirement for an advantageous form of the delivery system comes from user ergonomy. The personnel taking care of the patient often work near the mouth of the patient and with the above described breathing circuit. The less additional equipment required in this area, the better the equipment will be from the ergonometric standpoint.
State of the art technology includes various delivery systems to deliver the special gas in preset amounts through the breathing circuitry to the patient. The delivery systems are fitted with the respiratory breath circuitry. The delivery system may operate either continuously or synchronously with inspiration. EP 640356 presents a continuous flow delivery system for spontaneously breathing patients. In this system the special gas is mixed with the breathing gas in the gas mixer. The breathing circuit is modified with a connecting tube. Both the inspiratory and expiratory limbs are connected to this connecting tube. Thus, the patient inhales the gas through the inspiratory limb from the connecting tube and exhales through the expiratory limb to the connection tube. The mixer delivers a continuous flow of breathing gas with an added, predetermined concentration of the special gas, to the connecting tube. In the delivery system, the continuous flow is set to 20 liters/min to fulfill peak flow requirements. Even larger peak flows are possible as the backflow from the connecting tube. The relatively high flow rate is used to minimize the reaction time of NO and O 2 and to minimize the risk of rebreathing the gas the patient has already expired through the connecting tube. The arrangement solves the forementioned problems of the NO delivery, but due to the high flow, this arrangement causes a very large loss of breathing gas and NO. Particularly, the NO may be very expensive causing also economic losses. Due to the toxicity of NO and the end product NO 2 , an evacuation system is a prerequisite for safe operation. Further, this arrangement does not solve the delivery problems with patients requiring breathing aid from respirator.
A delivery system in connection with a respirator is shown in EP 640357. The system described is for delivery of special gas, which in this case is a mixture of NO, a tracer gas, and diluent gas, in constant concentration, through the breathing circuit into lungs. The special gas is delivered into the breathing circuit via a connecting tube. The delivery system is feedback controlled through a tracer gas measured from the expiratory end of the respirator. As the delivery system is controlled by the ventilator, although not so described, one can, thus, conclude that the special gas delivery is pulsatile in nature and synchronous with inspiration flow variations. To minimize the risk for NO 2 formation, it is presented as advantageous to lead the special gas mixture connecting tube as close to the patient lungs as possible, even through the endotracheal tube to inside the lungs.
However, the problem of small flows of the special gas remains and is even emphasized. Firstly, the longer the connection tube is, the longer time it will take before the special gas will reach the patient end of the tube when starting the system. An example of a small delivery could be as follows. A 0.5 ppm NO concentration from 1000 ppm source, in a tidal volume of 50 ml is to be delivered in one second. This requires a pulse volume of 0.025 ml. For a connecting tube having diameter 1 mm, this volume will occupy 3 cm in the tube. Secondly, and even worse, during inspiration, when the special gas should be delivered, the pressure within the breathing circuit will increase. The increasing pressure will cause gas compression in the connecting tube preventing the small special gas flow into lungs. During expiration the pressure is relieved and the compressed special gas flows out from the connecting tube directly into the expiration flow and the required therapeutic effect is not achieved. Both of these problems are made worse the smaller the special gas flow is and the longer the connecting tube is. Thirdly, the closer the connection tube or the second gas mixer is to the patient, the worse the solution becomes ergonomically. In another embodiment of EP 640357, the special gas is mixed within the respirator. The NO 2 formation may however be increased due to the prolonged reaction time between the special gas and the breathing gas described in an article written by R. Kuhlen et al. entitled "Nitrogen dioxide (NO 2 ) production for different doses of inhaled nitric oxide (NO) during mechanical ventilation with different tidal volumes using the prototypes for the administration of NO. " The harmful composites may however be removed from the breathing gas immediately before inhalation by scrubbers as presented in U.S. Pat. No. 5,485,827. Also, some wastage of special gas takes place, since all the breathing gas leaving the respirator does not reach the lungs. Thus the arrangement causes a need for evacuation of the gas exhaled from the respirator. From the point of view of ergonometry, this embodiment is advantageous since no additional equipment near the patient is required. However, the possible need of scrubbers will impair the ergonomy.
U.S. Pat. No. 5,423,313 describes a special gas delivery arrangement to be used in connection with respiratory treatment apparatus comprising similar elements to that of EP 640357. This arrangement differs from EP 640357 from the point of view of the control. Whereas EP 640357 targets for constant concentration of the special gas in the inspired mixture, the system described in U.S. Pat No. 5,423,313 delivers the special gas in pulses independently of the respiratory breath cycle. An advantageous pulse frequency is defined to be 53 Hz. It is claimed that with the high frequency pulses, more even gas distribution is reached in the lungs due to diffusion. However, the high frequency pulses do not change the fact that the total special gas flow range may be very low, and as such, the problems listed for EP 640357 also exist here.
A further NO delivery system is presented in EP 659445. This document also describes an arrangement designed for delivering a constant NO concentration into the inspired breathing gas. It is characteristic of this arrangement that the device can be used with respirator treatment but is not bound to that. A breathing gas flow sensor is included in the equipment. From this sensor, the control unit receives data to regulate the NO gas flow to maintain the required breathing gas concentration. The NO gas is derived from an NO/N 2 mixture gas reservoir containing 1000 ppm NO. In the event such a low concentration of NO is required that the system is otherwise unable to reduce the concentration to the desired point, a further equipment in the form of an N 2 pressure source, regulating valve, and NO concentration analyzer are provided to further dilute the NO mixture concentration, thus adding gas volume to the NO mixture flow to be regulated. The increasing flow decreases also the described problems caused by the ventilatory pressure variations and the outlet channel volume filling, but does not eliminate same.
BRIEF SUMMARY OF THE PRESENT INVENTION
The object of the present invention is to provide apparatus for mixing a special gas with breathing gas. This special gas may be a therapeutic gas, such as NO supplied in predetermined mixture with N 2 , or diagnostic gas, such as SF 6 (sulphur hexa fluoride) or N 2 O.
Another object of the present invention is to provide an apparatus for mixing special gas with breathing gas optimizing usage of the special gas to minimize the special gas consumption and to reduce the environmental contamination either with the special gas or in connection with its reaction products with other gases.
A further object of the invention is the provision of an apparatus for mixing special gas with breathing gas that makes the interaction time between the special gas and the breathing gas before it is inhaled by the patient as short as possible.
Yet another object of the invention is the provision of an apparatus for mixing even the smallest required amounts of special gas with breathing gas even under the worst case breathing circuit pressure variations.
The apparatus of the invention is also designed to be ergonomic in use. To reach this objective, the equipment in the central working area near the patient mouth or throat is minimized.
The desired effects of the special gas mixed with the breathing gas take place in definitive gas dependent areas in the lungs. According to the invention, to optimize the usage of the special gas, the special gas is mixed with the breathing gas at the point in time when the breathing gas flowing to the target area of the lungs passes a special gas delivery point in the apparatus. As an example, the NO diffusion from the lungs into the pulmonary capillary circulation takes place in the alveoli, the deepest section of the lungs. Therefore, the NO mixture is advantageously delivered into the breathing gas inspiratory flow as near the lungs and as rapidly as possible just as the inspiration starts or at the end of expiration.
It is known that the NO is absorbed into the lung tissue and pulmonary circulation very rapidly, and thus will not remain in the breathing gas to react with oxygen. Environmental contamination is also reduced or even eliminated. Mixing the NO with the breathing gas as near the lungs as possible will also minimize the reaction time with the breathing gas oxygen before the NO is absorbed.
The problem arising from the pressure variations in the breathing circuit and small doses of the special gas to be mixed with the breathing gas is solved in the invention by positioning a special gas dosing valve, separating the high pressure (advantageously 0.9-2 bar above ambient pressure) special gas channel, from the breathing circuit pressure, to discharge the gas directly into the breathing circuit without any intermediate volume to be filled with the special gas or to be compressed with the breathing circuit pressure variations.
The working environment around the Y-piece of the breathing circuit, specially between the Y-piece and patient mouth or throat is often very crowded. The patient is often suctioned periodically through the endotracheal tube either through an openable opening provided in the patient limb or simply by detaching the endotracheal tube from the breathing circuit. The patient is also moved, or even moves by himself. The breathing circuit must follow these movements. Thus the weight and amount of equipment on this moveable area should be minimized.
The present invention meets these requirements in an apparatus mixing the special gas with breathing gas. The device doses a user defined volume of special gas synchronously with the patient inhalation flow, the synchronization also being defined by the user. A special gas dosing valve discharges the dose directly into the breathing circuit section essentially at the breathing circuit pressure. The dosing equipment is located at a distance from the patient, advantageously within or near the respirator or the breathing gas source, not to disturb the crowded working environment. The small volume dose of the special gas is dosed to a carrier gas outlet conduit of small diameter, advantageously 0.5-2 mm, located in parallel with the inspiratory conduit. This carrier gas outlet conduit extends from a carrier gas source to the point where the special gas is to be mixed with the breathing gas, advantageously between the breathing circuit Y-piece and patient lungs. Within the carrier gas outlet conduit there is a high speed, though small volume, gas flow. While dosing the special gas into this conduit, the dose is rapidly carried by the carrier gas flow to the breathing gas mixing point. As an example, with a carrier gas outlet conduit of one meter from the dosing point to the mixing point and one millimeter in diameter, a carrier gas flow of 0.5 liter/min will flush the special gas dose into the mixing point in 100 ms, a time frame which is very acceptable in comparison with the total inhalation times, starting most typically from one second up to a couple of seconds. The magnitude of the carrier gas flow is not critical and measuring the flow in the delivery point of view is not essential. Although it may be an advantage in the safety point of view to monitor the carrier gas flow for proper flushing of the special gas. The carrier gas flow is advantageously started at the end of the special gas dosing or simultaneously with the special gas dosing. In the case where reaction between the carrier gas and the special gas may take place, the reaction time is minimized when the special gas and the carrier gas are transported as successive bolus in the carrier gas outlet conduit. The carrier gas flow lasts, in time, advantageously at least the dose flow time through the carrier gas outlet conduit beyond the end of the special gas dose to guarantee the mixing of the whole special gas dose with the breathing gas. The carrier gas flow can be continuous, if desired.
The carrier gas source can be a pressure source, e.g. air or O 2 . It must be kept in mind, however, that with the smallest tidal volumes, even this smallest carrier gas flow can adversely affect the inhaled gas composition. Further, an additional pressurized source is required.
Advantageously, the carrier gas should have the same composition as the breathing gas to be inhaled. This can be accomplished with a respirator having an additional outlet for breathing gas at elevated pressure by using the additional outlet as the carrier gas flow supply. A more general solution may be achieved when the special gas dosing unit itself includes a carrier gas source in a form of a pump suctioning breathing gas from the inspiratory limb of the breathing circuit and discharging into the carrier gas line. Pumping the breathing gas as the carrier gas with high speed from the inspiratory limb to the patient limb does not affect the breathing gas composition, inhalation tidal volume (because the breathing circuit volume does not change), or inhalation pressure. The only additional equipments needed in the breathing circuit are the carrier gas suctioning connection and the carrier gas line end connection. The first of these can be located in the respirator end of the inspiratory limb. Thus, the only equipment in the working area are the carrier gas outlet conduit end connection and the carrier gas outlet conduit itself. The carrier gas outlet conduit is advantageously on the order of 2 mm outside diameter and the short time the special gas is located within the tubing expands the selection of useable materials. The small and flexible carrier gas outlet conduit is easy to handle and integrating it and its connector with the breathing circuit is ordinary state of the art technology widely utilized already in different kinds of monitoring equipment. The arrangement increases also the reliability of the special gas dosing unit since no sensitive equipment or high concentration-high pressure special gas tubings are located in the working area and thus liable to damage.
In another embodiment of the invention the carrier gas flow can be suctioned during expiration through the same carrier gas outlet conduit through which it is discharged during inspiration. In this case, however, the inspiratory breath volume will be affected due to the changing breathing circuit volume and if the carrier gas outlet conduit is discharging into the patient limb, an increased dead space will take place. Also, the risk of NO 2 formation is increased in the case the absorption of NO is not perfect. Alternatively, the carrier gas outlet conduit could discharge into the inspiratory limb, but this will increase the delivery delay for the increased volume from the discharge point to lungs.
Various other features, objects, and advantages of the invention will be made apparent from the following detailed description and the drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a schematic view showing an apparatus of the invention; and
FIG. 2 is a schematic view showing an alternative apparatus of the invention.
DETAILED DESCRIPTION OF THE INVENTION
In a first embodiment shown in FIG. 1, the respirator 1 is a conventional respirator used to ventilate patient lungs by simulating the spontaneous breath volumes and frequencies. The respirator technology is well known to the extent required herein and will not be described in detail.
The breathing circuit 2 comprises inspiratory limb 3, Y-piece connector 4, expiratory limb 5, and patient limb 6. The inspiratory limb 3 extends from respirator inspiration outlet to Y-piece connector 4 and includes a suction point 12 for the carrier gas flow. The expiratory limb 5 connects the Y-piece connector 4 with the respirator expiration inlet. Included in patient limb 6 are optional flow measuring element 7, carrier gas discharge point 8, and endotracheal tube 9 or a breathing mask forming a conduit from the Y-piece into patient airways 10 and further into lungs 11 of the patient. The breathing circuit may contain also other components for monitoring and therapeutic purposes, such as a humidifier or a filter, depending on the needs of the patient.
The special gas dosing unit 13 is shown separated from the respirator 1, but the two elements could be integrated together if desired. In that case, the control unit of the special gas dosing unit could be the same as that for the respirator control unit. The dosing unit 13 includes an inlet line 14 for the special gas. This conduit connects the high pressure special gas source 15 with a pressure regulator 16. The outlet pressure of pressure regulator 16 is regulated advantageously to at least to 0.9 bar. To monitor the existence and amount of this pressure, a pressure sensor 17 is coupled to the regulated pressure line. The pressure regulator 16 could just as well be located in connection with the special gas as source 15. Pressure regulator 16 is connected to flow measuring unit 18 by flow conduit 19. As shown in FIG. 1, the flow sensing is doubled by connecting two flow sensors in series. This is for supervision purposes, which supervision could also be arranged with some other means. The flow measuring unit 18 discharges the flow into a first valve 20 and further to a dosing valve 21. The dosing valve discharges the special gas into the carrier gas outlet conduit 22 reaching from the carrier gas source 23 to the carrier gas discharge point 8. The discharge of the special gas into the carrier gas takes place at the special gas dosing point 24.
In FIG. 1 there is presented an embodiment of the invention where the carrier gas source 23 is sucking carrier gas flow from the inspiratory limb 3 through suction line 25.
The control unit 26 of the special gas dosing unit 13 is connected with the breathing gas flow sensor 7 located in patient limb 6. As well, the control unit is connected to the sensors 18a and 18b, the valves 20 and 21, and the carrier gas source 23. A further connection of the control unit 26 is with the control panel 27. This control panel is used for providing preset dose related parameters to control unit 26 and optionally also for presenting information on the operation of the special gas dosing unit. In view of the possibility of different kinds of special gases to be delivered, containers for these gases should advantageously be automatically identified. This identification can be e.g. pin code, bar code, magnetic pin indexing, magnetic or electrical memory elements or even gas composition measurement. This identification information from the special gas source 15 to the control unit 26 is transmitted through identification signal line 28.
A flow sensor 29 and a check valve 30 is positioned between carrier gas source 23 and special gas dosing point 24. Flow sensor 29 is used to monitor the carrier gas flow. Although the exact magnitude of this flow is not essential for the operation of the device, for safety reasons it may be essential to guarantee delivery of carrier gas to the patient by monitoring its flow. Check valve 30 controls the direction of carrier gas flow.
The operation of the special gas dosing unit 13 of the present invention will now be described in detail. As the dosing of special gas takes place into the inhaled breathing gas, the control unit 13 is informed of the breathing cycle. This information is transmitted from the breathing gas flow sensor 7 but could as well be derived from the respirator. By having an independent flow sensor, a more universal dosing unit is achieved and the dosing system can be used even with spontaneously breathing patients. The flow sensor could also be located within the inspiratory limb 3.
Through control panel 27 the user can define the special gas dosing related parameters, such as the starting point related to the breath cycle, the end point, or alternatively the duration of the dose, the periodicity in relation to breaths, the dose volume to be delivered per inhalation, or alternatively the special gas concentration in the inspired gas. From the information the control unit 26 obtains from flow sensor 7 and control panel 27, it calculates the desired special gas pulse parameters such as the flow during the pulse, opens the control valve 21 to deliver the pulse, and monitors the delivered pulse volume with the flow sensor 18. Synchronously, with the dose delivery as described above, the special gas control unit also activates the carrier gas source 23 to create the carrier gas flow, unless the carrier gas flow is continuous. This flow may be monitored for safety reasons by flow sensor 29. If the carrier gas flow is not detected, an alarm is given. A check valve 30 is added to direct the special gas dose flow in the correct direction in the case where the carrier gas flow is started after the special gas pulse. This check valve 30 may also be an integral part of the carrier gas source 23. The control valve 21 is advantageously a proportional valve, but alternatively a digitally controlled valve could be used. In the latter case, however, the fact that the flow through the valve may be constant must be considered in controlling its operation.
The valve 20 is a safety backup for the control valve 21. If the flow sensor 18 detects special gas doses in excess of the required dose, the flow can be shut off by the valve 20. Valve 20 may be an ordinary solenoid valve.
The flow sensor 18 is advantageously located at the special gas flow conduit 19 and as near the control valve 21 as possible. Positioning the flow sensor downstream of the control valve 21 would violate the discharge from the control valve 21 directly into the carrier gas line and further, the carrier gas line being essentially at the breathing circuit pressure, the variations in this pressure would cause reciprocating flow through the flow sensor. In the regulated pressure line, the sensor location near the control valve 21 shortens the pneumatic response time from the control valve operation to flow detection by the flow sensor 18.
The special gas regulated pressure is advantageously high enough to fulfill sonic flow conditions in discharging the pressure from the control valve 21 into the carrier gas outlet conduit 22. Fulfilling this criteria makes the special gas dosing insensitive to the pressure variations in the breathing circuit. The carrier gas source 23 is advantageously a pump. Variable types of state of the art pumps can be employed, such as a positive displacement pump. The pump actuator can be e.g. a motor or a coil that provides the movement required by the pump.
A second embodiment of the invention is shown in FIG. 2 for a special gas dose delivery system to be used with spontaneously breathing patients. In this embodiment, there is no respirator, no Y-piece connector, no inspiratory limb and no expiratory limb.
The breathing circuit 2 includes patient limb 6. Included in patient limb 6 are breathing gas flow sensor 7, carrier gas discharge point 8, and endotracheal tube 9 or a breathing mask forming a conduit into patient airways 10 and further into lungs 11 of the patient.
The special gas dosing unit 13 includes an inlet line 14 from a special gas source 15. This special gas inlet line 14 connects the high pressure special gas source 15 to a dose control means 31. The dose control means 31 is the equivalent of the pressure regulator 16, pressure sensor 17, flow sensors 18 and control valves 20, 21, in FIG. 1. The dose control means 31 discharges the special gas into a carrier gas outlet conduit 22. The carrier gas outlet conduit 22 connects from the carrier gas source 23 to the carrier gas discharge point 8. The discharge of the special gas into the carrier gas takes place at the special gas dosing point 24. The carrier gas source 23 is equivalent to the carrier gas source or pump 23 in FIG. 1. The carrier gas source 23 provides the carrier gas to be mixed with the special gas at special gas dosing point 24.
The control unit 26 of the special gas dosing unit 13 is connected with the breathing gas flow sensor 7 located in patient limb 6. Patient breathing cycle information is transmitted from the breathing gas flow sensor 7 to the control unit 26. The control unit is also connected to the dose control means 31 and the carrier gas source 23. A further connection of the control unit 26 is with the control panel 27. This control panel is used for providing preset dose related parameters to control unit 26 and optionally also for presenting information on the operation of the special gas dose control means 31.
High speed gas flow is provided in carrier gas outlet conduit 22 to provide the patient with the special gas very quickly. This is achieved by using a small diameter conduit for carrier gas outlet conduit 22 to increase pressure and thus increase speed. There are differences in the gas line cross-sectional areas between the carrier gas outlet conduit 22 and the breathing circuit conduits 3, 5, and 9. The small volumetric conduit of carrier gas outlet conduit 22 provides the high speed gas flow.
It is recognized that other equivalents, alternatives, and modifications aside from those expressly stated, are possible and within the scope of the appended claims. | A special gas dose delivery unit for respiratory equipment has a special gas flow conduit connected to a special gas source. The unit includes a supply of carrier gas for the special gas, preferably obtained by withdrawing gas from the inspiration limb of the patient breathing circuit. A valve, controllable in accordance with desired special gas dose parameters and the breathing pattern of the patient, injects the special gas into the carrier gas for provision to the outlet conduit of the special gas dose delivery unit. The outlet conduit is connected to the patient limb of the breathing circuit for delivery to the patient. | 0 |
RELATED APPLICATIONS
This is a continuation of application Ser. No. 142,644, filed May 12, 1971, now abandoned.
FIELD OF THE INVENTION
This invention relates, in general, to multi-story or high-rise construction and relates in particular to a unique module capable of being formed away from the construction site and installed in place in the building and including the elevator shaft, the necessary hardware for the elevator and also utility chases.
DESCRIPTION OF THE PRIOR ART
In the art of high-rise construction wherein elevators are employed, elevator shafts and utility chases have conventionally been produced by merely leaving an opening in the floor area with the walls of the elevator and utility chases then being erected floor by floor and with the various items of hardware required for such erection being assembled or installed during erection or after the walls have been cast in place and hardened. Stated otherwise, in the past the shaft for the elevator has first been completely built as regards structural elements, and then assembly of the elevator with its associated hardware within the shaft commences.
SUMMARY OF THE INVENTION
The present invention contemplates precasting the elevator shaft and utility chases into a single unitary structure at a site preferably removed from the construction site.
The elevator module includes a shaft portion that has leveling devices associated with the top and bottom edges thereof so that complete vertical alignment of the walls and the shaft can be achieved at the time of placement of the module.
The elevator module further includes several built-in features, such as a door opening having prefinished door jamb and head sections and partially embedded steel plates, that serve to minimize the assembly time required at the finish of erecting the module. Additionally, the module includes most of the hardware necessary for installing the elevator per se including side rail brackets and side rails, door headers and door header inserts, door hanger and door hanger inserts, an electrical duct and a push-button control station box as well as sill inserts.
Production of an improved building module having the above-desired advantages accordingly becomes the principal object of this invention, with other objects of the invention becoming more apparent upon the reading of the following brief specification, considered and interpreted in view of the accompanying drawings.
OF THE DRAWINGS:
FIG. 1 is a perspective view of the improved module, with a fragmentary portion of a lower module and an upper module being illustrated in connection with the module shown in perspective.
FIG. 2 is a plan view in cross section of the module.
FIG. 3 is a vertical section taken on the lines 3--3 of FIG. 1.
FIG. 4 is a sectional view taken on the lines 4--4 of FIG. 3.
FIGS. 5 and 6 are sections taken on the lines 5--5 and 6--6 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings and in particular to FIG. 1 thereof, each elevator and utility module is generally indicated by the numeral 10 and includes a front wall 11, a rear wall 12, a side wall 13, and a partition wall 14, with partition wall 14 connecting with parallel projecting flanges 15, 16, 17, and 18 so as to define three utility chases that are respectively indicated by the numerals 19, 20, and 21, with the elevator shaft being formed by walls 11, 12, 13 and 14 and being indicated generally by the numeral 22, as best shown in FIG. 1 of the drawings. Actually, the flanges 15 and 18 are merely extensions of the walls 11 and 12. For the purpose of access, the front wall 11 has a door opening 26 provided therein, while the wall of the rib member 18 includes a ventilating opening 27, as again clearly shown in FIG. 1 of the drawings.
Referring now to FIG. 5, it will be noted that the upper portion 26a of the door opening is provided with a smooth finish on all surfaces such as the door jamb and head that, in effect, serves as the finished door opening for the elevator unit, with the walls 26b and all remaining walls of the door opening 26 being similarly flared out to serve as a finished door jamb.
Also included in the precast module is a push-button control box 60 and an electrical duct 60a (FIG. 6) which permits ready installation of the actual controls themselves together with their associated wiring. Furthermore, the prefinished module includes a plurality of embedded channels 70,70 on the interior of walls 13 and 14, with these channels serving to support the side rails (not shown) upon which the elevator runs. In addition to these channels, channels 71, 71 are provided adjacent the opening 26 to provide support for the door header (not shown). Another series of channels 72, 72 are provided to support the door sill and finally a plurality of channels 73, 73 are embedded in the walls to provide a support for the door side rails or stops (not shown).
All of these channels are of similar configuration and provide an anchoring point for the various items of hardware just described.
Also, and again referring to FIG. 5, the lower edge of the front wall 11 is shown offset as at 30 so as to permit concrete C to be cast in place following erection to form the floor. To ensure proper connection, the lowermost portion of the wall 11 is provided with a tapped plug 31 within which may be received a threaded rod 32, with the rod projecting prior to raising of the concrete C to the level shown in FIG. 5. In this regard, it is contemplated that the floor would be precast as indicated at PC and then brought to the job site. When the module has been placed into position and the tapped plug 31 and rod 32 have been mounted, the floor would then be cast so that the concrete rises to the level shown and indicated by the letter C, thereby making the module structurally integral with the overall building.
The wall members 11, 12, 13 and 14 have the usual vertical reinforcing rods 35,35 provided therein, with these rods preferably being connected with horizontal rods 36,36 for strengthening purposes in a manner well known in the art. T-rods 37,37 are also provided, as shown in FIG. 2, for the purpose of strengthening the point of connection between the rib 16, for example, and the wall 14, as is clearly shown in the drawings.
For the purpose of imparting leveling to the modules following installation on top of each other in the manner shown, as best shown in FIGS. 1 and 3, the tops of the wall members 13 and 14 have a pair of angles 40a and 41a which are cast into the top surfaces 13b and 14b and would be welded to rods 35,35 for positioning purposes.
Again referring to FIGS. 1 and 3, the lower edges 13a are provided with notch-like openings within which angles 42 and 43 may be received and welded in place to each other and to rods 35,35 which hold them in place, as shown in FIG. 3 of the drawings. By this arrangement, a third pair of angles 44 and 45 may be inserted within the space between the legs of flanges 42 and 43, as shown in FIG. 2, and following this, it is merely necessary to put a jack between the flanges 42 and 43, on the one hand, and the flanges 44 and 45 on the other hand, to cause an expanding movement in the direction of the arrow 46. When the proper height has been achieved, it is merely necessary to weld the angles 44 to the member 42 and the angle 45 to the member 43, as indicated by the weld marks 50,50 (see FIGS. 3 and 4).
It is also contemplated within the scope of the invention to embed metal plates within the wall surfaces themselves so as to permit attachment of the rails prior to the lifting of the module into position at the construction site as described above with regard to channels 70,70.
In use or operation of the improved module, it will first be assumed that the module has been poured to the condition shown in FIG. 1 of the drawings. At this time, the same can be shipped as a unit to the construction site, and following arrival there, the modules are merely stacked one upon the other until the desired elevator height is obtained.
As each module is placed on the one beneath it, it is recommended that the adjusting members be welded in place so that when all of the modules have been stacked on each other, a completely plumb elevator shaft will have been erected. Following erection in the manner just described, it is believed apparent that the floor can be poured as previously described, and it will be noted that the elevator door opening is already finished, with the result that it is merely necessary to have minor assembly work following erection of the elevator modules in the manner just described.
It will be noted that simultaneously with the erection of the elevator shaft there are attained three utility chases through which the main utility supply lines may be run, with exhaust at each floor being made preferably through opening 27 of the utility chase 21.
While a full and complete description of the invention has been set forth in accordance with the dictates of the Patent Statutes, it is to be understood that the invention is not intended to be limited to the specific form herein shown.
Accordingly, modifications of the invention may be resorted to without departing from the spirit hereof or the scope of the appended claims. | A precast concrete module defining a combined elevator shaft and utility chase area that is one story high and stacking of the modules on top of each other during construction, resulting in a completely finished elevator shaft and utility chase at the completion of erection. By this method of construction, considerable installation time following erection is eliminated in view of the fact that many of the components are already preassembled in the module prior to lifting to location. | 4 |
REFERENCE TO PRIOR APPLICATIONS
This application is a continuation-in-part of Ser. No. 893,976, Aug. 7, 1986 and now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to new and useful improvements in governors for vehicle engines and more particularly is concerned with means to limit powered RPM's in pressure time vehicle engine fuel systems.
Various types of governors have been employed to control upper speed limits of vehicles for safety, for fuel economy, for protection of mechanical portions of the vehicle, for complying with governmental or management regulations, and for other reasons. Some devices heretofore used shut down the power by stopping the fuel flow when a selected vehicle or engine speed is reached. This type of system has the disadvantage of providing only "on and off" control over the power means. Such has been found to be detrimental to the drive train of the vehicle and also makes driving difficult. That is, an on-off control causes a sudden, stressful reaction, or backlash, on the drive elements of the vehicle and such causes damage to the mechanism as well as reducing driver control, especially under slippery road conditions. Other governors utilize mechanisms which adjust fuel flow according to the speed of the vehicle. Such speed control may result in compliance with required conditions, but here again there may be backlash and reduction of driver control. Driver control of a vehicle is very important, particularly for trucks. Many prior devices also have the disadvantage of being complicated and thus expensive.
SUMMARY OF THE INVENTION
The present invention operates as an RPM limiter for an internal combustion engine of the type utilizing a pressured fuel feed system with return means for bypass fuel, the bypassed fuel being fed to the fuel tank or other holding means which is at atmospheric pressure or at least at a pressure lower than the fuel feed system. The invention is especially adaptable to diesel engines which use a pressure-time type of fuel system and which have a primary governing mechanism to maintain an idle speed and to limit the RPM of the engine to a predetermined maximum. The so-called pressure time fuel metering system accomplishes its metering by means of an externally mounted pump in combination with a metering orifice in mechanically actuated injectors.
A primary objective of the invention is to provide an auxiliary governing mechanism which at a selected RPM of the vehicle engine or drive line, in all gears, reduces the flow of power producing fuel but does not fully cut it off. The system utilizes delay mechanism activated by RPM counting means to delay activation of the governing mechanism.
Another object of the invention is to provide an embodiment of the invention which utilizes electrically operating RPM counting means of the vehicle engine or drive line and associated valve means arranged to be associated with the pressured fuel feed system and a lower pressure return means. Electrically operated control means are activated by the counter means at a selected RPM to allow some of the pressured fuel to bypass the fuel feed means, thus reducing the flow of power producing fuel.
Another object of the invention is to provide an RPM limiter which in another embodiment is arranged to be adapted for use with a manual fuel flow override in fuel pumps.
It is another object of the invention to employ signal means for alerting the operator of impending power reduction. Said signal means in one embodiment employs a signal that is activated simultaneously with activation of the delay mechanism whereby to alert the operator that the power producing fuel will be reduced at the end of the delay period. In another embodiment, a companion signal is employed which is activated a short time prior to the delay indicating signal, thus warning the operator that he is approaching the governing function.
In carrying out the objectives of the invention, electrically operated adjustable counting means are used to count the individual revolutions of vehicle rotating mechanism, such as an engine, or by association with flywheel rotation, or to count the individual revolutions of the drive line by association of the transmission output shaft. Means are provided which are movable by electrically operated control means to reduce the flow of power producing fuel. The electrically operated control means are activated by the counting means at a selected RPM setting of the counting means to move the fuel reducing means from an inoperative position to an operative position whereby to reduce the flow of power producing fuel t the engine. The system includes adjustable delay means which delay operation of the control means for a selected interval after the RPM of the rotating mechanism has reached the RPM setting of the counting means as pre-set to activate the secondary governing mechanism. Signal means in the operator's compartment is provided which is activated simultaneously with activation of the delay to give the operator of the vehicle a warning that he is nearing power reduction and that the RPM must be reduced to avoid power reduction. Also, another signal may be provided that is activated just prior to activation of the delay signal.
The invention will be better understood and additional objects and advantages will become apparent from the following description taken in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a diagrammatic view of a first form of powered RPM limiter and signal means embodying features of the invention, this view also showing a first form of vehicle fuel system;
FIG. 2 is a diagrammatic view of another form of fuel system with which the broad concept of the invention may be employed; and
FIG. 3 is a diagrammatic view of an embodiment of the invention used with the fuel system of FIG. 2, this view also including a further form of signal means.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
As noted above, the present RPM limiter is utilized in combination with a vehicle fuel feed system which operates under pressure and which has return means from injectors for bypass fuel leading to a source which is of lower pressure than the fuel feed, such as to the fuel tank. A fuel system of this type, as embodied in an engine (not shown) is diagrammatically shown in FIG. 1 which illustrates a first embodiment of the invention. Conventionally, an engine utilizes injectors 10 connected to a pump 11 by a fuel line and common manifold 12. The pump draws fuel from a tank 13 through a suction line 14. Unused fuel is returned from the injectors to the tank via a return line 15 with its attendant collecting manifold. The flywheel 20 of the engine has gear teeth 21 on its outer periphery and is encased in a flywheel housing 22.
According to the embodiment of FIG. 1, an electrically operated engine speed or RPM counter 24 is incorporated in an electrical circuit 26 and is associated with an electro-magnetic pickup 28 (positioned at the teeth of the flywheel) in the circuit which accurately reads and reports flywheel rotational speed to the RPM counter 24 via circuit 27. Such counter converts the flywheel speed into engine RPM in a well-known manner. RPM counter 24 has conventional internal circuitry which operates to activate a delay 30 at a selected RPM setting, such counter having external adjustment mean 32 for making preselected settings.
The counter 24 also controls activation of a signal device 34 in a circuit 35 and located, typically in the operator's compartment, to alert the operator that the selected overspeed RPM has been reached. This signal may comprise a visual signal such as a red light, or it may comprise an audio signal, or both. The delay 30 controls operation of an electrically actuated relay mechanism 36 arranged when energized to connect an output circuit 33 with a power supply circuit 37 but only after a selected time lapse as controlled by the delay 30. The delay has adjustment means 38 for setting its function to selected delay times. The delay and adjustment circuitry therefor are of conventional design. Signal 34 and delay 30 are activated simultaneously.
Relay 36 controls the operation of a solenoid actuated valve 40 having a plunger 42 with a valve end 44 engageable with a valve seat 46 within the valve 40. Plunger 42 is normally held in a closed position by a compression spring 48 but is capable of being lifted against the action of this spring by the solenoid-generated force when the circuit 33 is connected to circuit 37.
The valve 40 is connectably inserted between the pressured fuel line 12 and the fuel tank 13 by suitable fittings 50, 51 and provides controlled communication between these fittings and through the valve 40 by passageways 52 and 54. These passageways are of reduced size relative to the size of fuel line 12 for a reason now to be explained.
According to the present arrangement, the normal pressured operation of the fuel system comprising elements 10 through 15 is not affected when the valve 40 is closed. Pressure to the injectors 10 is thus maintained at the level controlled by the pump 11 for normal powered operation. However, in the event that the solenoid valve 40 is energized, a flow of fuel occurs through the valve and return line 15 to the tank 13. This opened bypass circuit in the fuel supply system causes a reduction of pressure in the fuel line 12 and a consequent reduction of fuel injected into the engine by the injectors 10 to thus lower the power of the engine. The amount of pressure reduction to the injectors depends upon the volume of flow through the passageways 52 and 54. The flow resistance for example, one-half the volume of the fuel line 12, is preselected to accomplish the desired power reduction but with fuel still being supplied to the injectors at the desired reduced flow. Thus, with the valve 42 open, the power output of the engine is reduced and the vehicle speed will reduce to accomplish a governing function.
In the operation of the FIG. 1 embodiment, the RPM counter 24 is set selectively to the RPM setting at which it is desired that the vehicle not be operated at or above. The limiter will limit powered RPM in all gears or selected gears. When the vehicle reaches such RPM setting, the delay 30 and signal 34 are activated which in turn causes signal 34 to warn the driver that the governor is now under control of the delay. Relay 36 will be energized after the selected time delay has elapsed unless the RPM's are lowered. Thus, the operator is made aware that within the time set in the delay the engine power is going to be lessened. The operator can then, if accelerating by progressive gear shifting, up-shift in a normal manner to the next higher gear which reduces the RPM and avoids the power reduction. If in top gear and the delay 30 and signal 34 are activated, the operator is then warned that a power reduction is imminent and a slight slowing of RPM/MPH will occur before full power is available again. The delay also allows the operator to have full power during the delay period. Thus, the operator can judge when to make the shift so that there will not be unnecessary or unexpected slowing of the vehicle when shifting gears. Braking may be required, according to road grade, to be in compliance with speed or other regulations. The governing system shuts off when the RPM's are reduced below the setting of RPM counter 24.
FIGS. 2 and 3 illustrate a second embodiment of the invention. This embodiment has the same purpose as the embodiment of FIG. 1, namely, to provide a controlled reduction of the flow of power producing fuel. It is used, however, with a fuel system using an existing operator-controlled fuel flow override shaft associated with the fuel pump. FIG. 2 illustrates the usual diesel fuel components with which this embodiment is used, comprising injectors 10, pump 11, fuel lines 12, fuel tank 13, and suction line 14. The existing operator controlled override shaft is shown diagrammatically and comprises a rotary type member 60 having a metering orifice 62 which is associated with the pump 11 to allow full flow of the engine fuel for normal operation or to control the flow. Rotary valve member 60 projects from the pump so as to be connectable to the conventional operator shutoff mechanism or to the present governor, or both, to be described and in its usual structure requires forced rotation in one direction but has spring return.
This second embodiment is arranged to rotate the rotary valve member 60 a selected amount, as controlled by RPM's, for reducing fuel flow and thus serving, as in FIG. 1, as an auxiliary governor. It has dual counter means 63 which also similar to FIG. 1 employs an electrically operated engine speed or RPM counter 24' incorporated in an electrical circuit 26' and associated with an electromagnetic pickup 28' accurately reading and reporting rotational speed to the counter 24' via a circuit 27'. RPM counter 24' has conventional internal circuitry which activates a delay 30' at a selected RPM setting and includes external adjustment means 32' for making preselected settings. Also, the counter 24' controls operation of a signal device 34' which alerts the operator that the selected overspeed RPM has been reached. The delay 30' controls operation of an electrically actuated relay mechanism 36' arranged when energized to connect an output circuit 33' with a power supply circuit 37' but only after a selected time lapse as controlled by the delay 30'. Delay 30' has adjustment means 38' for setting its function to selected delay times. Signal 34' and delay 30' are activated simultaneously.
Dual counter means 63 includes a second counter 64 electrically connected to another signal 66 by circuitry 68. Counter 64 is arranged to activate signal 66 at a slightly lower count than counter 24 thus warning the operator of nearing activation of delay 30' and signal 34' resulting in reduced power. Such reduced power can be avoided by holding or slightly reducing RPM below the overspeed setting of the counter 24'. RPM counter 64 has adjustment means for controlling activation of the signal means 66 at a selected RPM.
Mechanism responding to operation of the relay 36' comprises a solenoid 70 connected into the circuit 33' and having a plunger 72 normally held outwardly by a compression spring 74 engageable between a washer 76 threaded on the end of the plunger and the housing of the solenoid. The projecting end of the plunger 72 and the spring are confined within a bellows-type cover 78.
Solenoid 70 is adjustably mounted on a base 80 in turn having a bracket 81 thereon which suitably secures it on a vehicle engine in the area of the rotary member 60. The end of plunger 72 is fitted with a pull cable 82 and the end of this cable is adjustably connected to a lever 84 in turn secured non-rotatably to the rotary valve member 60, whereby upon energization of the solenoid 70, plunger 72 draws inwardly and rotates the lever 84 in a counterclockwise direction as viewed in FIG. 3 and controls the flow of fuel by means of metering orifice 62 through the fuel line 12. More particularly, in the deenergized condition of the solenoid, fuel flow through the manifold is uninterrupted. In the energized condition thereof, however, the lever 84 will rotate the rotary valve member a selected amount to reduce the flow of power producing fuel. The extent of reduction of fuel flow is predetermined the same as is accomplished by the valve 40 in FIG. 1 whereby power is reduced but not fully shut off. The amount of rotation of rotary valve member 60 to the position of reducing fuel flow is accomplished by the length of throw of the solenoid plunger 72 and suitable adjusted mounting of the solenoid on its base or by adjusted connection of lever 84 with the cable.
In operation of the embodiment shown in FIGS. 2 and 3, solenoid 70 by means of its pull cable 82 is selectively connected to the rotary valve member 60 such that in the deenergized or rest position of the solenoid full or normal fuel flow occurs through the fuel line 12, namely, the metering orifice 62 is fully open. When the solenoid is energized, however, it rotates the valve member 60 selectively to provide the reduction in power producing fuel flow. With the exception of the signal 66, to be described, the system works exactly the same as that described in connection with the FIG. 1 embodiment, namely, the RPM counter 24' is set selectively to the RPM at which it is desired that the vehicle RPM be controlled and when the vehicle reaches this RPM setting, the delay 30' and signal 34' are activated and relay 36' is energized after the selected delay time has lapsed for energizing the solenoid 70. Similarly, the operator is made aware that within the time set in the delay the engine power is going to be lessened and he can take necessary steps to operate the vehicle in an efficient manner.
Since RPM counter 64 is activated at an RPM less than RPM counter 24' the operator is always made aware beforehand, for example, two or three seconds, that the governing system is going to be activated. Signal 66 can be of any desired type such as visual, audio, or both and would be located adjacent to signal 34' in the operator's compartment. As an example, signal 66 may be yellow and signal 34' may be red. Signal 66 thus gives the operator the choice whether or not to stay in compliance with the pre-set regulations. If the operator does not heed the warning, the governing system will be activated. The governing system shuts off when RPM's are slightly reduced below the setting of RPM counter 24'. Lever 84 and solenoid plunger return to their normal position by the spring return means associated with rotary valve member 60 and also by solenoid spring 74 if such is necessary.
The embodiment of FIG. 1 could also incorporate the second signal 66 therein.
Not only does the present invention encourage compliance with governmental and other regulations but also through its delay the operator can, as noted, maintain good vehicle operation.
Availability of the RPM limiter, in all gears, to avoid prolonged high RPM engine operation is vital to fuel consumption and engine life even though the vehicle is not necessarily operating at a high MPH. It is common knowledge that considerable savings can be experienced at the lower RPM's. Since the power to the engine is reduced rather than shut off completely, there is no backlash generated in the drive train of the vehicle. The system works in all powered conditions of the engine and in all gears.
It is to be understood that the forms of my invention herein shown and described are to be taken as preferred examples of the same and that various changes in the shape, size and arrangement of pars may be resorted to without departing from the spirit of my invention, or the scope of the subjoined claims. | An electrically operated counter is associated with a valve communicating with fuel feed mechanism of a diesel engine. The valve has a first position which allows normal fuel flow to the engine and has a second position allowing only partial fuel flow to the engine. An electrically operated control is activated by the counter at a selected RPM reading of the counter to move the valve to its second position to reduce fuel flow to the engine and consequent reduction of power. The control has a delay therein for delaying operation of the valve for a selected interval after the RPM of the engine has reached the RPM setting of the counter. Activation of the delay is made apparent to the operator by a signal energized simultaneously with initial actuation of the delay. A signal may also be employed that is activated prior to the delay and its signal to warn the operator of impending governing functions. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a disposable applicator, which allows the consumers to sample cosmetic products such as lipsticks, liquid makeups, eye shadows and other types of viscous cosmetics as well as non-cosmetic products such as crayons, prior to making a purchase.
Cosmetic retailers do not normally provide "trial-size" samples at the counter. Consequently, when a consumer wishes to sample cosmetic products, the retailers usually offer her full-size items that have been previously sampled by other customers. Due to hygienic reasons the consumer may not want to apply the previously used cosmetics directly on herself. In the case of lipsticks, the consumer usually applies the lipstick to her hand and tries to imagine how the sample would look on her lips.
Also, consumer protection and health regulations have been enacted in at least one state which ban shared testers and require retailers and cosmetic companies to provide customers with disposable makeup applicators or samples, or post warning signs and safety instructions.
In response, manufacturers have introduced cosmetic samples to be provided to customers in encapsulated blisters. For lipsticks, customers may apply this type of samples to their lips with cotton swabs. This is a less satisfactory solution. At the present time, there is no disposable applicator that allows the consumers to extract lipstick at the retail counters.
Other types of applicators are known, e.g., U.S. Pat. No. 5,301,697 to Gueret discloses a disposable applicator having the cosmetics pre-applied to it at the factory under high temperature and pressure conditions; U.S. Pat. No. 5,040,914 to Fitjer discloses a permanent plastic applicator that is porous and sponge-like; U.S. Pat. No. 4,955,745 also discloses a soft porous applicator for applying nail polish; and U.S. Pat. No. 4,050,826 discloses a permanent applicator that allows viscous fluid to pass through via capillary action.
Thus, there remains an unresolved need in the cosmetic industry for a disposable applicator which is capable of extracting an amount of cosmetics, e.g., lipsticks, sufficient for a single use. Additionally, the applicator would be stored "dry", i.e., without cosmetics, so that the consumer can extract different types or colors of cosmetics with the applicator at the retail counter prior to sampling.
SUMMARY OF THE INVENTION
The present invention provides a cosmetic applicator comprising a body member made out of a porous material and having sufficient stiffness to withstand a pressure exerted by an user, wherein the user can extract an amount of cosmetic sufficient for a single use with the applicator. Preferably, in the case of lipsticks, the applicator has a generally cylindrical shape with at least one round or blunt end, or having a beveled surface at one end.
The applicator can also be hollow, wherein the cosmetic is deposited within the hollow applicator and is pushed through the top portion of the body member.
The present invention also provides methods for sampling cosmetic comprising the steps of (i) extracting an amount of cosmetic sufficient for a single use with a disposable porous applicator; and (ii) applying the cosmetic to the body of a consumer, wherein the cosmetic is extracted immediately prior to sampling the cosmetic.
Therefore, an object of the present invention is to provide a hygienic cosmetic applicator for consumer sampling.
Another object of the present invention is to provide a hygienic cosmetic applicator that carries an amount of cosmetic sufficient for a single use.
Another object of the present invention is to provide a disposable applicator that can be used by the consumer to extract cosmetic samples at the retail counter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a cross-sectional view of a lipstick applicator according to the present invention;
FIG. 1B is a cross-sectional view of an alternative embodiment of the lipstick applicator according to the present invention;
FIG. 2 is a cross-sectional view of a premeasured amount of lipstick in a disposable container;
FIG. 3 is a cross-sectional view of the lipstick applicator of the present invention being used in conjunction with the disposable container shown in FIG. 2;
FIG. 4 is a cross-sectional view of the lipstick applicator of the present invention being used in conjunction with a permanent lipstick dispenser;
FIG. 5A is a cross-sectional view of a hollow lipstick applicator according to the present invention;
FIG. 5B is a cross-sectional view of another alternative embodiment of a hollow applicator according to the present invention; and
FIG. 6 is a cross-sectional view of a hollow applicator as shown in either FIGS. 5A and B being used with a further alternative embodiment of permanent lipstick dispenser.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The cosmetic applicator of the present invention can be used with a number of cosmetics, i.e., lipsticks, liquid makeups, eye shadows, lip balms, etc. For simplicity lipstick will be used when describing the present invention, but it will be noted that the present invention is not restricted to only lipstick.
Now referring to the Figures, wherein like numerals are used to designate like parts and according to FIG. 1, applicator 10 is depicted in FIG. 1A as having a shape that resembles that of a tube of lipstick. Applicator 10 is substantially rigid and is made out of porous polyethylene or other suitable materials that are capable of holding its shape. Applicator 10 should have sufficient stiffness to resist bending or other types of deformation when used by the consumer.
Applicator 10 comprises body portion 12 and base portion 14. Body portion 12 has a beveled surface 16. Beveled surface 16 is provided at the top of body portion 12 to facilitate the application of the lipstick stored on the applicator onto the lips. However, the top portion of bullet portion 12 may have other convenient shapes, e.g., round as shown in FIG. 1B or conical shape. It will be noted that surface 16 may also have either concave or convex curvature. Preferably, the tip of body portion 12 resembles the tip of a non-sample tube of lipstick.
The disposable applicator 10 of the present invention can be made with sintered polyethylene. In this process, granules of polyethylene are poured into a mold which has the desired lipstick tube shape. The granules are then compressed lightly and heat is added to bond the granules together to form solid applicator 10. It will be noted that in this process the granules are bonded but not melted. Applicator made with sintered polyethylene are porous having pores substantially the size of the polyethylene granules. Such pores are also interconnected in a way that lipstick would be able to flow from one pore to the next.
As stated above, it is desirable that the applicator can withstand the pressure exerted by the consumers during the extraction and application. The stiffness of the applicator is determined by the grain size of the polyethylene granules and the overall dimensions of the applicator. Thus, by varying the grain size and the dimensions of applicator 10, the desired stiffness as explained above can be achieved.
The grain size also controls the texture of applicator 10. The smaller the grain size the smoother the surface of applicator 10 would feel to the user. Smaller grain size can also aid in the product delivery. When grain size is small, the lipstick that are stored within the pores can be drawn out and be applied to the user due to capillary action.
Applicator 10 can be made out of other materials such as styrofoam and other processes such as extrusion, molding, die casting, etc. Thus, the example given above is only to illustrate, and not to limit, the present invention.
Applicator 10 may be used to extract a pre-measured amount of lipstick as shown in FIGS. 2 and 3. The lipstick is contained in capsule 20, where an amount of lipstick sufficient for one use is stored within. Capsule 20 is covered by lid 22, which is made out of a thin flexible material such as foil or plastics. Lid 22 is attached to capsule 20 by thermal methods or by adhesives. Capsule 20 can be manufactured on sheets or "blister" packs containing a large number of lipstick capsules. The individual capsule may be separated from each other by perforations for easy separation.
The lidding material may be peeled back or punctured to expose the lipstick and applicator 10 is inserted into capsule 20 to extract the lipstick. The consumer simply exerts a slight pressure on the lipstick. Such pressure forces some of the lipstick to enter the porous area and leaves a layer of lipstick on the surface of the applicator.
After the lipstick is transferred to the applicator, the consumer can apply the lipstick to her lips. Frictional contact between the applicator and the lips deposits a film or thin layer of lipstick on the lips. Further, due to the capillary action of the lipstick inside the pores, some of the lipstick stored in the pores of applicator 10 will also be applied to the lips. The used applicator may be discarded after one use.
Lipstick sampling in accordance with the present invention therefore provides an inexpensive, realistic and hygienic method of sampling lipsticks for the consumers. Blister packs of capsules 20 can be manufactured to contain many different shades, colors and textures of lipsticks. The consumer will be able to apply the lipsticks directly on her lips for sampling with the actual lipstick, and will not have to apply lipsticks to her hand and resort to her imagination with regard to appearance.
In another embodiment depicted in FIG. 4, applicator 10 can also be used in conjunction with bulk sources of lipsticks. As shown, a permanent well 24 having storage portion 26 and flat portion 28 is provided. Storage portion 26 is in communication with a bulk source of lipstick L contained within dispensing unit 30 through an aperture 32 defined at the bottom of storage portion 26. Well 24 is attached to dispensing unit 30 in such a way that when bulk source L is pressurized, lipstick will flow from bulk source L through aperture 32.
The amount of lipstick dispensed may be measured by several methods. For examples, it can be measured by applying a known pressure to bulk source L for a fixed time period. The pressure can be produced by a simple electrical motor driving a piston acting on dispensing unit 30, or the piston can be pushed by the consumer. The pressure can also be provided by a distensible bladder disposed inside bulk source L and connected to a source of compressed inert gas, such as air, nitrogen or carbon dioxide.
The lipstick can also be dispensed in premeasured volumes with devices such as calibration markings on dispensing unit 30 and a piston linearly advancing from one marking to the next. Lipstick can also be dispensed by a pusher rotationally and threadedly attached to a bottom of dispensing unit 30 such that by rotating the pusher one revolution a known volume of lipstick is released. The lipstick dispensed can be measured by the number of revolutions turned. The pusher may be rotated by hand or by an electrical motor.
Alternatively, the bulk source inside dispensing unit 30 may be contained in a disposable bag, and a pressure source as described above may be applied directly to the bag to dispense lipstick. An advantage of using the disposable bag is the relative ease in replacing the bulk lipstick once it is empty. The retailer can simply discard the empty bag and insert a new bag. For example, the disposable bag may be used in conjunction with the distensible bladder contained within the bag. As the distensible bladder is expanded within the bag, lipstick is dispensed. When the bladder has expanded to substantially the same size as the bag, most of the lipstick would have been dispensed.
Well 24 should be securely attached to dispensing unit 30. As shown in FIG. 4, flat portion 28 is shown to be connected to the walls of dispensing unit 30. Flat portion 28 may have threaded channel to receive a threaded top portion of the walls of dispensing unit 30. With the threaded connection, well 24 can easily be removed for cleaning or replacement. It is also desirable for the purpose of cleaning to minimize the outer area of well 24 that contacts lipstick. For this purpose there is provided a seal 34 disposed above but approximate aperture 32. This seal will prevent lipstick from bulk source L from advancing far beyond aperture 32. Thus, well 24 can be easily cleaned after it is removed from dispensing unit 30.
It will be noted that FIGS. 2-4 depict a well with a round nose applicator 10. However, well 24 and capsule 20 may also have shapes that would accommodate beveled surface 16 or the other shapes described above.
So long as the applicator has sufficient stiffness to resist the force exerted by the consumer, it may have a hollow construction as shown in. FIGS. 5A and 5B. Hollow applicator 40 may be used with well 24 and capsule 20 as shown in FIGS. 2-4. Hollow applicator 40 can also be used in conjunction with another dispensing unit as shown in FIG. 6.
In another alternative embodiment, an elongated member 42 with a channel 44 defined longitudinally therein is provided as shown in FIG. 6. Channel 44 is in communication with a bulk source of lipstick such that lipstick can be dispensed through channel 44 by pressure sources described above. When a consumer wishes to sample a particular shade or color of lipstick, she simply places hollow applicator 40 over the elongated member 42 so that hollow applicator 40 snugly covers elongated member 42 as shown in FIG. 6. A sealing member 46 is provided to keep the dispensed lipstick within the vicinity of the top of porous applicator 40.
The pressure applied to the bulk source will also drive the dispensed lipstick through the interconnected pores of the applicator to the top portion of hollow applicator 40. In this embodiment, when the lipstick reaches the outer surface of applicator 40, a sufficient amount of lipstick has been dispensed. Thus, the amount of lipstick dispensed can also be controlled by visual inspection.
While various embodiments of the present invention are described above, it is understood that various features of the preferred embodiments can be used singly or in any combination thereof. Thus the present invention will not be limited to only the specifically embodiments depicted herein. | The present invention provides a disposable applicator for sampling cosmetics including lipsticks at the retail counters. Also provided are methods for extracting or otherwise transferring the cosmetics onto the applicator and sampling the cosmetics. | 0 |
This patent application is a Continuation In Part of the Proximate Atom Nanotube Growth patent application Ser. No. 13/694,088 filed on Oct. 29, 2012.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the growth of nanotubes (NTs). The growth is accomplished by transporting the feedatoms of the NT to the catpar of the NT without the atom being chemically bound to a molecule in the atmosphere environment that surrounds the growing nanotube. The current situation can be illustrated by considering the example of CNTs.
Manmade CNTs are created by various means. Consider one of the most useful techniques, chemical vapor deposition (CVD). Basically, the CVD process involves a carbon bearing gas as a constituent of the atmosphere in a reaction chamber. Some of these gas molecules react with a catpar in the chamber and if the temperature, partial gas pressure and many other parameters are correct, a carbon atom from a gas molecule migrates into or onto the surface of the catpar and a CNT will grow out of the catpar. This process is quite popular because the CVD process, in general, has proven to be extremely useful, over many decades, in other endeavors including semiconductor microcircuit fabrication. However, there are drawbacks when this technology is used for CNT growth.
The first drawback is that although initial growth of the CNTs is quite rapid, the growth quickly slows to a crawl and for all intents and purposes stops. Breakthroughs have been made that allow the growth to continue perceptibly, albeit slowly, but a second problem comes into play. The already formed CNTs are immersed in an environment of hot, carbon bearing gasses. Reactions continue on the surface of the CNTs that create imperfections in their highly structured carbon lattice. These imperfections dramatically degrade the physical properties of the CNTs. The longer the growth continues in this environment, the more damage is done to the CNTs. Therefore significant quantities of long (≧1 centimeter for CNTs, many centimeters for BNNTs), highq CNTs are impossible to fabricate. For over a decade, researchers have been trying to find the “right set” of CVD parameters to produce long, highq CNTs without success.
Causes of the dramatic slowdown of CNT growth during the CVD process are currently understood to include:
1) The accumulation of material on the surface of the catpar, suspected to be amorphous carbon. This coating reduces the surface area of the catpar thereby decreasing the opportunity for carbon atoms, appropriate to combine with the growing CNT, to either pass into the catpar or migrate on its surface to the CNT growth location. Thus CNT growth is slowed or terminated. 2) The effect of Ostwald ripening tends to reduce the size of small catpars and increase the size of large catpars by mass transfer from the small to the large. Conceptually this is because small particles are thermodynamically less stable than larger particles. This thermodynamically-driven process is seeking to minimize the system surface energy. The catpar size is important since CNT growth will cease (or not begin in the first place) if the catpar is too large or too small. 3) Although substrates upon which CNTs are grown can be many different substances, the most common substrate is silicon dioxide, in part because of the decades of experience with it in the semiconductor industry. Silicon dioxide was thought to be impervious to catalyst elements, but in CNT fabrication it has been found that at least some catalyst materials can diffuse into the silicon dioxide layer. Thus the effective size of the catpar gets smaller and can become incapable of supporting CNT growth. Other substrates may be porous to catalyst materials as well.
2. Description of the Prior Art
U.S. Pat. No. 7,045,108 describes the growth of CNTs on a substrate and the subsequent drawing of those CNTs off the substrate in a continuous bundle. The abstract states: A method of fabricating a long carbon nanotube yarn includes the following steps: (1) providing a flat and smooth substrate; (2) depositing a catalyst on the substrate; (3) positioning the substrate with the catalyst in a furnace; (4) heating the furnace to a predetermined temperature; (5) supplying a mixture of carbon containing gas and protecting gas into the furnace; (6) controlling a difference between the local temperature of the catalyst and the furnace temperature to be at least 50 .degree. C.; (7) controlling the partial pressure of the carbon containing gas to be less than 0.2; (8) growing a number of carbon nanotubes on the substrate such that a carbon nanotube array is formed on the substrate; and (9) drawing out a bundle of carbon nanotubes from the carbon nanotube array such that a carbon nanotube yarn is formed.
The technique described in the previous paragraph is a representative example of the popular and useful “forest growth” of CNTs and the drawing of a CNT bundle from the forest. It does not discuss any technique for mitigating the causes for CNT growth slowdown.
U.S. Pat. No. 8,206,674 describes a growth technique for boron nitride nanotubes (BNNTs). From the abstract: Boron nitride nanotubes are prepared by a process which includes: (a) creating a source of boron vapor; (b) mixing the boron vapor with nitrogen gas so that a mixture of boron vapor and nitrogen gas is present at a nucleation site, which is a surface, the nitrogen gas being provided at a pressure elevated above atmospheric, e.g., from greater than about 2 atmospheres up to about 250 atmospheres; and (c) harvesting boron nitride nanotubes, which are formed at the nucleation site.
The above technique forms centimeter long BNNT using laser ablation of the boron into a nitrogen atmosphere. The growth occurs at a rough spot around the ablation crater and the growth streams in the direction of the nitrogen flow. A catalyst material need not be present. The technology does not allow for the control of growth or the use of this laser ablation technology to grow CNTs.
U.S. Pat. No. 8,173,211 describes CVD CNT growth process that is continuous. From the abstract: A method of production of carbon nanoparticles comprises the steps of: providing on substrate particles a transition metal compound which is decomposable to yield the transition metal under conditions permitting carbon nanoparticle formation, contacting a gaseous carbon source with the substrate particles, before, during or after said contacting step, decomposing the transition metal compound to yield the transition metal on the substrate particles, forming carbon nanoparticles by decomposition of the carbon source catalyzed by the transition metal, and collecting the carbon nanoparticles formed.
The technique described in the previous paragraph is the technique in which the catalyst is dispersed into the carbon-bearing gas flow of the reactor. It produces CNTs of up to approximately 0.5 mm in length. The CNTs appear as smoke and can be drawn off continuously. However, the technology has been unable to grow long, highq CNTs.
SUMMARY OF THE INVENTION
The present invention is a technology for growing NTs by transporting the feedatoms of the NT to the catpar of the NT without the atom being chemically bound to a molecule in the atmosphere environment that surrounds the growing NT. Conceptually, various mechanisms can be used to transport feedatoms to the catpar with the proper energy to combine with the growing NT. One possible embodiment, shown in FIG. 1 , is to fabricate a substrate with a layer of feedstock atoms as a surface, then liberate these atoms from the surface below a catpar using a pulse of radiation incident upon the bottom of the substrate that is transported to the feedstock layer by a wavide in the substrate. The parameters of the radiation pulse and wavide properties can be used to ensure that the feedatoms arrive at the catpar with the appropriate energy to facilitate the process that results in the feedatoms being incorporated into the NT growing from the catpar.
The present invention circumvents unwanted, extraneous chemical reactions that occur at the catpar and the NT that arise from the gasses comprising the atmosphere in the reaction chamber, by eliminating the need for reactive gasses. Once freed of the requirements for supplying the feedatoms, the interatmo of the reaction chamber can be controlled to promote the growth of highq NTs and their processing into a final form.
The present invention includes the recognition that enabling the growth of highq, long (≧1 centimeter for CNTs, many centimeters for BNNTs) NTs represents a fundamental breakthrough. With such a technology, industrial processing of long and highq NTs is within reach. Moreover, industrial production for nanotubes will lower the cost and increase the availability of nanotubes to allow a materials revolution on Earth. This materials revolution will enable the use of nanotubes in high strength materials, electrical conductors, semiconductors, electrical components, electrical micro and nano circuits, and sensors. The most extreme example of the benefits may be that high strength CNT materials will enable the Space Elevator, thereby opening the resources of space to mankind in the form of enhanced Earth observation, space-based solar power, asteroid mining, planetary defense and colonization of the moons and planets of our solar system!
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is the best mode of the Trekking Atom Nanotube Growth according to the present invention, also named the BM embodiment.
FIG. 2 is the feedvoir (FV) embodiment of the present invention wherein a feedvoir below the catpar and above the wavide provide the feedatoms for the CNT growth.
FIG. 3 is the wavide tratip (WT) embodiment of the present invention wherein emrad stimulated NT growth is accomplished using a tratip.
FIG. 4 is the atomgun (AB) embodiment of the present invention wherein an atomgun is used to deliver the feedatoms to the catpar through a small tunnel in the substrate.
FIG. 5 is the angled atomgun (AA) embodiment of the present invention wherein the tunnel runs at angle other than 90 degrees from the substrate plane.
FIG. 6 is a magnetic atomgun (MA) embodiment of the present invention wherein the tunnel is 90 degrees from the substrate plane; but not under the catpar; and magnetic fields are used to accelerate the feedatoms to the catpar.
FIG. 7 illustrates the ionizing laser (IL) embodiment of the present invention wherein a laser and an electric field are used to propel the feedatoms to the catpar.
FIG. 8 illustrates the ablation laser (AL) embodiment of the present invention wherein a laser ablates the feedatoms off a surface and to the catpar.
FIG. 9 is the ballistic tratip (BT) embodiment of the present invention wherein feedatom acceleration NT growth is accomplished using a tratip.
FIG. 10 is the catalyst flow (CF) embodiment of the present invention in which feedatoms are transported to the catpar as a constituent of a catalyst flow.
FIG. 11 is the flow tratip (FT) embodiment of the present invention wherein catalyst flow NT growth is accomplished using a tratip.
FIG. 12 is an industrial embodiment of the present invention wherein laser techniques (as in FIGS. 1-3, 7, 8 and in some cases 9 ) are used to transport feedatoms to catpars residing on a large array of substrates growing NTs.
FIG. 13 is an industrial embodiment of the present invention wherein atomgun techniques (as in FIGS. 4-6 , and in some cases 9 ) are used to transport feedatoms to catpars residing on a large array of substrates growing NTs.
FIG. 14 is an industrial embodiment of the present invention wherein a flowing catalyst ( FIG. 10 ) is transporting feedatoms to catpars residing on a large array of substrates growing NTs.
FIG. 15 is an industrial embodiment of the present invention wherein a tratip (as in FIGS. 3, 9 and 11 ), mounted on a cantilever arm is growing and depositing NTs on a substrate (as seen from above) in three dimensions to create a circuit or structure out of NTs.
DETAILED DESCRIPTION OF THE INVENTION
1. Definitions
Atomgun—When used herein shall mean an atomic or molecular ion source capable of accelerating ionized feedatoms to energies sufficient to transport them to the catpar, such that they arrive with the optimum energy to become a part of nanotube fabrication: an atom gun. In some cases the atomgun may also be used to accelerate catalyst particles.
BNNT—When used herein shall mean a boron nitride nanotube.
Catpar—When used herein shall mean a volume of catalyst material, wherein the size, shape and elemental constituents are appropriate for growing a nanotube: a catalyst particle. The catalyst may contain one or more elemental constituents.
CNT—When used herein shall mean a carbon nanotube.
Emrad—When used herein shall mean electromagnetic radiation, however generated and of appropriate wavelength, to stimulate CNT growth within the technique being described.
Feedatom—When used herein shall mean an atom or molecule that is a chemical constituent of a nanotube: the atomic feedstock of a nanotube.
Feedlayer—When used herein shall mean a layer of NT feedstock atoms (feedatoms) that may comprise other constituents such as catalyst material.
Feedvoir—When used herein shall mean a reservoir of NT feedstock atoms (feedatoms) that may contain other constituents such as catalyst material.
Highq—When used herein shall mean nearly defect free: high quality. A highq NT is a nanotube that is nearly pristine, perfect and defect free. As such its tensile strength and electrical properties are maximal.
Ineratmo—When used herein shall mean the inert, gaseous atmosphere in a CNT growth chamber: an inert atmosphere. If the sides of the substrate are isolated then it refers to the atmosphere on the nanotube growth side (front side) of the substrate. This “inert” atmosphere generally is made up of inert gasses. However, if partial pressures of other gasses, including ones introduced to react with NTs, catpars and/or free carbon, are introduced into the atmosphere during the growth process, the term interatmo still applies.
NT—When used herein shall mean a nanotube.
Plasmon—When used herein shall mean a quantum of plasma oscillation. This includes all types of plasmons and polaritons such as exciton-polaritons and surface plasmon polaritons. In the context of the current invention, under the right conditions, electromagnetic energy can be transformed at a surface into plasmons capable of propagating the energy through a medium.
Retun—When used herein shall mean a replenishment tunnel or other structure in a substrate or wavide that facilitates the replenishment of feedatoms, catalyst material, and/or other materials for NT growth. FIG. 2 illustrates a notional retun.
Tratip—When used herein shall mean a traveling micro or nanoscale platform or tip. An NT is grown from a catpar attached to the end of the tratip, a moveable platform. The platform or tip is a part of a cantilever or other support structure that facilitates the movement of the nanoscale NT growing system. Thus the NT may be grown vertically, horizontally or at an angle to enable structured CNT growths to be fabricated. A tratip is analogous to the sensing tip of an atomic force microscope which is attached to a cantilever. FIGS. 3, 9 and 11 illustrate tratips. Alternatively, the tratip could be stationary and the target surface or volume, upon which the NT growth is being deposited, could be mobile.
Trek—When used herein shall mean the process or processes by which a feedatom travels from a feedlayer or feedvoir to a catpar after being energized. Trekking is the verb form of trek.
Wavide—When used herein shall mean a waveguide through a substrate that transports energy in the form of emrad or plasmons.
2. Best Mode of the Invention
FIG. 1 illustrates the best mode contemplated by the inventor of Trekking Atom Nanotube Growth according to the present invention.
3. How to Make the Invention
Emrad and Plasmon Techniques
In a reaction chamber, the system shown in FIG. 1 , which illustrates the best mode (BM embodiment), grows NTs. Emrad incident on the bottom of the substrate is coupled into the wavide fabricated as part of the substrate. The energy of the emrad, either in the form of electromagnetic radiation or as plasmons is transported along the wavide to the feedlayer. This energy stimulates some of the feedlayer feedatoms to trek (shown by the arrow) into the catpar growing an NT. The feedatoms are transported to the catpar with an optimal energy for becoming a part of the NT growing from the catpar. Unwanted, extraneous chemical reactions are mitigated because the NTs grow in an ineratmo environment. The substrate is contoured to concentrate the catalyst and position the catpar. The substrate material is a surface impervious to the catalyst material so the catalyst will not migrate through the surface. The ineratmo's constituent gasses and physical characteristics can be chosen to mitigate unwanted, extraneous chemical reactions and support the growth process yielding highq NTs.
FIG. 2 illustrates the feedvoir (FV) embodiment of the current invention which comprises a feedvoir sitting between the catpar and wavide instead of a feedlayer. The larger the feedvoir, the more feedatoms, catalyst material and/or other materials are available for NT growth. Sizing these feedvoirs or the amount of material deposited in feedvoirs enables the tailoring of the growth of NTs, including tailoring the length of the NTs resulting from a given growth run.
One of the feedvoirs in FIG. 2 illustrates a retun through the substrate for replenishing the feedatoms, catalyst material and/or other materials for NT growth. This represents a variation of the FV embodiment wherein retuns facilitate the replenishment of feedatoms, catalyst material and/or other materials for NT growth from another reservoir. This reservoir would most probably be off the substrate on which the NTs are growing. In this way, continuous NT growth may be accomplished, especially in the case of industrial-scale growth in a manufacturing environment.
FIG. 3 illustrates the wavide tratip (WT) embodiment of the current invention comprising a catpar residing on a tratip. The feedatom delivery system is the same as in the BM ( FIG. 1 ) and FV ( FIG. 2 ) embodiments. In this case the tratip can grow the NT while on the move, enabling growth of an NT in three dimensions. Such capability facilitates the fabrication of nano and microscale electronic components or other patterned devices and structures. If a catpar becomes fouled, or in any way becomes non-operational, it could be replaced during a growth run. Note that the feedvoir could be replaced by a feedlayer for a variation of this embodiment.
The substrate, emrad and wavide system properties can be used to tune the amount of energy delivered to the feedlayer or feedvoir. These properties include the substrate contour, thickness and material properties (such as index of refraction); the emrad intensity, wavelength of radiation and pulse duration; and the wavide properties (such as index of refraction, absorption, etc.) and shape. Indeed as seen schematically in FIGS. 1-3 , the wavide's funnel shape concentrates the emrad's energy thereby increasing the energy density presented to the feedlayer directly above the wavide. In FIGS. 1 and 2 , one wavide for each catpar is shown, however, a wavide might encompass many catpars, delivering energy to the feedlayers or feedvoirs and stimulating the feedatoms to trek into the catpar.
The emrad may be generated by laser, light emitting diode (LED), fluorescent or incandescent flashlamp or other illumination technology. An LED, nanolaser and/or nano optical amplifier may be fabricated separately or as part of the substrate as a source or part of a source of emrad. In the case the LED, nanolaser and/or nano optical amplifier are fabricated as a part of the substrate, the wavide could in all or in part be the LED, laser or optical amplifier cavity. Structures such as gratings may be fabricated onto the substrate to facilitate the coupling of emrad into the wavide.
A feature of the BM ( FIG. 1 ), FV ( FIG. 2 ) and WT ( FIG. 3 ) embodiments is that NT growth may be paused or ceased by stopping the emrad. This could allow the fine tuning of NT length or a way to accurately begin and end different stages of NT growth in a multi-stage growth scenario.
Because of the very small nanoscale size of the wavide, the emrad energy coupling into and transport along the wavide may require plasmon processes. In that case the wavide structure may be a series of surfaces, parallel to the energy transport flow upon which surface plasmons can be induced. Moreover, the use of metallic nanoparticles within the wavide may be fabricated to support plasmon creation and hence energy flow through the wavide. Structures such as gratings may be fabricated onto the substrate to facilitate the coupling of emrad energy into plasmon modes in the wavide.
A variation of the delivery of the energy through the wavide by plasmons is the direct generation of plasmons by direct electrical stimulation. One method uses a metal grating structure laid down on a quantum well. Current injection into the quantum well creates electron-hole pairs which generate plasmons. The metal grating couples the plasmons (and the energy they carry) into the wavide or directly into the feedlayer or feedvoir. In the present invention, the plasmons propagate to the feedatom location and stimulate some of these feedatoms to trek into the catpar. This removes the emrad stimulation component of plasmon energy delivery.
The constituents of the material filling the feedlayers and feedvoirs may include feedatoms, catalyst and/or any other material needed for NT growth or processing. In this way, catalyst released will replenish any catalyst lost through Ostwald ripening or by the catpar diffusing into the substrate. Indeed, if the catpar diffuses slightly into the feedlayer or feedvoir, then the transport of feedatoms to the NT may be enhanced and growth rate of the NT may increase as long as the catpar size can support NT growth. The feedlayer depth and feedvoir volume could be designed for a given substrate to control the length of the NTs grown by that substrate.
Feedatom Acceleration Techniques
In a reaction chamber, the AB ( FIG. 4 ) embodiment of the present invention grows NTs. An atomgun fires, through a tunnel in the substrate, feedatoms of the proper energy, into a catpar growing an NT. The feedatoms are transported to the catpar with an optimal energy for becoming a part of the NT growing from the catpar.
The atomgun is an ion source; an electromagnetic apparatus used to ionize and accelerate charged particles. In the AB ( FIG. 4 ) embodiment, ionized feedatoms are transported to the tunnel entrances on the back side of the substrate by the acceleration provided by an atomgun. Requirements for these components of the current invention include the ability to create nearly monoenergetic ions, the capability to steer the beam of ionized feedatoms to the back of the substrate and sufficiently high current of ions to satisfy the growth requirements of the NTs. In FIG. 4 , one atomgun is shown notionally for each tunnel! In reality one atomgun is envisioned as providing feedatoms to many, many tunnels.
Ion sources are usually capable of accelerating more than just one atomic species. Therefore, it can be imagined that different ions could be accelerated into the catpar by the atomgun, or other acceleration technologies. Other ions might replenish catalyst material, alter the composition of the catpar to optimize or control growth and/or supply two different elements of feedatoms as in the case of the boron and nitrogen atoms of a BNNT.
When accelerating ions in an atmosphere, it is important to minimize the distance that the ions traverse in the atmosphere and the pressure of the atmosphere. The energy spread of the ions (through collisions) and the probability of atoms being scattered out of their path increases as the distance and pressure increase. Therefore, the backside atmosphere, which may be the interatmo or may be separated from the front side interatmo, will be kept at the minimal possible pressure and the distances the feedatom ions must travel will be kept to a minimum. If the substrate can support the pressure difference, the backside could be held as a vacuum.
The diameter of the tunnel openings at the substrate are smaller than the catpar diameter but on the order of one nanometer to tens of nanometers. The tunnels may be shaped in various ways other than cylinders if desired. Surface tension in the catpar allows it to straddle the tunnel.
Another version of the AB ( FIG. 4 ) embodiment could incorporate a thin film across the upper tunnel surface that could support the catpar. Moreover, a thin film across either the front (ineratmo) and/or back (atomgun environment) sides of the substrate could isolate these sides and act as a barrier to catalyst diffusion into the substrate. In this case, the feedatoms would require extra energy to penetrate the thin film and would emerge into the catpar with a range of energies since the energy loss of a particle through a thin film is a statistical process. Nonetheless, by tuning the peak of the energy distribution to the optimal energy of a feedatom, NT growth may continue.
FIG. 5 illustrates the angled atomgun (AA) embodiment of the current invention in which the tunnels traverse the substrate at an angle not normal to the substrate plane and offset from the catpar. In the case that the surface tension of the catpar is insufficient to straddle the tunnel through the substrate or for other reasons, the tunnel can be formed as shown in FIG. 5 , enabling the physical process of transporting the feedatoms of the optimal energy to the catpar growing an NT through a tunnel angled toward the catpar.
FIG. 6 illustrates the magnetic atomgun (MA) embodiment of the current invention in which the catpar once again does not straddle the tunnel. In the case that the surface tension of the catpar is insufficient to straddle the nanoscopic tunnel through the substrate or for other reasons, the tunnel can be formed as shown in FIG. 6 . Note that the angle of the tunnel need not be 90 degrees with respect to the substrate surface. A magnetic field can be used in the front side of the substrate to accelerate the ionized feedatoms, emerging from the tunnel, in an arc to the catpar. In this case the feedatom velocity and magnetic field magnitude and direction must be matched to bring the feedatoms to the catpar. Electric fields or a combination of electric and magnetic fields may also be used to accelerate the ionized feedatoms to the catpar.
FIG. 7 illustrates the ionizing laser (IL) embodiment of the present invention. In this version, the atomgun is replaced by ionizing and accelerating mechanisms that uses the substrate. For example, the backside of the substrate (or a coating on the substrate) acts as a negative “electrode plate” of the accelerating mechanism, and another surface (or a coating on the surface) spaced farther behind the substrate acts as the positive electrode plate. Feedatom or feedatom bearing gas fills the volume in between. A laser or other illumination device, fires ionizing radiation into the feedatom gas through a window and creates some feedatom ions. An electric field is applied, and the positively charged feedatom ions are accelerated toward the backside of the substrate. A few ions are accelerated into the tunnels and impact the catpar. The laser may be pulsed or continuously operated, and the electric field could be pulsed or constantly applied. The laser, feedatom gas, and electric field properties and application may be adjusted to optimize continuous NT growth. The gas could comprise feedatoms and other constitutents that would optimize NT growth. For example, a noble gas that will not be ionized by the radiation wavelength may be added to maintain a desired pressure. Other embodiments may use another ionization method and/or combine electric and/or magnetic fields to accelerate the feedatom ions to the catpar.
FIG. 8 illustrates the ablation laser (AL) embodiment of the present invention. A laser, or other illumination device, fires through a transmission window to the surface of the tunnel that has been coated with feedatoms. The laser pulse ionizes a number of feedatoms on the tunnel surface and liberates them from the surface. Some of these feedatoms impinge on the catpar and supply the nanotube growth. The laser may be pulsed or continuous wave. The cadence of the laser pulses is adjusted to maintain a sufficient supply of feedatoms to the growth site. Indeed, laser power, pulse length and wavelength as well as the geometry of the tunnel can be adjusted to optimize the feedatoms transported to the catpar.
The energy of these feedatoms is not as controlled as in other embodiments since laser ablation creates a plasma of high temperature. Nonetheless, the catpar will mediate the feedatom's energy and these feedatoms may feed the catpar's NT growth. Also, the transmission window could be a sheet of transmissive material on the bottom of the substrate. This transmissive window or surface could be used to isolate the backside of the substrate from the front side and tunnels, separating the laser environment from the reaction chamber environment. One embodiment of this approach is to eschew the transmissive window altogether and have the laser fire into the tunnel directly.
FIG. 9 illustrates the ballistic tratip (BT) embodiment of the present invention. This is the feedatom acceleration tratip version of the WT ( FIG. 3 ) embodiment. Any of the accelerating mechanisms in the AB ( FIG. 4 ), AA ( FIG. 5 ), MA ( FIG. 6 ), IL ( FIG. 7 ) or AL ( FIG. 8 ) embodiments may be used to accelerate the feedatoms down the tunnel into the catpar at the end of the tratip. Except for its feedatom delivery system, its operation and capabilities are similar to the WT ( FIG. 3 ) embodiment.
One feature of the AB ( FIG. 4 ), AA ( FIG. 5 ), MA ( FIG. 6 ), IL ( FIG. 7 ), AL ( FIG. 8 ) and BT ( FIG. 9 ) embodiments is that NT growth may be paused or ceased by stopping the atomgun or laser operation. This could allow the fine tuning of NT length or a way to accurately begin and end different stages of growth in a multi-stage growth scenario.
Catalyst Flow Techniques
FIG. 10 illustrates the CF embodiment of the current invention, wherein catalyst material bearing dissolved feedatoms flows in a chamber the top of which is the substrate. A molten catalyst flows in the chamber. Catpars are created by adjusting the pressure slightly to force catalyst through holes in the top of the chamber. The pressure within the flow and in the ineratmo can be adjusted separately or concurrently to create catpars. Feedatoms are dissolved in the catalyst in a precisely controlled process not shown in the figure. As the nanotube growth depletes the feedatom in the catpar catalyst, the depleted catalyst is replaced with feedatom rich catalyst by an eddy current set up by the flow passing underneath the catpar. Additionally, diffusion of feedatoms from the flowing, feedatom-rich, catalyst reservoir will bring feedatoms into the catpar. The temperature of the catpars and concentration of feedatoms can be adjusted to optimize NT growth.
The dimensions of the chamber may be nanoscopic, microscopic or macroscopic. Indeed the chamber can be of any cross section geometry as long as it provides for catalyst flow and tunnels (nominally on top) through which the catpars may be forced. Note that in this embodiment, the eddy flow is enhanced as the tunnel is shortened.
FIG. 11 illustrates the flow tratip (FT) embodiment of the present invention. This is the catalyst flow tratip version of the WT ( FIG. 3 ) embodiment. The catalyst flow of the CF ( FIG. 10 ) embodiment also delivers new feeatoms to the catpar on the tratip in the FT embodiment. Such a flow system, present in the FT tratip, can additionally be used to manage the catpar, including changing the size, replenishing lost catalyst and re-forming a catpar if the previous one is removed either by accident or design. Indeed, WT and BT ( FIG. 9 ) embodiments could be enhanced with a flow system to manage the catpar as well. Except for its feedatom delivery system, the FT operation and capabilities are similar to the WT embodiment.
A feature of the CF ( FIG. 10 ) and FT ( FIG. 11 ) embodiments is that NT growth may be paused or ceased by stopping the flow, although the cessation of growth might not be as abrupt as in the other embodiments. This could allow the fine tuning of NT length or a way to accurately begin and end different stages of NT growth in a multi-stage growth scenario.
Characteristics of all Techniques
The contoured substrate is useful for initially gathering catalyst atoms that form the catpar onto the favored growth site directly above the wavide, feedvoir or tunnel. In the catalyst flow case, the contoured surface is not as important but could still help to contain the catpar material. On the substrate bottom, a reflective surface may be placed on the areas outside the wavides so that unwanted heat is not coupled into the substrate from the emrad. Note that in the tratip embodiments (WT, FIG. 3 BT, FIG. 9 and FT, FIG. 11 ), no catpar alignment issues are expected since the catpar must be attached or deposited onto the tratip directly. Another embodiment of the current invention is to use a flat substrate.
The substrate can be heated or cooled to optimize the nanotube growth at the catpar. Also, mitigation of Ostwald ripening may require a cooled substrate. Techniques to accomplish this thermal control of the substrate include conduction, convection with the interatmo, radiation from above or below and to a lesser extent from losses from the feedatom delivery systems in the wavide or substrate. Note that the WT ( FIG. 3 ), BT ( FIG. 9 ) and FT ( FIG. 11 ) embodiments are not expected to have an Ostwald ripening problem although the stability of the catpar on the tratip may be of concern. The cooling of the substrate in the CF ( FIG. 10 ) and FT ( FIG. 11 ) embodiments, may allow the catpar to be in a slightly different state, that is, cooler than the flowing catalyst, thereby improving the conditions for NT growth.
Because the Trekking Atom Nanotube Growth technology does not require a hot environment to facilitate the chemical reactions inherent in chemical vapor deposition CNT growth, the temperature of the growth environment might be very different, probably lower. A lower temperature would decrease, possibly dramatically, Ostwald ripening. A different temperature might open up the possibilities for catalysts to an even larger number than are now available for CNT growth.
The catpar could be heated by electromagnetic radiation, probably from above, by radiation tuned to the catalyst material absorption and/or the catpar size to maximize absorption by the catpar. In this way local heating of the catpar is maximized. The catpar may be heated by the energetic feedatoms, which lose their energy to the catpar as they become a part of the growing NT. This enables a temperature differential between the catpar and substrate.
The ineratmo mitigates extraneous reactions from atmospheric gasses. Because the feedatoms for NT growth do not come from the atmospheric gasses; the constituent gasses, pressure and temperature of the atmosphere can be adjusted to suppress mechanisms that hinder NT growth. For example, in the case that the substrate heating maintains the catpar and NT growth site optimum temperature, the temperature and pressure of the atmosphere may be lowered to limit the energy of atmosphere-borne free atoms and molecules capable of bonding to the NT or catpar. The atmosphere gasses may be circulated, filtered, exchanged, monitored and/or changed to facilitate control of the constituents, temperature and pressure, thereby maintaining an optimal atmosphere in the reaction chamber. Finally, the atmosphere can be altered during growth process as required to continue growth, change NT characteristics, and/or functionalize NTs.
The atmospheres present at the nanotube growth side (front) and opposite side (back) of the substrate can be identical or composed of different constituent gasses and have different physical properties as long as barriers are present to separate the atmospheres and the catpar, and its NT growth is not disrupted.
The ineratmo may be modified by the introduction of gasses at any time during the growth process. One embodiment comprises using gasses to functionalize the growing or already grown NTs before they are removed from the growth environment. In this process, the functionalizing chemicals would be introduced into the ineratmo to chemically bond to the NTs for specific uses or further processing. The composition, temperature and pressure of the ineratmo may be altered to facilitate the functionalization reactions. Moreover, functionalized NTs may be accomplished by altering the materials and/or properties of the feedstock, feedstock transport, substrate, catalyst, and catpar.
The ability to clean and recondition the substrate or tratip between growth runs, including stripping and reapplying a feedlayer; stripping and replenishing feedvoirs; flushing a substrate surface by flooding with a catalyst flow; stripping the residue from the substrate backside after a growth run; clearing the tunnels and surfaces after a growth run; and reapplying catalyst material enable the efficient industrial process to grow NTs. Moreover, the greater control of the growth process afforded by all of embodiments of the present invention, facilitate the industrialization of the process.
Prudent choice of the substrate, substrate thin film, catalyst material(s), catpar, ineratmo or combination of these materials and their physical properties may mitigate the dissolution of the catalyst material into the substrate, thereby enabling continued NT growth. This unwanted diffusion shrinks the effective size of the catpar and stops NT growth
Accurate and precise control of the chemical reaction that forms NTs is enabled by the control of the feedatoms onto the catpar surfaces and/or into the catpars as well as the environment within which the reaction is taking place. This environment includes the ineratmo composition, temperature, pressure and density as well as the catpar composition, temperature, pressure and density. Moreover, the various feedatom transport methods to the catpar of the different embodiments and environmental control enable the suppression of other, unwanted chemical reactions, such as amorphous carbon that can stop CNT growth.
The accurate and precise control enabled by the growth technique facilitates the maintaining or changing of growing NT properties, such as NT diameter and chirality, during the growth process. The control may be accomplished by altering one or more of the materials and/or physical properties of the feedatoms, feedatom transport, substrate, catalyst, catpar, and/or ineratmo. Thus NTs of novel properties could be produced and tailor-made to specific applications. One example is to constantly increase the catpar size (within limits that permit continued growth) during a growth run so that the NT may undergo transitions to larger diameters.
Real time diagnostic measurements may be employed to measure and control the growth and functionalization of NTs. These diagnostics include the NT growth rate and structure; catalyst temperatures, pressures and compositions; feedatom transport; and ineratmo compositions, temperatures and pressures.
Trekking Atom Nanotube Growth technology may also be used to grow assemblages of atoms thereby forming molecules, structures, shapes and machines in an accurate and controlled manner. These assemblages of atoms include crystals, allotropes of an element, polymorphisms of compounds, polymers, minerals, metals, and polyamorphisms of amorphous materials. These processes may or may not require a catalyst to facilitate the formation of the assemblage.
The examples outlined in the present invention have all included the transport of a feedatom to a catpar. Control of feedatom transport at the sub-nanoscopic level and with precise energy and orientation, will enable fundamental building processes both catalytic and independent of a catalyst. In this case, the feedatoms are transported to an atomic, target site with the optimum energy distribution and orientation to promote bonding at its precise atomic position and with its intended bond(s) in the assemblage of atoms. The construction of designed structures will open up possibilities for materials science, physics, chemistry, medicine, biology, electronics/electromagnetics, optics, agriculture, and industrial and consumer products that are now undreamt.
4. EXAMPLES
The technologies required for the creation of the wavide and tunneling techniques in the present invention exist or are subjects of active research and development. These include:
1) Fabrication of waveguides in semiconductors and other materials.
2) Laying down layers of atoms/molecules onto surfaces to form a feedlayer.
3) Laying down atoms/molecules and populating a feedvoir.
4) Coupling of electromagnetic radiation in materials, including semiconductors.
5) Coupling of electromagnetic energy into plasmon modes in materials, including semiconductors.
6) Semiconductor laser technology and the fabrication of these lasers as a part of devices.
7) Generation of plasmons by direct current injection, including using quantum wells as a medium for the conversion
8) “Traveling tips” such as in an atomic force microscope.
9) Laser drilling techniques;
10) Focused ion beam drilling;
11) Forming boules (in analogy with microchannel plate fabrication but at smaller scales) with a microscopic tube pattern filled with sacrificial material, drawing these structures to the level that the tubes are of nano-scopic cross section, thin slicing the boules transverse to the tubes, then etching away the sacrificial material with a plasma torch.
12) Creating a forming die out of CNT material through patterned growth and subsequent manipulation, forming a ceramic material around the CNT forming die, and destructively removing CNT forming die material with a plasma torch.
Technique #12 above is also a possible approach to creating the chamber illustrated in FIG. 10 . The die would be formed as two separate pieces. A forest growth of CNTs (on a substrate that can survive the processing and be removed) is the forming die for the top surface with nanoscopic holes. A second piece is a cylindrical assembly of CNTs for the flow chamber. These two assemblies would be combined and the ceramic material formed over them, forming the ceramic flow chamber volume and its top surface with tiny holes. Finally, the CNT forming die (and substrate) would be removed, probably with a plasma torch that leaves the ceramic undamaged.
Generally, rough surfaces are easier to produce than flat, smooth surfaces. Thus there are many ways to make rough substrates. However, if the contoured surface structure is important then a controlled way to create the contours of the substrate surface may be used. One possible example is to use laser ablation. Indeed, one could create an ablation “crater” and then drill a hole through the bottom of the crater. This could be accomplished by first defocusing slightly the laser beam to ablate the crater and then focusing and collimating the beam to drill a hole through the substrate. In this case the drilling process may be seen as sequentially blasting many little craters vertically until the substrate is penetrated. The same crater technique could be used for wavide/feedvoir siting by excavating the wavide/feedvoir at the crater and depositing the wavide/feedvoir material into the excavation.
The surface of the substrate may have any one of various wavide and/or hole patterns. An array of regularly spaced wavides/holes could be chosen to grow NTs in bulk whereas a particular pattern could be used to fabricate: 1) electronic components and circuits; 2) single sensors and arrays; 3) receivers, rectennas or electromagnetic radiation emitting structures; 4) surface geometries to promote or prevent biological growth; 5) surfaces with special optical, reflective, interference or diffractive properties; 6) surfaces to promote or prevent chemical reactions; 7) structures with certain material properties including strength, hardness, flexibility, density, porosity, etc.; and 8) surfaces that emit particles such as electrons under electrical stimulation (field emission). Note that in the FV ( FIG. 2 ) embodiment the feedvoirs will be formed above the wavides as well.
Continuous replenishment of feedatoms to the catpars growing NTs and the mitigation of the phenomena that stop NT growth described by the various emdobiments above enables continuous growth of NTs. This continuous growth enables the industrialization of bulk NT growth as well as patterned NT growth described in the previous paragraph. Specifically, the retun variation of the FV ( FIG. 2 ) embodiment facilitates continuous replenishment of the feedstock and other materials for NT growth.
5. How to Use the Invention
In the research laboratory, the Trekking Atom Nanotube Growth technology will enable researchers to grow large amounts of long, highq NTs thereby stimulating research into the properties of the NTs and the macroscopic assemblages formed using these materials. In the case of CNTs these properties include very high tensile strength, high thermal conductivity, for some chiralities low conductivity and the ability to sustain very high electrical current densities, and for other chiralities semiconductor properties. In the case of BNNTs, interesting properties include high tensile strength, high thermal conductivity, low electrical conductivity and neutron absorption based upon the presence of boron. Indeed, the long, highq NTs may reveal properties and applications that are not possible with the currently available NTs. Moreover, the long, highq nanotubes can be used to construct: 1) enhanced strength structures; 2) enhanced conductivity conductors, wires, microscale and nanoscale integrated circuits, microscale and nanoscale transistors, diodes, gates, switches, resistors, capacitors, single sensors and arrays; 3) receivers, rectennas or electromagnetic radiation emitting structures; 4) surface geometries to promote or prevent biological growth; 5) surfaces with special optical, reflective, interference or diffractive properties; 6) surfaces to promote or prevent chemical reactions; 7) structures with certain material properties including strength, hardness, flexibility, density, porosity, etc.; and 8) surfaces that emit particles such as electrons under electrical stimulation (field emission).
The inventor envisions transforming the present invention into an industrial process in which a vast amounts of long, highq NTs are created. FIG. 12 illustrates schematically this vision. FIG. 12 shows the side view inside a reaction chamber. Five assemblies each consisting of a substrate with catpars arranged on it sitting above a laser. This configuration could facilitate the BM ( FIG. 1 ), FV ( FIG. 2 ), WT ( FIG. 3 ), IL ( FIG. 7 ) and AL ( FIG. 8 ) embodiments. In between is a lens that transports the photons from the laser to the backside of the substrate. Above the front surface of the five substrates is a “draw bar harvester”. When the NT growth has progressed for a time, the bar moves down, attaches to the growing NT surface and then rises in cadence with the growth. When the NTs are ready to be harvested, an industrial laser cuts the NTs off, above the substrate and catpar levels. The bar then transports the harvested NTs out of the reaction chamber to a processing location.
FIG. 13 illustrates another embodiment of an industrial process for the Trekking Atom Nanotube Growth Technology. The difference is that the laser energy source of the FIG. 12 system is replaced by the atomgun energy source of the AB ( FIG. 4 ), AA ( FIG. 5 ), MA ( FIG. 6 ) and BT ( FIG. 9 ) embodiments. Five assemblies each consisting of a substrate with catpars arranged on it sitting above an atomgun. In between is an ion lens that steers the feedatom ion beam from the atomgun to appropriate trajectories toward the backside of the substrate.
FIG. 14 illustrates another embodiment of an industrial process for the Trekking Atom Nanotube Growth Technology. The difference is that the flowing catalyst feedatom transport system of the CF ( FIG. 10 ) and FT ( FIG. 11 ) embodiments replaces either the laser of FIG. 12 or the atomgun of FIG. 13 .
The industrialization concepts described above and illustrated in FIGS. 12-14 run continuously and are modular so can be scaled up to any size desired.
FIG. 15 is an overhead view of another embodiment of an industrial process for the Trekking Atom Nanotube Growth Technology, in this case a tratip system. The tratip head assembly, to which the tratip system attaches, is mounted on a cantilever arm and moves in three dimensions: X and Y (in the plane of the substrate surface/page) by the motions of the support structure and cantilever arm and the Z direction by the tratip moving vertically (with respect to the plane of the substrate surface/page). Additionally, to efficiently deposit vertical NTs, the tratip head assembly also rotates in two axes. Two raised platforms and a sloped surface on the drawing facilitate the vertical NT and NT bridge structure features. The varied forms of the patterns of NTs deposited on the surface illustrate the potential capabilities of this system as envisioned by the inventor.
Achieving industrial-scale manufacturing of long, highq NTs means that these materials will become increasingly plentiful and inexpensive. In the case of CNTs, with their remarkable tensile strength and electrical properties, new ways of building existing commodities will be developed and new products will be invented using the superior material properties. CNT high strength material, possibly exceeding in tensile strength all existing materials by an order of magnitude or more, will revolutionize life on Earth. Additionally, with patterned growth technology, CNT electrical components created at the nanometer scale lengths will enable smaller, lower power integrated circuits and will transform human society. The most extreme example of the benefits may be that high strength CNTs will enable the Space Elevator, thereby opening the resources of space to mankind in the form of enhanced Earth observation, space-based solar power, asteroid mining, planetary defense and colonization of the moons and planets of our solar system!
It will be appreciated by those skilled in the art that the present invention is not restricted to the particular preferred embodiments described with reference to the drawings, and that variations may be made therein without departing from the scope of the present invention as defined in the appended claims and equivalents thereof. | Disclosed is a trekking atom nanotube growth technology capable of continuously growing long, high quality nanotubes. This patent application is a Continuation In Part of the Proximate Atom Nanotube Growth patent application Ser. No. 13/694,088 filed on Oct. 29, 2012. The current invention represents a departure from chemical vapor deposition technology as the atomic feedstock does not originate in the gaseous environment surrounding the nanotubes. The technology mitigates the problems that cease carbon nanotube growth in chemical vapor deposition growth techniques:
1) The accumulation of material on the surface of the catalyst particles, suspected to be primarily amorphous carbon, 2) The effect of Ostwald ripening that reduces the size of smaller catalyst particles and enlarges larger catalyst particles, 3) The effect of some catalyst materials diffusing into the substrate used to grow carbon nanotubes and ceasing growth when the catalyst particle becomes too small. | 2 |
BACKGROUND OF THE INVENTION
The present invention concerns devices for reducing pollutants discharged by an internal combustion engine. More specifically, the invention relates to such devices adaptable to diesel engines which trap particles and vapor carried by the exhaust gas discharged from the engine.
It is recognized that the production of noxious oxides of nitrogen (NO x ) which pollute the atmosphere are undesirable. Steps are therefore typically taken to eliminate, or at least minimize, the formation of NO x constituents in the exhaust gas products of an internal combustion engine. The presence of NO x in the exhaust gas of internal combustion engines is generally understood to depend, in large part, on the temperature of combustion within the cylinders of the engine. In connection with controlling the emissions of such unwanted exhaust gas constituents from internal combustion engines, it is widely known to recirculate a portion of the exhaust gas back to the air intake portion of the engine (so-called exhaust gas recirculation or EGR). Since the recirculated exhaust gas effectively reduces the oxygen concentration of the combustion air, the flame temperature at combustion is correspondingly reduced, and since NO x production rate is exponentially related to flame temperature, such exhaust gas recirculation (EGR) has the effect of reducing the emission of NO x .
It is further known to adapt the engine with electronic sensors to evaluate and control various operational parameters of the engine. One example includes providing a differential pressure transducer across an orifice to measure mass flow rate of the exhaust gas. Using this mass flow rate measurements of the exhaust gas, exhaust gas recirculation may be controlled to optimize engine performance and decrease emission levels. These sensors are typically placed in direct contact with the intake or exhaust gas which are often hostile to the electronic sensor itself. For example, the differential pressure sensor may be placed within the exhaust system that is in direct contact with debris laden exhaust gas.
Debris mixed with the exhaust gas includes particulate emissions can cause extensive damage to engines turbochargers or superchargers. Particulate debris is abrasive and enters the engine oil causing undue wear on the piston rings, valves, and other parts of the engine. A common form of particulate matter is “soot” which is a sticky substance that can lead to carbon build-up on surfaces exposed to the soot. The soot is particularly damaging to electronic sensors such as temperature and pressure sensors. Soot build-up on the sensor causes a degradation in sensor accuracy and in some instances permanent damage.
FIG. 1 depicts a typical engine and EGR system 10 including known components for actively controlling the mass flow of the recirculated exhaust gas. An internal combustion engine 12 includes an air intake manifold 14 attached to the engine 12 and coupled to the various cylinders 16 of the engine, typically through valves (not shown). Intake manifold 14 receives intake ambient air via conduit 18 . An exhaust gas manifold 20 is attached to the engine 12 and coupled to the exhaust gas ports of the various combustion cylinders typically through valves (not shown). The exhaust manifold 20 exhaust combustion gas to the atmosphere via exhaust gas conduit 22 . The engine 12 typically includes a fan 24 which is driven by the rotary motion of the engine to cool engine coolant fluid flowing through a radiator (not shown) positioned proximate the fan 24 .
An exhaust gas recirculation line 26 is connected at one end 28 to the exhaust gas conduit 22 , and at its opposite end 30 to an EGR cooler 32 . The cooler 32 reduces the temperature of the exhaust gas in anticipation of re-entering the inlet air stream of conduit 18 . An EGR flow control valve 34 is connected at one end 36 thereof to EGR cooler 32 via conduit 38 , and at an opposite end 40 thereof to exhaust manifold 20 via conduit 42 . The valve 40 is controllable to open or close the EGR path in response to engine performance requirements.
An air intake system (not shown) provides a supply of fresh intake air through a filter (not shown) to compressor 44 of a turbocharger 46 . A first portion of the exhaust gas discharged from exhaust manifold 20 of engine 12 is supplied to intake conduit 18 through exhaust gas recirculating line 26 to combine with fresh air driven by the turbocharger compressor. A second portion of the exhaust gas flows through turbine 48 of turbocharger 46 to rotate compressor 44 . As a result, intake air exiting from compressor 44 of turbocharger 46 is compressed and heated. The compressed intake air preferably flows through an intake air cooler 50 to reduce the air temperature to a level for optimum combustion in the engine cylinders. Intake air cooler 50 may be an air-to-air type heat exchanger, however, other types of diesel engine coolers or heat exchangers may be satisfactorily used. In operation, the EGR flow control valve 34 is controlled by an engine control module 52 (ECM) in response to differential pressure sensed through a pressure sensor 54 providing a pressure signal to the ECM 52 , via signal path 56 . The ECM 52 uses the differential pressure to calculate the mass flow rate of recirculated exhaust gas through valve 34 . In response to the pressure signal, ECM 52 provides a corresponding control signal to EGR valve 34 , through control circuit 58 . Therefore, the EGR valve 34 is controlled via the ECM 52 to divert any desired amount of exhaust gas directly from the exhaust gas recirculation line 26 to intake conduit 18 .
In one attempt to decrease particulate carried by the exhaust gas, devices referred to as “baghouses” have been employed to filter solid material carried by the exhaust gas. The baghouses can be provided with a fiber bag to capture debris with little on no exhaust gas backpressure. However, once a substantial amount of particulate is captured by the bag the device would lead to a detrimental increase in exhaust gas backpressure. This backpressure can result in a build up of debris within the exhaust system causing poor engine performance and ultimately failure of the engine.
Other known devices which decrease particulate emissions carried by the exhaust gas include regeneration devices which burn away the accumulation of debris. U.S. Pat. No. 5,390,492 to Levendis discloses a regeneration device for use with a filter assembly to decrease the particulate emission in the system. The regeneration device includes a collection chamber fitted with an electric powered incinerator to burn away material accumulating in the collection chamber. Unfortunately, the device is complicated and not a viable alternative for internal combustion engines utilizing after market equipment to decrease exhaust particulate. Furthermore, regeneration devices tend to be expensive to implement and are susceptible to malfunction.
U.S. Pat. No. 5,458,664 issued to Ishii et al. discloses a particle trap provided with a metallic mesh filter, the particle trap is placed directly in the exhaust gas line and is sized to avoid significant exhaust gas backpressure. However, the filter inherently accumulates debris and decreases the flow area, and consequently, an unwarranted back pressure develops. The backpressure in the exhaust line causes degradation of engine power and permanent engine damage, after a period of time.
What is therefore needed is a device for trapping debris in the form of exhaust gas particulate and vapor to protect equipment downstream and at the same time cause only insignificant restriction of exhaust gas from the engine. Moreover, a device that is inexpensive to manufacture and includes widespread adaptability to virtually all sizes and types of engines is desirable. Preferably, such a device should be serviceable rather than warranting periodic device replacement.
SUMMARY OF THE INVENTION
These unmet needs are addressed by the exhaust gas recirculation system of the present invention. In one aspect of the invention, an exhaust gas recirculation system for an internal combustion engine includes intake and exhaust manifolds to respectively receive ambient air and expel exhaust gas. A recirculation line fluidly connects the exhaust and intake manifolds. An exhaust gas recirculation valve is included in the recirculation line and is controlled to distribute exhaust gas into the intake manifold. A particle and/or vapor trap is arranged to receive all of the exhaust gas from the exhaust manifold and includes a particle collection chamber therein. A stagnation region is provided within the particle trap configured so that all the exhaust gas passing through the trap is directed toward the stagnation region therein and at least a portion of debris carried with the exhaust gas is retained within the particle collection chamber.
The present invention further provides a particle trap for an exhaust gas recirculation control system for use with an internal combustion engine including a housing having at least one inlet and at least one outlet. A flow deflector is included in the housing and is arranged to deflect a flow of exhaust gas discharged from the inlet. A stagnation region is provided within the housing and is in fluid communication with the inlet and is placed in relation to the flow deflector to receive all exhaust gas from the inlet. The stagnation region is in fluid communication with the outlet through an exhaust gas portal wherein substantially all of the flow of exhaust gas is directed toward the stagnation chamber to urge separation and collection of debris entrained in the exhaust gas.
In one aspect of the invention, the flow deflector is in fluid communication with an inlet cavity. The inlet cavity is in fluid communication with the stagnation region through an exhaust gas acceleration region to urge the flow of exhaust gas toward the stagnation chamber.
It is one object of the present invention to provide an exhaust gas recirculation system that receives substantially all of the exhaust gas expelled from the internal combustion engine such that debris carried by the exhaust gas is trapped and prevented from accumulating on operational sensors and the EGR valve.
Another object of the present invention is to provide a particle trap for an internal combustion engine which traps substantially all the debris, in the form of soot and vapor, expelled from the engine without a significant backpressure caused by the particle trap.
Yet another object is to provide a particle trap which may be readily integrated into new and existing internal combustion engines alike and one which is serviceable rather than requiring periodic replacement. Also, a particle trap which does not require electrical connection to operate and one which is inexpensive and not complicated to manufacture is desirous.
These and other objects, advantages and features are accomplished according to the systems and methods of the present invention, as described herein with reference to the accompanying figures.
DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic diagram of a typical known engine and exhaust gas recirculation system.
FIG. 2 is a schematic diagram of an exhaust gas recirculation system including a particle trap according to one embodiment of the present invention.
FIG. 3 is a side cross-sectional view of the particle trap depicted in FIG. 2 .
FIG. 4 is an end cross-sectional view of the trap shown in FIG. 3, taken along line 4 — 4 , illustrating the connecting passageway and inlet cavity.
FIG. 5 is an end cross-sectional view of the particle trap shown in FIG. 3, taken along line 5 — 5 , illustrating the exhaust gas portal.
FIG. 6 is a perspective cross-sectional view of the particle trap of FIGS. 2-5, including a schematic diagram of the flow of exhaust gas and the trapping of particulate and vapor therein.
FIG. 7 is a plan view of the schematic flow diagram of FIG. 6, and further illustrating the length L of an exhaust gas portal of the inventive trap.
FIG. 8 is a graph depicting percent particle escape versus particle size for three differing particle trap assemblies according to the present invention.
FIG. 9 is a graph depicting flow coefficients for the particle trap assemblies depicted in FIG. 8 .
FIG. 10 is a side cross-sectional view of a second embodiment particle trap of according to the present invention.
FIG. 11 is a sectional view of the particle trap taken along line 11 — 11 of FIG. 10, illustrating the pair of exhaust gas portals.
Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent embodiments of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the present invention. The exemplification set out herein illustrate embodiments of the invention and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. The invention includes any alterations and further modifications in the illustrated devices and described methods and further applications of the principles of the invention which would normally occur to one skilled in the art to which the invention relates.
The present invention provides an exhaust gas particle trap to divert and contain substantially all of the soot and vapor discharged by an internal combustion engine carried by the exhaust gas from the engine. The particle trap is preferably fitted within the exhaust line exiting the exhaust manifold to trap debris carried by the exhaust gas before such debris reaches the EGR valve and electronic equipment employed to efficiently operate, with environmental consciousness, an internal combustion engine.
Referring to FIG. 2, an exhaust gas recirculation system 60 according to one embodiment of the present invention is shown. The system 60 differs from the known system 10 (FIG. 1) in that system 60 includes a particle trap 62 to contain debris 64 carried by the exhaust gas and provide exhaust gas that is substantially free of solid material.
Differential pressure sensor 54 is interposed in the EGR to aid in the control of the EGR valve 34 . The sensor is typically a diaphragm type sensor, and is generally susceptible to performance degradation due to debris carried by the exhaust gas. The debris carried by the exhaust gas includes a sticky carbon rich substance which quickly accumulates and gums up equipment and narrows flow passages. The pressure sensor 54 , and the remaining equipment positioned downstream relative to particle trap 62 , are protected from debris discharged from the engine 12 . Preferably, particle trap 62 is adapted to fit within exhaust gas conduit 22 , connecting the exhaust manifold 20 and recirculation line 26 . Notably, in this most preferred arrangement all the exhaust gas discharged from the exhaust manifold 20 is received by the particle trap 62 .
Referring now to FIGS. 3-5, details of the structure of the particle trap 62 will be explained. Trap 62 includes a housing 68 with threaded ports 70 , 72 , respectively, provided on the opposite axial ends 74 , 76 of housing 68 . Axial end 74 of housing 68 receives threaded fitting 78 sealably connected with inlet conduit 80 through a pressure fit engagement, as is customary. Inlet conduit 80 is in direct fluid communication with the exhaust manifold 20 such that exhaust gas is transported from exhaust manifold 20 to particle trap 62 through inlet conduit 80 (FIG. 2 ).
Threaded port 72 of housing 68 threadably receives fitting 82 sealably connected with outlet conduit 84 through a pressure fit engagement. Outlet conduit 84 provides a discharge passage for cleaned exhaust gas to exit particle trap 62 and is fluidly connected with the turbine 48 and recirculation line 26 (FIG. 2 ). It is understood that other fittings can be utilized that are capable of achieving a fluid-tight connection of the trap between the conduits 80 and 84 .
Housing 68 of particle trap 62 preferably includes a flow deflector 86 at the end of an inlet cavity 92 that is transversely positioned relative to inlet opening 88 of inlet conduit 80 . Flow deflector 86 is provided to divert debris laden exhaust gas to a remote portion of the particle trap for further processing of the gas. Immediately downstream of flow deflector 86 is gas acceleration region 90 . Acceleration region 90 is annular in shape and is located between inlet cavity 92 and an outer surface 94 of inlet conduit 80 . Acceleration region 90 is provided immediately downstream from the flow deflector 86 to further guide the gas through the particle trap. Additionally, acceleration region 90 represents a decrease in flow area relative to the immediately preceding inlet cavity 92 consequently causing the exhaust gas to speed up through acceleration region 90 . The moving exhaust gas exits acceleration region 90 having a significant velocity and is projected beyond exhaust gas portal 114 such that debris laden exhaust gas does not prematurely escape through the exhaust gas portal 114 . Annular shaped stagnation region 96 is positioned downstream relative to acceleration region 90 and is located between counterbore 98 and outer surface 94 of inlet conduit 80 . Funnel shaped transition portion 99 connects acceleration region 90 and stagnation region 96 . Transition portion 99 includes an inner diameter that progressively increases from acceleration region 90 to stagnation region 96 and as a result exhaust gas flowing through transition portion 99 experiences a significant decrease in velocity. Stagnation region 96 is provided to significantly slow the exhaust gas discharged from acceleration region 90 . Once slowed, the relatively heavy debris particles carried by the exhaust gas tend to attach to the walls of counterbore 98 while the exhaust gas remains diffuse. Particle collection chamber 100 is located between face surface 104 of counterbore 98 and outer surface 94 of inlet conduit 80 . Transverse face 102 of threaded plug 78 provides a floor for particle collection chamber 100 .
Axial end 76 of housing 68 includes an outlet cavity 106 in fluid communication with outlet conduit 84 . Outlet cavity 106 and inlet cavity 92 communicate through a connecting passageway 108 provided in housing 68 (FIG. 4 ). Connecting passageway 108 extends from a transversely positioned floor 110 of outlet cavity 106 towards outer radial portion 112 of counterbore 98 (FIG. 5 ). As best seen in FIG. 5, an exhaust gas portal 114 is formed between the intersection of counterbore 98 and connecting passageway 108 .
In the preferred embodiment of the invention, the centerline of inlet conduit 80 extends axially along a first reference axis 116 and the centerline of outlet conduit 84 extends along a second reference axis 118 . First and second reference axes 116 , 118 are arranged parallel relative to one another. Preferably the two axes are offset, although the present invention contemplates first and second reference axes 116 , 118 being arranged such that they are coincident. A third reference axis 120 represents the centerline of connecting passageway 108 and is parallel relative to first reference axis 116 of inlet conduit 80 . Third reference axis 120 may be offset a distance of 1.0 inch, for example, relative to first axis 116 . For machining purposes, it is preferred that the axes 116 and 118 are offset a distance equal to the radius of the connecting passageways 108 .
One advantage of trap 62 is that it may be inexpensively manufactured from bar stock. For example, housing 68 may be made from a piece of “off the shelf” cylindrical or hexagonal carbon steel bar stock. The threaded plugs 78 , 82 may be selected from a variety of standard fittings such as NPT fittings. Moreover, the inlet and outlet conduits 80 , 84 may be pressure fitted with their respective threaded plugs 78 , 82 as is customary. It is contemplated that the threaded plugs should be reusable such that housing 68 may be removed, the debris accumulated therein extracted, and the housing then replaced as a course of periodic maintenance.
To manufacture housing 68 through machining operations only the axial ends 74 , 76 of housing 68 need be accessed. Inlet cavity 92 and counterbore 98 of axial end 74 are machined. Similarly, inlet cavity 106 and connecting passageway 108 of axial end 76 are machined, the threads in each axial end 74 , 76 may then be formed to substantially complete the housing. Specifically, outlet cavity 106 in housing 68 may be formed by drilling, for example using a 1.625 inch drill, boring into the housing 68 , along second reference axis 118 . The connecting passageway 108 may then be drilled using a 0.375 inch drill along third reference axis 120 . The inlet cavity 92 may then be formed by drilling, using a 1.25 inch drill, along the first reference axis 116 . The first reference axis 116 is offset 0.25 inch, relative to second reference axis 118 , for example. Counterbore 98 , may then be provided in housing 68 by drilling, using a 1.5 inch drill, for example along the first reference axis 116 . Although the trap is most easily formed by machining, it is contemplated that housing 68 , alternatively, may be a cast or forged component having cored internal passageways rather than drilled passageways to reduce labor costs corresponding to machining the housing.
Referring to FIGS. 6 and 7, it may be seen that connecting passageway 108 intersects counterbore 98 to form the truncated cylindrical shaped exhaust gas portal 114 . The flow characteristic of particle trap is, in part, dependent on the size of portal 114 which spans length “L” as best illustrated in FIG. 7 .
In operation, exhaust gas carrying debris in the form of soot and vapor, illustrated by arrows 122 , is discharged from inlet opening and strikes the flow deflector 86 . The flow, laden with debris, is introduced into inlet cavity 92 and thereafter forced into the annular acceleration region 90 . The debris carried with the exhaust gas is accelerated through the acceleration region 90 and directed toward stagnation region 96 . As the flow transitions from acceleration region 90 to stagnation region 96 through transition portion 99 , the flow expands and accordingly decreases in velocity. Once in the stagnation region, the debris 124 settles in the particle collection chamber 100 . The debris 126 tends to separate from the gas when the combination is exposed to the stagnation region 96 and accumulates within the particle collection chamber 100 . Thereafter, “cleaned” exhaust gas, as illustrated by arrows 128 , is discharged through exhaust gas portal 114 and is eventually dispatched from particle trap 62 to turbine 48 , EGR valve 34 and pressure sensor 54 as illustrated by arrows 66 (FIG. 2 ). The exhaust gas recirculation system 60 , operating without the inventive particle trap 62 would lead to poor engine performance or premature failure resulting in costly repairs and equipment downtime.
Referring to FIG. 7, exhaust gas portal 114 is positioned axially adjacent the acceleration region 90 , such that exhaust gas and debris is directed toward the stagnation region 96 , before it is allowed to exit the exhaust gas portal 114 . The acceleration region ensures that the debris laden exhaust gas is projected past the exhaust portal 114 so that the exhaust gas may be cleaned within the stagnation region prior to exiting through the exhaust gas portal 114 .
The exhaust gas and debris carried therewith introduced into inlet conduit 80 enter as pressure pulses discharged from the engine 12 (FIG. 2) and the pressure pulses urge further circulation of the flow through particle trap 62 . Thus, particle trap 62 may be oriented in a variety of positions and effectively trap debris. However, it may be seen that particle trap 62 is most effective if vertically oriented, whereby particle collection chamber 100 is arranged beneath flow deflector 86 such that gravity assists the debris toward particle collection chamber 100 .
Referring to FIG. 8, shown is particle retention data corresponding to three different particle trap constructions differing by the length L (FIG. 7) of exhaust gas portal 114 . L 1 is the shortest length and is 1.75 inch, for example. L 2 and L 3 are 1.95 inch and 2.23 inch, respectively. Therefore, it may be seen that as the length of the exhaust gas portal is increased, i.e., as the flow area is increased, the percentage of total particulate debris allowed to escape through the portal increases for each portal dimension, the escape ratio for different particle sizes does not vary significantly.
Referring to FIG. 9, a second graph is provided representing the flow characteristics for the particle trap structures having respective portal lengths L 1 , L 2 and L 3 . It is contemplated that flow through the particle trap 62 will coincide with relatively low flow rates, such as a flow having a Reynolds Number of 13,000. The data, illustrated in FIGS. 8 and 9, was collected at low flow velocity (Re 13,000) except for one instance wherein data was collected for a particle trap having the portal length L 2 at a high Reynolds Number (FIG. 9 ). It may be seen that the flow loss coefficient improves, (i.e., the particle trap causes less impedance to exhaust gas discharged from exhaust manifold 20 (FIG. 2 )) as the length of the portal is increased. Portal length L 3 provides a significant improvement in flow over the particle trap having a portal length of L 2 . Further, and with reference to FIG. 8, the percent of particle escape between the particle vapor traps having portal lengths L 2 and L 3 is not significantly different, yet a significant improvement in flow loss coefficient is provided by the trap having portal length L 3 . The formula used to calculate each flow loss coefficient may be expressed as: K Flow Loss Coefficient = P Total Inlet - P Total Outlet P Dynamic Inlet
A second embodiment of a particle trap is shown in FIG. 10 and differs from the first embodiment 62 by having a pair of particle traps combined in a single housing 130 . Particle trap 132 includes housing 130 with threaded ports 134 , 136 provided on axial end 138 . The other axial end 140 of housing 130 includes threaded ports 142 , 144 . Axial end 138 of housing 130 receives threaded fittings 146 , 148 sealably connected with inlet conduits 150 , 152 through respective pressure fit engagements, as is customary. Inlet conduits 150 , 152 are in direct fluid communication with the exhaust manifold such that exhaust gas is transported from the exhaust manifold to particle trap 132 through inlet conduits 150 , 152 . Threaded ports 142 , 144 of housing 130 threadably receive fittings 154 , 156 sealably connected with outlet conduits 158 , 160 through pressure fit engagements. Outlet conduits 158 , 160 provide discharge passages for clean exhaust gas to exit particle trap 132 and are fluidly connected with both the turbine and recirculation line. Therefore, cleaned exhaust gas is discharged from trap 132 and is introduced to the turbine, the EGR valve and pressure sensor without having soot and vapor carried by the exhaust gas.
Housing 130 of particle trap 132 includes a pair of flow deflectors 162 , 164 that are transversely positioned relative to respective inlet openings 166 , 168 of respective inlet conduits 150 , 152 . Immediately downstream of the flow deflectors 162 , 164 are inlet cavities 174 , 176 and gas acceleration regions 170 , 172 . Acceleration regions 170 , 172 are annular in shape, and respectively located between inlet cavities 174 , 176 and outer surfaces 178 , 180 of inlet conduits 150 , 152 . Annular shaped stagnation regions 182 , 184 are positioned downstream relative to acceleration region 170 , 172 and are located between counterbores 186 , 188 and outer surfaces 178 , 180 of inlet conduits 150 , 152 . Particle collection chambers 190 , 192 are located between wall surfaces 194 , 196 of counterbores 186 , 188 and outer surfaces 178 , 180 of inlet conduits 150 , 152 . Transverse faces 198 , 200 of threaded plugs 146 , 148 provide respective floors for particle collection chambers 190 , 192 .
Axial end 140 of housing 130 includes outlet cavities 202 , 204 in fluid communication with outlet conduit 158 , 160 . Outlet cavities 202 , 204 and inlet cavities 174 , 176 are in respective fluid communication through connecting passageways 206 , 208 provided in housing 130 . Connecting passageways 206 , 208 respectively extend from transversely positioned floors 210 , 212 of outlet cavities 202 , 204 towards outer radial portions 214 , 216 of counterbores 186 , 188 . Exhaust gas portals 218 , 220 are formed between the respective intersections of counterbores 186 , 188 and connecting passageways 206 , 208 (FIG. 11 ).
In the preferred embodiment of the invention, the centerlines of inlet conduits 150 , 152 extend axially along a pair of first reference axes 222 a , 222 b and the centerlines of outlet conduits 158 , 160 extend along a pair of second reference axes 224 a , 224 b . First and second pairs of reference axes 222 a , 222 b , 224 a , 224 b are arranged parallel to one another. Preferably the two pair of axes are offset, although, it is envisioned that, alternatively, first and second pairs of reference axes 222 a , 222 b , 224 a , 224 b may be arranged such that each inlet conduit is axially aligned with each outlet conduit. A third pair of reference axes 226 a , 226 b represent the centerlines of connecting passageways 206 , 208 and are preferably parallel relative to respective first pair of reference axes 222 a , 222 b of inlet conduits 150 , 152 . Each of the pair of third reference axes 226 a , 226 b may be offset relative to each respective first reference axis 222 a , 222 b a distance as that was previously described in accordance with the distance between axes 120 and 116 associated with particle trap 62 , illustrated in FIG. 3 . For machining purposes it is preferred that the pair of axes 222 a , 222 b are offset relative to axes 224 a , 224 b , by a distance equal to the radius of the respective connecting passageways 226 a , 226 b.
Particle trap 132 may be manufactured utilizing similar techniques and materials as previously described in association with particle trap 62 of the first embodiment. In order for exhaust gas to flow into intake conduits 158 , 160 , from the exhaust manifold a tee fitting (not shown) may be provided to accordingly divert the flow from the exhaust conduit, attached to the exhaust manifold, to the inlet conduits of the particle trap 132 . Similarly, a tee fitting may be provided to transport cleaned exhaust gas away from the particle trap 132 through outlet conduits 158 , 160 .
In a preferred embodiment, the dimensions of each individual trap of the pair of traps illustrated are similar to the dimensions previously described in accordance with first embodiment particle trap 62 . However, the present invention contemplates that the length of each exhaust gas portal L a and L b may be independently varied to provide an overall suitable particulate retention and flow loss coefficient for the particle trap 132 .
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character. It should be understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.
For instance, it is understood that a vehicle engine and EGR system may be adapted with a particle trap having multiple stagnation chambers and associated collection chambers in a single housing such that adapting the trap to an exhaust system does not cause a significant backpressure of exhaust gas during extended use and concomitantly provides for a significant collective volume to retain trapped debris. | An exhaust gas recirculation system for an internal combustion engine includes intake and exhaust manifolds that respectively receive ambient air and expel exhaust gas. A recirculation line fluidly connects the exhaust and intake manifolds. An exhaust gas recirculation valve is included in the recirculation line and is controlled to distribute exhaust gas into the intake manifold. A particle trap is arranged to receive all of the exhaust gases from the exhaust manifold and includes a particle collection chamber therein. A stagnation region is provided within the particle trap such that all the exhaust gas passed through the exhaust gas particle trap is directed toward the stagnation region therein and at least a portion of debris carried with the exhaust gas is retained within the particle collection chamber. | 5 |
BACKGROUND
[0001] 1. Technical Field
[0002] The present invention relates generally to electronic module testing. More specifically, the invention relates to a process for efficient testing of the modules for a wire sweep.
[0003] 2. Background
[0004] In bond and assembly of an electronic package or module, wires are bonded to a die and finger on a laminate. These wires serve to connect the die to the outer laminate, enabling the function of the module at an associated card attachment location.
[0005] Electronic modules however, may be defective as a result of a variety of manufacturing defects. One such defect is known as a wire sweep, wherein the wires of the module are not properly aligned. Misalignment of the wires may cause a short and may be detectable prior to the short. While testing for wires that are in physical contact is somewhat rudimentary, wires that are close together, yet not in contact, do not fail this shorting test and are therefore more difficult to detect. One solution is to use an x-ray to detect a wire sweep. However, this process is expensive, making the X-ray screening of many modules undesirable.
SUMMARY OF THE INVENTION
[0006] The invention comprises a method, system, and computer program product for efficiently testing electronic modules for a defect.
[0007] In one aspect, a method is provided for performing a quality control review of electronic modules. Individual modules include a functional assembly of electrical components. In response to a wire sweep detection on a set of modules, a current leakage screening is performed on each module determined to have passed the first test phase. The electronic current leakage screening test excludes each module determined to have failed the first test phase.
[0008] In another aspect, a computer program product is provided to perform quality review of electronic modules. The computer program product is in communication with a computer-readable non-transitory storage device having computer readable program code embodied thereon. When executed, the computer implements testing on the electronic modules. Upon detection of a wire sweep failure on a selection of modules, program code employs a electronic current leakage screening on each module determined to have passed the first test. The electronic current leakage screening excludes each module determined to have failed the first test phase.
[0009] In yet another aspect, a system is provided for quality control review of one or more electronic modules. A processing unit is provided in communication with memory. A functional unit is provided in communication with the processing unit, the functional unit has tools to support the quality control review of the modules, including but not limited to, a first test manager and a screening manager. The first test manager conducts a first phase of testing of a selection of electronic modules. The screening manager, in communication with the first test phase manager, performs an electronic current leakage screening for each module determined to have passed the first test phase and excludes each module determined to have failed the first test.
[0010] Other features and advantages of this invention will become apparent from the following detailed description of the presently preferred embodiment of the invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The drawings referenced herein form a part of the specification. Features shown in the drawings are meant as illustrative of only some embodiments of the invention, and not of all embodiments of the invention unless otherwise explicitly indicated. Implications to the contrary are otherwise not to be made.
[0012] FIG. 1 is a flow chart illustrating a method for a first and second phase of a first module test.
[0013] FIG. 2 is a flow chart illustrating a method for a second module test.
[0014] FIG. 3 depicts a block diagram of a system for electronic module quality assurance testing.
[0015] FIG. 4 depicts a block diagram showing a system for implementing an embodiment of the present invention.
DETAILED DESCRIPTION
[0016] It will be readily understood that the components of the present invention, as generally described and illustrated in the Figures herein, may be arranged and designed in a wide variety of different configurations. Thus, the following detailed description of the embodiments of the apparatus, system, and method of the present invention, as presented in the Figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention.
[0017] The functional unit described in this specification has been labeled with tools, modules, and/or managers. The functional unit may be implemented in programmable hardware devices such as field programmable gate arrays, programmable array logic, programmable logic devices, or the like. The functional unit may also be implemented in software for execution by various types of processors. An identified functional unit of executable code may, for instance, comprise one or more physical or logical blocks of computer instructions which may, for instance, be organized as an object, procedure, function, or other construct. Nevertheless, the executable of an identified functional unit need not be physically located together, but may comprise disparate instructions stored in different locations which, when joined logically together, comprise the functional unit and achieve the stated purpose of the functional unit.
[0018] Indeed, a functional unit of executable code could be a single instruction, or many instructions, and may even be distributed over several different code segments, among different applications, and across several memory devices. Similarly, operational data may be identified and illustrated herein within the functional unit, and may be embodied in any suitable form and organized within any suitable type of data structure. The operational data may be collected as a single data set, or may be distributed over different locations including over different storage devices, and may exist, at least partially, as electronic signals on a system or network.
[0019] Reference throughout this specification to “a select embodiment,” “one embodiment,” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “a select embodiment,” “in one embodiment,” or “in an embodiment” in various places throughout this specification are not necessarily referring to the same embodiment.
[0020] Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided, such as examples of managers, to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
[0021] The illustrated embodiments of the invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and processes that are consistent with the invention as claimed herein.
[0022] In the following description of the embodiments, reference is made to the accompanying drawings that form a part hereof, and which shows by way of illustration the specific embodiment in which the invention may be practiced. It is to be understood that other embodiments may be utilized because structural changes may be made without departing from the scope of the present invention.
[0023] In order to maximize efficiency of module testing, multiple tests may be employed, in which further assessments are reserved for a smaller batch of modules for improved testing efficiency. FIG. 1 is a flow chart ( 100 ) illustrating a method for a first set of testing that employs at least two such tests for assessing the modules. Initially, a first test of module testing is employed on a batch of modules ( 102 ). This first test, also referred to as a first phase, is employed to detect a gross failure associated with modules within the batch. A failure rate is determined from the first test, and it is determined if this failure rate is greater than a first threshold ( 104 ). A negative response is an indication the batch, or a significant portion of the modules in the batch has passed the first test in the assessment and in one embodiment, the batch is designated for shipment ( 106 ). Accordingly, the first test determines an initial disposition lot.
[0024] A positive response to the determination at step ( 104 ) is an indication that there is a detected defect within at least some of the tested module(s) of the batch. In one embodiment, the detected defect is an indication of a high occurrence of a short or shorting defect in the batch. This detection is an indication that it might be a wire sweep since there is the indication of a possible shorting defect in the batch. The number of failed modules is assigned to the variable, X total ( 108 ). In addition, a counting variable x is initialized for the failed modules ( 110 ), and a counting variable y is initialized to count modules ( 112 ). A second test in the form of an x-ray wire sweep is performed on failed module x ( 114 ). From this testing, it is determined if the module has a wire sweep deficiency ( 116 ). In one embodiment, the wire sweep is a misalignment of one or more wires in an electronic module. A negative response to step ( 116 ) is followed by designating the module, module x for an additional assessment ( 118 ) followed by incrementing the variable x ( 120 ). Any module determined to have failed the first test but does not have evidence of a wire sweep is indicative of a different problem that requires further failure analysis. Conversely, a positive response to the determination at step ( 116 ) is followed by an increment of the variable y ( 122 ). For each module determined to have a wire sweep deficiency, it is determined if the percentage of modules with wire sweeps is greater than a defined threshold ( 124 ). The threshold analysis at step ( 124 ) provides an indicator on which modules to carry out additional analysis. A positive response is followed by evidence of a wire sweep in the failed lot of the first testing phase ( 126 ). Conversely, a negative response to the determination at step ( 124 ) is followed by an increment of the module counting variable, x, ( 120 ) and determining if a detailed failure analysis has been performed on a large or significant quantity of failed modules for the failed lot of the first test ( 130 ). In one embodiment, the determination at step ( 130 ) is subjective. A negative response to the determination at step ( 130 ) is followed by a return to step ( 114 ), and a positive response is followed by a return to step ( 106 ).
[0025] A second set of testing is limited to modules that have passed the first set of testing. FIG. 2 is a flow chart ( 200 ) illustrating a method for the second set of testing which pertains to assessing current leakage in the individual modules. This second set of testing, like the first set of testing, includes two parts. The variable N Total is assigned to the number of original modules in the batch ( 202 ) and the variable X Total is assigned to the number of failed modules from the first set of testing ( 204 ). The variable M Total is defined as the difference between N Total and X Total ( 206 ). The counting variable M is initialized ( 208 ), and a current leakage test is performed on module M at a first leakage limit ( 210 ). Accordingly, each module M is tested for current leakage up to a specified current leakage limit.
[0026] Following the current leakage test at step ( 210 ), it is determined whether the module, module M , failed the current leakage limit test ( 212 ). A negative response is followed by updating the database records of the results and designating the passed module for shipment ( 214 ). Conversely, a positive response to the determination at step ( 212 ) designates the failed module to be scrapped or otherwise disposed ( 216 ). Following either step ( 214 ) or ( 216 ), the counting variable M is incremented for testing of additional modules ( 218 ) and it is determined whether each module designated for the current leakage test has been assessed ( 220 ). A negative response to the determination at step ( 220 ) is followed by a return to step ( 210 ), and a positive response is followed by a termination of the method. Accordingly, each module that did not fail the first test shown in FIG. 1 is tested for excessive current leakage.
[0027] As will be appreciated by one skilled in the art, aspects of the present invention may be embodied as a system, method or computer program product. Accordingly, aspects of the present invention may take the form of an entirely hardware based embodiment, an entirely software based embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, aspects of the present invention may take the form of a computer program product embodied in one or more computer readable medium(s) having computer readable program code embodied thereon.
[0028] Any combination of one or more computer readable medium(s) may be utilized. The computer readable medium may be a computer readable signal medium or a computer readable storage medium. A computer readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.
[0029] A computer readable signal medium may include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electro-magnetic, optical, or any suitable combination thereof. A computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device.
[0030] Program code embodied on a computer readable medium may be transmitted using any appropriate medium, including but not limited to wireless, wire line, optical fiber cable, RF, etc., or any suitable combination of the foregoing.
[0031] Computer program code for carrying out operations for aspects of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
[0032] Aspects of the present invention are described above with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0033] These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.
[0034] The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0035] A system is also provided for implementing the electronic module testing method as described above. FIG. 3 is a block diagram ( 300 ) illustrating a system for module testing. A computer is provided ( 302 ) having a processing unit ( 304 ) in communication with memory ( 306 ) across a bus ( 308 ). A functional unit ( 310 ) is provided in communication with memory ( 306 ) having tools for implementation of module testing. The tools provided include, but are not limited to: a test manager ( 312 ), a screening manager ( 316 ), and in one embodiment a modification manager ( 318 ). Accordingly, a computer is provided with a functional unit having tools for the automation of module testing.
[0036] As the electronic module(s) ( 330 ) advance through a testing location ( 350 ), a first test ( 322 ) is performed on the electronic module(s) to determine if the electronic module(s) ( 330 ) experience any gross failure. The first test ( 322 ), as implemented by the test manager ( 312 ), assesses a batch of modules for any significant or gross defects, such as shorting. Modules determined to have passed the first test ( 322 ) are redirected to a location ( 352 ) for shipment away from the testing location ( 350 ). The test manager ( 312 ) performs a failure rate analysis for the modules subject to the first test ( 322 ). If the failure rate does not exceed a threshold, e.g. the modules passed the initial assessment; the modules subject to the first test ( 322 ) passed the first test ( 322 ) in the module assessment process. In one embodiment, the passed modules may be designated for shipment. Accordingly, the test manager ( 312 ) assesses an initial disposition of the modules.
[0037] However, if the test manager ( 312 ) assesses a failure rate based on the threshold assessment, then there is a detected defect within at least one or more tested modules. In one embodiment, identification of a defect is an indication of a high occurrence of a short or shorting defect. One such possible defect is a wire sweep. A second test ( 324 ) in the form of an x-ray wire sweep is performed on one or more of the failed modules from the first test ( 324 ). From this testing, it is determined if the module has a wire sweep deficiency. In one embodiment, the test manager ( 312 ) manages the x-ray of the failed modules. The test manager ( 312 ) assesses if a percentage of modules with a wire sweep is greater than a defined threshold. This threshold analysis provides an indicator as to which modules additional analysis should be carried out.
[0038] A screening manager ( 316 ) is provided in communication with the first test manager ( 312 ) and performs an electronic current leakage screening ( 326 ) for modules that passed the first test ( 322 ), and in one embodiment, the current leakage screening test is performed on modules that passed the wire sweep assessment and have been determined not to contain a wire sweep defect. In one embodiment, the modification manager ( 318 ) is provided in communication with the screening manager ( 316 ). The modification manager ( 318 ) establishes an electric current leakage setting for the screening manager ( 316 ). In one embodiment, the modification manager ( 318 ) modifies the current leakage setting, including a reduced leakage setting or an increased leakage setting. In one embodiment, the select grouping module(s) are tested twice by the screening manager ( 316 ), wherein the second time the module(s) are tested, the current leakage setting on the module(s) is adjusted by the modification manager ( 318 ). The screening manager ( 316 ) may individually eliminate modules that have failed the current leakage screening. In one embodiment, the screening manager ( 316 ) may replace the wire sweep from a population of non-failed modules with the screening for current leakage. Accordingly, the screening manager ( 316 ) performs a current leakage screening test, and the modification manager ( 318 ) sets and/or adjusts the electric current leakage setting to further assess current leakage in the select grouping of modules.
[0039] Referring now to the block diagram of FIG. 4 , additional details are now described with respect to implementing an embodiment of the present invention. The computer system includes one or more processors, such as a processor ( 402 ). The processor ( 402 ) is connected to a communication infrastructure ( 404 ) (e.g., a communications bus, cross-over bar, or network).
[0040] The computer system can include a display interface ( 406 ) that forwards graphics, text, and other data from the communication infrastructure ( 404 ) (or from a frame buffer not shown) for display on a display unit ( 408 ). The computer system also includes a main memory ( 410 ), preferably random access memory (RAM), and may also include a secondary memory ( 412 ). The secondary memory ( 412 ) may include, for example, a hard disk drive ( 414 ) and/or a removable storage drive ( 416 ), representing, for example, a floppy disk drive, a magnetic tape drive, or an optical disk drive. The removable storage drive ( 416 ) reads from and/or writes to a removable storage unit ( 418 ) in a manner well known to those having ordinary skill in the art. Removable storage unit ( 418 ) represents, for example, a floppy disk, a compact disc, a magnetic tape, or an optical disk, etc., which is read by and written to a removable storage drive ( 416 ). As will be appreciated, the removable storage unit ( 418 ) includes a computer readable medium having stored therein computer software and/or data.
[0041] In alternative embodiments, the secondary memory ( 412 ) may include other similar means for allowing computer programs or other instructions to be loaded into the computer system. Such means may include, for example, a removable storage unit ( 420 ) and an interface ( 422 ). Examples of such means may include a program package and package interface (such as that found in video game devices), a removable memory chip (such as an EPROM, or PROM) and associated socket, and other removable storage units ( 420 ) and interfaces ( 422 ) which allow software and data to be transferred from the removable storage unit ( 420 ) to the computer system.
[0042] The computer system may also include a communications interface ( 424 ). A communications interface ( 424 ) allows software and data to be transferred between the computer system and external devices. Examples of a communication interface ( 424 ) may include a modem, a network interface (such as an Ethernet card), a communications port, or a PCMCIA slot and card, etc. Software and data transferred via a communication interface ( 424 ) is in the form of signals which may be, for example, electronic, electromagnetic, optical, or another signal capable of being received by communications interface ( 424 ). These signals are provided to communications interface ( 424 ) via a communications path (i.e., channel) ( 426 ). This communications path ( 426 ) carries signals and may be implemented using wire or cable, fiber optics, a phone line, a cellular phone link, a radio frequency (RF) link, and/or other communication channels.
[0043] In this document, the terms “computer program medium,” “computer usable medium,” and “computer readable medium” are used to generally refer to media such as main memory ( 410 ) and secondary memory ( 412 ), removable storage drive ( 416 ), and a hard disk installed in a hard disk drive ( 414 ).
[0044] Computer programs (also called computer control logic) are stored in main memory ( 410 ) and/or secondary memory ( 412 ). Computer programs may also be received via a communication interface ( 424 ). Such computer programs, when run, enable the computer system to perform the features of the present invention as discussed herein. In particular, the computer programs, when run, enable the processor ( 402 ) to perform the features of the computer system. Accordingly, such computer programs represent controllers of the computer system.
[0045] The flowchart(s) and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.
[0046] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
[0047] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed.
[0048] Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
Alternative Embodiment
[0049] It will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without departing from the spirit and scope of the invention. Accordingly, the scope of protection of this invention is limited only by the following claims and their equivalents. | Quality control testing for a batch of electronic modules. A series of tests are performed on manufactured electronic modules, including tests sensitive to the failure rate of previously tested modules. Specifically, a first test comprised of two phases is performed on the module batch. Further screening is then performed responsive to detection of a wire sweep failure in a subset of failed modules from the first test phase. The further screening is on modules that passed the first test phase and excludes modules that failed the first test phase. | 6 |
INTRODUCTION
This invention relates to preparations for application to the skin. More particularly, it relates to lotions and creams incorporating fish oils, such as shark liver oil, squalane, and squalene, that are used as moisturizers, as bases for cosmetics, as hand and body lotions, and as sunburn preventives.
BACKGROUND AND SUMMARY OF THE INVENTION
Various compositions have been developed for the purpose of moisturizing the skin and protecting it from harsh detergents. The composition of such products may contain various ingredients in various proportions and percents that may alter or promote the synergetic effects of fish oils. The present invention is based upon the results of a series of research and experiments of an oil-in-water base emulsion that has synergetic ingredients that achieve and utilize the benefits of shark oils (i.e. shark liver oil, squalene, or squalane) and maintain a suitable shelf life, measured in years. A two-year shelf life has been found to be satisfactory.
Shark liver oil is an unsaturated oil that contains triglycerides, lipids, and fatty acids, and is especially noted for its high content of vitamin A and squalene, the latter being a highly unsaturated terpenic hydrocarbon that is a biochemical precursor of cholesterol. Squalene, in fact, is a constituent of normal skin sebum. A study of the prior art has revealed patents relating to shark liver oil, squalane, and squalene as constituents in cosmetic formulations. Examples of such prior art are: U.S. Pat. No. 4,189,465, issued to Rosenthal; U.S. Pat. No. 3,930,000, issued to Margraff; and U.S. Pat. No. 4,021,572, issued to Van Scott, et al--none of which have any pertenence with respect to the present invention. The present invention will show a method of preparation and ingredients that will not alter, but will promote the effects of fish oils with synergetic ingredients and maintain a stable emulsion.
DETAILED DESCRIPTION OF THE INVENTION
Many ingredients were investigated to determine their compatibility with shark liver oil emulsions. The invention will show a method of preparation and ingredients to be used to promote the beneficial effects of shark liver oil.
Antioxidants and preservatives must be used to protect shark oil against harmful microorganisms. Thus, preservatives such as diazolidinyl urea at a concentration of from 0.05 to 1.0 wt. % is needed. As an alternative, a mixture of BHT and BHA, each at 0.05 wt. % is highly to be desired. All three preservatives could be included in the formulation without detriment.
An emulsifier is needed to initially create a stable emulsion and a stabilizer is needed to maintain such an emulsion. Emulsifying wax as, for example the variety, "polawax" N.F. at 0.5 to 8.0 wt. %, stearic acid at 0.5 to 4.0 wt. %, glyceryl stearate at 0.5 to 5.0 wt. %, and cetyl alcohol at 0.5 to 2.0 wt. % are essential for shark oil to form a lotion or cream emulsion. Triethanolamine (TEA) at 0.02 to 1.0 wt. % is also essential to prevent separating of the emulsion, once it is formed.
There are many oils that can be combined with shark liver oil--oils such as sesame oil at up to 30 wt. %, almond oil at up to 30 wt. %, or lanolin at up to 3.0 wt. %; these oils appear to be the most superior, although most organic oils can be used. Squalane or squalene may be substituted for shark liver or used in combination with shark liver oil in a range of 0.5 to 30 weight percent.
Thickening agents such as xanthan gum at 0.2 to 0.5 wt. % or Carbopol at 0 to 0.2 wt. % are useful to help form an emulsion. Sodium salts, such as a sodium salt of ethylene diamine tetraacetic acid (EDTA) at 0 to 0.2 wt. %, are also helpful.
There are many esters used in cosmetic preparations. I have found PPG2 myristyl ether propionate promotes a synergetic effect with shark oils at 0.5 to 2.0 wt. %; pentaerythritol tetracaprate/caprylate (trade name "Crodamol P.T.C."), has a similar effect at 0.5 to 2.0 wt. %, as does C 12 -C 15 alcohol benzoate at concentrations below 1 wt. %.
Many cholesterols are used in cosmetic formulations. I have found that C 10 -C 30 carboxylic acid esters of sterols, predominantly the sterols cholesterol and lanosterol, may be used as an emollient and resemble the active part of sebum that has emulsion stabilizing properties. They also act as viscosity builders and have the ability to absorb up to 50% of its weight of water, which feature promotes the effect of shark liver oil. I prefer to use C 10 -C 30 Cholesterol/Lanosterol Ester, trade name "Super Sterol Ester", at a concentration in the range of 0.1 to 8 wt. %.
When a fatty acid, such as stearic acid is used, it is essential to reduce or eliminate sudsing of the emulsion by using a defoaming agent, such as dimethicone at 0.1 to 4.0 wt. %. When fatty acids are absent, no defoaming agent is needed, although its inclusion does no harm.
If the shark liver oil has been refined, as by chromatography, thereby removing the naturally present vitamin A, then that vitamin may be replenished by adding retinyl palmitate AD 3 at 0.1 to 4.0 wt. %. This palmitate may also be used with squalane or squalene.
A humectant such as propylene glycol at 0.5-4.0 wt. %, or glycerine as an alternative at similar concentrations, is also desirable and is compatible with shark oils.
Other ingredients, such as collagen amino acids, hydrolyzed animal proteins, reticulin, and hydrolyzed elastin may be used. All of these materials are naturally synthesized by the human body and they are very compatible with shark liver oil, squalane, and squalene. I have found that each of these ingredients may be used in the range of 0 to 1.0 wt. % in a stable emulsion. Fragrance may be added as desired in a range of 0 tp 0.5%.
PREFERRED EMBODIMENT
The following examples are detailed descriptions of the preparation of two preferred embodiments of the present invention. The ingredient names are those commonly used by the Cosmetic Toiletry and Fragrance Association.
EXAMPLE 1
______________________________________Ingredient Weight Percent______________________________________PHASE A:Water as required for 100%Xanthan gum 0.2Carbopol 0.02PHASE B:Propylene glycol 4.0Triethanolamine (TEA) 0.5Tetrasodium EDTA 0.05PHASE C:Squalane 2.0Sesame oil 2.0Shark liver oil 0.5Lanolin 0.5Emulsifying wax (pola wax) N.F. 2.0PPG2 Myristyl ether propionate 2.0Glyceral stearate 1.0Dimethicone 0.5Cetyl alcohol 0.5Pentaerythritol tetra- 1.0caprate/caprylateBHT 0.05BHA 0.05Stearic acid 0.5Diazolidinyl urea 1.0Fragrance 0.5______________________________________
wherein, in making said composition, said water is first heated to 75 degrees Celsius and then the additional PHASE A ingredients are mixed in; PHASE B ingredients are added to PHASE A the resulting phase is mixed; PHASE C ingredients are mixed in a separate vessel at 75 degrees Celsius and then mixed into the combined PHASE A AND B. At 40 degrees Celsius, fragrance is added. The mixture has formed a stable emulsion.
EXAMPLE 2
______________________________________Ingredient Weight Percent______________________________________PHASE A:Water as required for 100%Xanthan gum 0.5Carbopol 0.2PHASE B:Propylene glycol 3.0Triethanolamine (TEA) 0.5Tetrasodium EDTA 0.05PHASE C:Almond oil 3.5Shark liver oil 0.5Squalane 2.0Emulsifying wax (pola wax) N.F. 3.0Cetyl alcohol 0.5BHT 0.05BHA 0.05Diazolidinyl urea 1.0C.sub.10 -C.sub.30 cholesterol/lanosterol 0.5esterRetinyl palmitate AD.sub.3 0.1PHASE D:Collagen amino acids 0.5Hydrolyzed animal protein 0.5Hydrolyzed elastin 0.5Fragrance 0.5______________________________________
wherein, in making said composition, said water is first heated to 75 degrees Celsius and then the additional PHASE A ingredients are mixed in; PHASE B ingredients are added to PHASE A the resulting phase is mixed; PHASE C ingredients are mixed in a separate vessel at 75 degrees Celsius and then mixed into the combined PHASE A AND B. At 40 degrees Celsius, Phase D, which has also been separately mixed, is mixed in to form a stable emulsion.
I have found that the various constituents I have tested are totally capable of being combined together in the concentrations indicated for each to achieve a product with superior cosmetic and therapeutic properties not anticipated from the individual constituents alone. The overall effect may be described as a synergetic effect of the combination of ingredients acting in concert to achieve the overall improved effect on the skin. I have found no prior art to anticipate the superior effect of the formulations I have disclosed herein.
Various modifications of the described invention will occur to those skilled in the art, and it should be understood that the invention includes such modifications as are embraced by, or equivalent to, the invention as claimed herein. | Cosmetic creams or lotions comprising emulsions of shark liver oil, squalane, and squalene along with numerous other ingredients with therapeutic and synergetic effects on the skin are disclosed. | 8 |
FIELD OF THE INVENTION
The present invention generally relates to noise attenuation in vehicle drivelines and more particularly to an improved noise-attenuating propshaft and a method for its construction.
BACKGROUND OF THE INVENTION
Propshafts are commonly employed for transmitting power from a rotational power source, such as the output shaft of a vehicle transmission, to a rotatably driven mechanism, such as a differential assembly. As is well known in the art, propshafts tend to transmit sound while transferring rotary power. When the propshaft is excited a harmonic frequency, vibration and noise may be amplified, creating noise that is undesirable to passengers riding in the vehicle. Thus, it is desirable and advantageous to attenuate vibrations within the propshaft in order to reduce noise within the vehicle passenger compartment.
Various devices have been employed to attenuate the propagation of noise from propshafts including inserts that are made from cardboard, foam or resilient materials, such as rubber. The inserts that are typically used for a given propshaft are generally identical in their configuration (i.e., construction, size, mass and density) and are installed in the propshaft such that they are equidistantly spaced along the length of the propshaft. Construction in this manner is advantageous in that it greatly simplifies the manufacturer of the propshaft. Despite this advantage, several drawbacks remain.
For example, symmetric positioning of the identically-configured inserts within the propshaft typically does not maximize the attenuation of the vibration within the propshaft. Accordingly, it is desirable to provide an improved propshaft that attenuates vibrations within the propshaft to a larger degree than that which is taught by the prior art.
SUMMARY OF THE INVENTION
In one preferred form, the present invention provides a shaft structure and at least two insert members. The shaft structure has a longitudinally-extending cavity and is configured to vibrate in response to the receipt of an input of a predetermined frequency such that at least two second bending mode anti-nodes are generated in spaced relation to one another along the longitudinal axis of the shaft structure. The insert members are disposed within the longitudinally extending cavity and engage an inner wall of the shaft structure. Each of the insert members is located at a position that approximately corresponds to an associated one of the anti-nodes and has a density that is tailored to an anticipated displacement of the associated anti-node. A method for attenuating noise transmission from a vehicle driveline is also disclosed.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional advantages and features of the present invention will become apparent from the subsequent description and the appended claims, taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a schematic illustration of an exemplary vehicle constructed in accordance with the teachings of the present invention;
FIG. 2 is a top partially cut-away view of a portion of the vehicle of FIG. 1 illustrating the rear axle and the propshaft in greater detail;
FIG. 3 is a sectional view of a portion of the rear axle and the propshaft;
FIG. 4 is a top, partially cut away view of the propshaft;
FIG. 5 is a schematic illustration of the maximum displacement associated with the bending mode of the propshaft; and
FIG. 6 is a plot illustrating noise as a function of the propshaft speed for three differently configured propshafts.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1 of the drawings, a vehicle having a propshaft assembly that is constructed in accordance with the teachings of the present invention is generally indicated by reference numeral 10 . The vehicle 10 includes a driveline 12 drivable via a connection to a power train 14 . The power train 14 includes an engine 16 and a transmission 18 . The driveline 12 includes a propshaft assembly 20 , a rear axle 22 and a plurality of wheels 24 . The engine 16 is mounted in an in-line or longitudinal orientation along the axis of the vehicle 10 and its output is selectively coupled via a conventional clutch to the input of the transmission 18 to transmit rotary power (i.e., drive torque) therebetween. The input of the transmission 18 is commonly aligned with the output of the engine 16 for rotation about a rotary axis. The transmission 18 also includes an output 18 a and a gear reduction unit. The gear reduction unit is operable for coupling the transmission input to the transmission output at a predetermined gear speed ratio. The propshaft assembly 20 is coupled for rotation with the output 18 a of the transmission 18 . Drive torque is transmitted through the propshaft assembly 20 to the rear axle 22 where it is selectively apportioned in a predetermined manner to the left and right rear wheels 24 a and 24 b , respectively.
With additional reference to FIGS. 2 and 3, the rear axle 22 is shown to include a differential assembly 30 , a left axle shaft assembly 32 and a right axle shaft assembly 34 . The differential assembly 30 includes a housing 40 , a differential unit 42 and an input shaft assembly 44 . The housing 40 supports the differential unit 42 for rotation about a first axis 46 and further supports the input shaft assembly 44 for rotation about a second axis 48 that is perpendicular to the first axis 46 .
The housing 40 is initially formed in a suitable casting process and thereafter machined as required. The housing includes a wall member 50 that defines a central cavity 52 having a left axle aperture 54 , a right axle aperture 56 , and an input shaft aperture 58 . The differential unit 42 is disposed within the central cavity 52 of the housing 40 and includes a case 70 , a ring gear 72 that is fixed for rotation with the case 70 , and a gearset 74 that is disposed within the case 70 . The gearset 74 includes first and second side gears 82 and 86 and a plurality of differential pinions 88 , which are rotatably supported on pinion shafts 90 that are mounted to the case 70 . The case 70 includes a pair of trunnions 92 and 96 and a gear cavity 98 . A pair of bearing assemblies 102 and 106 are shown to support the trunnions 92 and 96 , respectively, for rotation about the first axis 46 . The left and right axle assemblies 32 and 34 extend through the left and right axle apertures 54 and 56 , respectively, where they are coupled for rotation about the first axis 46 with the first and second side gears 82 and 86 , respectively. The case 70 is operable for supporting the plurality of differential pinions 88 for rotation within the gear cavity 98 about one or more axes that are perpendicular to the first axis 46 . The first and second side gears 82 and 86 each include a plurality of teeth 108 which meshingly engage teeth 110 that are formed on the differential pinions 88 .
The input shaft assembly 44 extends through the input shaft aperture 58 where it is supported in the housing 40 for rotation about the second axis 48 . The input shaft assembly 44 includes an input shaft 120 , a pinion gear 122 having a plurality of pinion teeth 124 that meshingly engage the teeth 126 that are formed on the ring gear 72 , and a pair of bearing assemblies 128 and 130 which cooperate with the housing 40 to rotatably support the input shaft 120 . The input shaft assembly 44 is coupled for rotation with the propshaft assembly 20 and is operable for transmitting drive torque to the differential unit 42 . More specifically, drive torque received the input shaft 120 is transmitted by the pinion teeth 124 to the teeth 126 of the ring gear 72 such that drive torque is distributed through the differential pinions 88 to the first and second side gears 82 and 86 .
The left and right axle shaft assemblies 32 and 34 include an axle tube 150 that is fixed to the associated axle aperture 54 and 56 , respectively, and an axle half-shaft 152 that is supported for rotation in the axle tube 150 about the first axis 46 . Each of the axle half-shafts 152 includes an externally splined portion 154 that meshingly engages a mating internally splined portion (not specifically shown) that is formed into the first and second side gears 82 and 86 , respectively.
With additional reference to FIG. 4, the propshaft assembly 20 is shown to include a shaft structure 200 , first and second trunnion caps 202 a and 202 b , first and second insert members 204 a and 204 b , first and second spiders 206 a and 206 b , a yoke assembly 208 and a yoke flange 210 . The first and second trunnion caps 202 a and 202 b , the first and second spider 206 a and 206 b , the yoke assembly 208 and the yoke flange 210 are conventional in their construction and operation and as such, need not be discussed in detail. Briefly, the first and second trunnion caps 202 a and 202 b are fixedly coupled to the opposite ends of the shaft structure 200 , typically via a weld. Each of the first and second spiders 206 a and 206 b is coupled to an associated one of the first and second trunnion caps 202 a and 202 b and to an associated one of the yoke assembly 208 and the yoke flange 210 . The yoke assembly, first spider 206 a , and first trunnion cap 202 a collectively form a first universal joint 212 , while the yoke flange 210 , second spider 206 b and second trunnion cap 202 b collectively form a second universal joint 214 .
A splined portion of the yoke assembly 208 is rotatably coupled with the transmission output shaft 18 a and the yoke flange 210 is rotatably coupled with the input shaft 120 . The first and second universal joints 212 and 214 facilitate a predetermined degree of vertical and horizontal offset between the transmission output shaft 18 a and the input shaft 120 .
The shaft structure 200 is illustrated to be generally cylindrical, having a hollow central cavity 220 and a longitudinal axis 222 . In the particular embodiment illustrated, the ends 224 of the shaft structure 200 are shown to have been similarly formed in a rotary swaging operation such that they are necked down somewhat relative to the central portion 226 of the shaft structure 200 . The shaft structure 200 is preferably formed from a welded seamless material, such as aluminum (e.g., 6061-T6 conforming to ASTM B-210) or steel.
The first and second insert members 204 a and 204 b are fabricated from an appropriate material and positioned within the hollow cavity at locations approximately corresponding to the locations of the second bending mode anti-nodes 230 . The configuration of each of the first and second insert members 204 a and 204 b is tailored to the anticipated maximum displacement of the shaft structure 200 at the anti-nodes 230 when the propshaft assembly 20 is excited at a predetermined frequency and the insert members 204 a and 204 b are not present. In this regard, the density, mass and/or resilience of the first and second insert members 204 a and 204 b is selected to provide a predetermined reduction in the anticipated maximum displacement of the shaft structure 200 at the anti-nodes 230 .
In the example provided, the first and second insert members 204 a and 204 b are identically sized, being cylindrical in shape with a diameter of about 5 inches and a length of about 18 inches. The first and second insert members 204 a and 204 b are disposed within the hollow central cavity 220 and engage the inner wall 228 of the shaft structure 200 . Preferably, the first and second insert members 204 a and 204 b engage the shaft structure 200 in a press-fit manner, but other retaining mechanisms, such as bonds or adhesives, may additionally or alternatively be employed.
The predetermined frequency at which vibration dampening is based is determined by monitoring the noise and vibration of the propshaft assembly 20 while performing a speed sweep (i.e., while operating the driveline 12 from a predetermined low speed, such as 750 r.p.m., to a predetermined high speed, such as 3250 r.p.m.). In the example provided, the first harmonic of the meshing of the pinion teeth 124 with the teeth 126 of the ring gear 72 was found to produce hypoid pear mesh vibration that excited the second bending and breathing modes of the propshaft assembly 20 when the propshaft assembly 20 was rotated at about 2280 r.p.m., as shown in FIG. 5 . As a result of the configuration of the propshaft assembly 20 , the anticipated maximum displacement of the anti-node 230 b is shown to be significantly larger than the anticipated displacement of the anti-node 230 a , which is generated in a spaced relation from anti-node 230 b . Accordingly, if the first and second insert members 204 a and 204 b are not tailored to their respective anti-node 230 , noise attenuation may not be as significant as possible and in extreme cases, could be counter-productive. As such, the first insert member 204 a is constructed from a material that is relatively denser than the material from which the second insert member 204 b is constructed. In the embodiment shown, the first insert member 204 a is formed from a CF-47 CONFOR™ foam manufactured by E-A-R Specialty Composites having a density of 5.8 lb/ft 3 , while the second insert member 204 b is formed from a CF-45 CONFOR™ foam manufactured by E-A-R Specialty Composites having a density of 6.0 lb/ft 3 . The foam material is porous, being of an open-celled construction, and has a combination of slow recovery and high energy absorption to provide effective damping and vibration isolation.
FIG. 6 is a plot that illustrates the noise attenuation that is attained by the propshaft assembly 20 as compared with an undamped propshaft assembly and a conventionally damped propshaft assembly. The plot of the undamped propshaft assembly is designated by reference numeral 300 , the plot of the conventionally damped propshaft assembly is designated by reference numeral 302 and the plot of the propshaft assembly 20 is designated by reference numeral 304 . The undamped propshaft assembly lacks the first and second insert members 204 a and 204 b but is otherwise configured identically to the propshaft assembly 20 . The conventionally damped propshaft assembly includes a single foam damping insert that is approximately 52 inches long and approximately centered within the propshaft. The foam insert has a density of about 1.8 lbs/ft 3 and provides a degree of dampening that is generally similar to other commercially-available damped propshaft assemblies. Notably, the propshaft construction methodology of the present invention provides significant noise reduction at the predetermined frequency as compared with the undamped and conventionally damped propshaft assemblies.
While the invention has been described in the specification and illustrated in the drawings with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention as defined in the claims. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment illustrated by the drawings and described in the specification as the best mode presently contemplated for carrying out this invention, but that the invention will include any embodiments falling within the foregoing description and the appended claims. | A shaft structure and at least two insert members. The shaft structure has a longitudinally extending cavity and is configured to vibrate in response to the receipt of an input of a predetermined frequency such that at least two second bending mode anti-nodes are generated in spaced relation to one another along the longitudinal axis of the shaft structure. The insert members are disposed within the longitudinally extending cavity and engage an inner wall of the shaft structure. Each of the insert members is located at a position that approximately corresponds to an associated one of the anti-nodes and has a density that is tailored to an anticipated displacement of the associated anti-node. A method for attenuating noise transmission from a vehicle driveline is also disclosed. | 5 |
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to an electronic circuit in a motor vehicle, in particular in an instrument cluster in which various indicating instruments, indicating fields, monitoring and warning lights and possibly operating parts as well as electrical and electronic parts are arranged in a common housing and covered by a common transparent pane.
Such instrument clusters have been known for a long time, for instance from Federal Republic of Germany AS 16 05 947, and are used instead of the previously customary individual instruments in order to monitor various functions of an automobile.
Electrically controlled displays are increasingly used in such instrument clusters which, in addition to greater freedom of design, make a more intelligent and thus more precise and meaningful indication possible. The control is effected in general with the use of microprocessors or highly integrated, application-specific circuits. The digital pulse trains processed therein have very steep flanks and contain high-frequency portions up into the VHF-range, thus constituting a source of radio interference which makes radio reception or radio communication difficult when the motor vehicle is in operation. Such circuits can be affected furthermore by high-frequency radiation from the outside.
It has already been proposed (German patent application No. P 37 36 761.7) to provide a display computer and locate it on the common printed-circuit board in a housing which insulates from high-frequencies.
From Federal Republic of Germany OS 35 15 910 there is known, a high-frequency-proof housing with connecting pieces which serves to shield high-frequency parts, but the subject matter deals with a tap or distributor for cable television systems with a network of coaxial cables.
SUMMARY OF THE INVENTION
It is an object of the present invention further to develop an electronic circuit for an instrument cluster in such a manner that the effects of both line-related and non-line-related interference are counteracted and that the wireless propagation of outgoing radio-frequency interferences is reduced.
It is another object of the invention that the required depth of installation of the electronic circuit be kept as small as possible, that its structural dimensions be kept small and that the mounting be simplified. In this connection, the electromagnetic compatibility is to be improved and dissipated heat which occurs is to be led off well to the environment. At the same time, the reliability of operation is to be increased and, in particular, the heat removal is to be improved in view of the close arrangement of the heat-generating components. Finally, it is to be possible to produce the electronic circuit, and thus the instrument cluster as a whole, in a simple and inexpensive manner.
According to the invention there is provided an electronic circuit for an instrument cluster in a motor vehicle, the circuit being constructed with at least one ceramic substrate provided with component parts in a shielding housing. In addition, the invention provides that a part of the surface (32) of the ceramic substrate (e.g. 31, 63) is kept free of components and can be brought into areal contact with a substantially congruent surface (48) which is recessed in an outer surface of the shielding housing (35).
It is advantageous in this connection that the invention measures extend only over a part of the instrument cluster and therefore entail only slight expense. It is furthermore advantageous that the previous construction of an instrument cluster need not be fundamentally changed. It is also advantageous that the electromagnetic compatibility be improved. It is finally advantageous that the lost heat which occurs is led away well to the environment.
According to a feature of the invention, the areal contact takes place with the interposition of an adhesive which is a good electrical conductor.
Still further according to the invention, the areal contact takes place with the interposition of an adhesive which is a good conductor of heat.
Further according to the invention, the connecting of ground to highly integrated circuits (70) which are to be arranged on the ceramic substrate (31, 63) takes place via feed-through connectors (69).
Still according to another feature of the invention, contact springs (33) are provided for holding and for electrical connection of the ceramic substrate (31, 63), end regions of which contact springs surround an edge contact of the substrate in U-shape or omega-shape. The springs are curved over their free length in the shape of an S and are alternately shaped differently so that their ends on the printed-circuit board side in each case form two rows which are arranged in parallel to each other.
Yet the invention further provides that the contact springs (33) are mounted in cleats (41) consisting of an insulating material.
Still further according to the invention, the shielding is provided on several places of its circumference and in an extension of its side walls with projections (39, 68). The projections extend through the cover (37) and the printed-circuit board (25) of the instrument cluster, and have free ends which are connected with good electrical conduction on a side of the printed-circuit board (25) facing away from the high-frequency-proof housing (35) to a ground connection or a ground surface of the surrounding circuit.
Another feature of the invention provides that the cover have at least three outward-facing bosses (40) in order to establish a distance of the cover surface from the printed-circuit board (25) of the instrument cluster.
Still according to another feature of the invention, a recessed surface (38, 62) is located on the side of the shielding housing (35) facing the supporting printed-circuit board (25).
BRIEF DESCRIPTION OF THE DRAWINGS
With the above and other objects and advantages in view, the present invention will become more clearly understood in connection with the detailed description of different embodiments, when considered with the accompanying drawings, of which:
FIG. 1 is by way of example a front view of the instrument cluster containing the electronic circuit;
FIG. 2 is an exploded perspective view, without the front pane, of the same instrument cluster;
FIG. 3 shows a first embodiment of an electronic circuit in accordance with the invention, in exploded perspective view;
FIG. 4 includes FIGS. 4a and 4b to show the electronic circuit of FIG. 3 in assembled 4a and 4b condition in partially cut away top view and in cross section;
FIG. 5 includes FIGS. 5a, 5b and 5c which are cross-sectional and perspective views of details of the embodiment of FIGS. 3 and 4; and
FIG. 6 is a view of a second embodiment of the electronic circuit, shown in section.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, 1 is the front mask or pane of an instrument cluster which has, arranged alongside of each other in essentially the same plane, a fuel gauge 2, a speedometer 3, a tachometer 4 with integrated consumption indicator 9, and a cooling-water indicator 5. Furthermore there is provided a control lamp 6 for a turn indicator as well as a liquid-crystal display 7 for an electronic distance indicator, and a dot-matrix indicator 8 for various selective functions.
FIG. 2 shows the construction of the instrument cluster. It consists of a rear wall 21 with edge 22 formed thereon. The rear wall has a plurality of openings 23, 24 for receiving plug connections which serve for the electrical connecting of the instrument cluster to the corresponding sensors and external circuits, such as, for example, a circuit for activating the turn indicator.
A printed-circuit board 25 can be inserted into the rear wall 21, the board 25 containing all the active and passive circuit elements, conductor paths, plug connectors and terminals. The printed-circuit board 25 furthermore bears the computer required for the signal processing, which computer may consist, for instance, of two single-chip microcomputers and application-specific integrated circuits. This computer is located in a manner which will be described below, in a shielding housing 35 on the printed-circuit board 25.
A mounting plate 26 is provided in front of the printed-circuit board 25, which plate may be produced in the same manner as the rear wall 21, from a thermoplastic resin of suitable composition by an injection molding process. Together with the edge 22 of the rear wall 21, the mounting plate determines the external shape of the instrument cluster and has a plurality of openings 27, 28, 29, 30 for receiving the electromechanical indicator systems for the analog indicators 2 to 5 and 9. As components of the instrument cluster, these indicating systems can be replaced to a certain extent, depending on the equipment version of the vehicle, and connected correspondingly to the printed-circuit board 25. Thus, a clock can be installed and operated instead of the tachometer 4 with integrated fuel gauge 9. Likewise, electro-optical displays can be used for these indicating functions, with corresponding development and design of the components used for the instrument cluster.
As already stated hereinabove, the use of highly integrated electronics in an instrument cluster for motor vehicles requires special measures for shielding and suppression of interference in two directions. In this connection, the remaining electronic systems of the vehicle, in particular the radio receiver, are to be protected from interference by the instrument computer, and the computer is to be protected against interference from the outside. Furthermore, the depth of installation is to be increased only to the extent absolutely necessary. For this purpose, essentially only the computer and a few peripheral modules is shielded.
In accordance with a first embodiment of the invention, the computer is therefore located in a high-frequency-proof housing 35 on the printed-circuit board 25 as shown in FIGS. 3 to 5. For this purpose components of the computer are so arranged on a ceramic substrate 31 in the region of the substrate edge that a region 32 of the ceramic substrate 31 remains free of circuit elements. Contact springs 33 grip around the edge of the ceramic substrate 31 and are fastened there with good electric conductivity, as by connection soldering or cementing. The springs 33 are connected to end surfaces of conducting paths present thereon, and establish connections to the rest of the circuit. The contact springs 33 are of two different embodiments which alternate with each other so that the pins extend through a holding frame 34 in each case in two rows staggered with respect to each other, the distances between two contact springs of each row being twice the conducting-path spacing on the ceramic substrate 31.
the computer unit which has been completed in this manner is arranged in a shielding housing 35 which consists of the shielding can 36 and the cover 37. The cover 37 has on its edge resilient tongues 38 which grip over the edge of the shielding can 36 and connect the latter in electrically conductive manner to the cover 37. In order to improve the high-frequency shielding action, the resilient tongues 38 can be soldered to the shielding can 36.
The free surface 32 of the ceramic substrate 31 consitutes a ground surface which is advisedly coated prior to assembly with an adhesive of good electrical and thermal conductivity and which, after assembly, rests against the surface 48 of the through-like depression on the bottom of the shielding can 36. In this way, both the electrical shielding action and the removal of the lost heat are improved. Since no current loops are formed by currents flowing through the blocking capacitors, the development of electromagnetic fields with radiating effect on the outside is avoided. The shielding can 36 advisedly has projections 39 on several places on its circumference and along the extension of the side walls, which projections extend through the cover 37 and serve for electrical connection to the reference ground line (for instance, the negative terminal) on the printed-circuit board 25 by bending them after the insertion, establishing a predetermined spacing. It can be noted from FIG. 4b that a desired spacing of the cover 37 of the shielding device 35 from the printed-circuit board 25 is established by spacing bosses 40. The holder frame 34 forms on the bottom side, concentric to each contact spring 33, a projection 41 for insulating the contact springs 33 from the cover 37.
FIG. 5 shows various embodiments of the contact springs. The contact spring 331 of FIG. 5a surrounds the edge region of the ceramic substrate 31 in U-shape. A sharp-edged projection 332 on the bottom side results in this case in an extensive self-cleaning effect and thus promoting good contact with a conducting path provided on the ceramic substrate 31. The distance between the ceramic substrate 31 and a contact housing 341 which has been provided instead of the plastic frame 34 is bridged by the contact spring 333 in various arches 331 and 334. In this way, thermal expansion can be absorbed gently and excessive stresses by formation of cracks can be avoided.
The contact spring 335 surrounds the ceramic substrate 31 in similar manner, the contact spring having approximately the shape of the Greek capital letter omega. It continues in two arches 336, 337 which again serve to absorb thermal stresses. The contact spring 335 is then bent at a right angle at the place 338 and embedded in the plastic holder 341. As already mentioned above, two types of contact springs are advisedly provided alternately, one of which has a transition piece 342 which is the transition to the adjacent row of contacts. In this way, substantially more contacts can be provided, staggered with respect to each other and then contacted, than would be the case with merely a single-row arrangement of the free ends 343, 344 of the contact springs. In FIG. 5c, the contact spring 335 is shown again detached from the surrounding components. It can be noted therefrom that the contact spring 335 can be produced in simple manner from a semifinished product consisting of a suitable material, for instance copper-beryllium wire.
In the embodiment shown in FIG. 6, the bottom 61 of the shielding housing is recessed instead of the cover. As can be noted from the cross-sectional showing, there is formed thereby a surface 62 which the ceramic substrate 63 of the computer adjoins with contact over a large area. The side of the ceramic substrate 63 facing the bottom is kept free of components in the surface in which it contacts the surface 62, while numerous blocking capacitors 64 are arranged in the edge region of the ceramic substrate 63. The integrated circuits 70 arranged on the top side of the ceramic substrate 63 are provided with ground lines via feed-through connectors 69. In this way, disturbing current loops are avoided.
In order to improve the electrical conduction and/or the heat transfer from the ceramic substrate 63 to the surface 62, the printed-circuit board is provided with a ground surface approximately congruent to the surface 62. The latter simultaneously represents the ground neutral point. As in the case of the first embodiment described above, the contacting of the surfaces can take place with the interposition of a layer of an adhesive of good electrical and/or thermal conductivity.
The construction of the shielding housing of FIG. 6 has the great advantage that the free space 65 on the printed-circuit board 25 of the instrument cluster below the raised surface 62 can be used for arrangement of additional components. Furthermore, the finished computer can be encapsulated in simple manner as protection against external influences and accelerations. In this case, the space 66 is filled with potting compound. The shielding housing 35 can then be closed without difficulty by the cover 67.
In addition, the mechanical attachment and the ground connection of the shielding housing 35 to the printed-circuit board 25 can be achieved in particularly simple manner by bending individual tongues 68 upward out of the bottom 61 and soldering them to the printed-circuit board 25. | A electronic circuit for an automobile, in particular in an instrument cluster, is disclosed. The electronic circuit comprises a computer having at least one microprocessor and application-specific integrated circuits and it is arranged in a shielding housing for suppression of electromagnetic interference. For improved removal of heat and high-frequency decoupling, surface areas of the external shielding are electrically and mechanically closely coupled to corresponding surface areas on the conducting path and, in addition, the incoming and outgoing lines which are subject to interference are protected by suitable filters. | 8 |
BACKGROUND OF THE INVENTION
As is well known to those versed in the art of carpentry, and particularly that of building houses, the hammering of nails generally required both hands of the carpenter, one to hold the nail during starting in the wood, and the other to swing the hammer. This two-handed operation severly limits the area to which one can reach, for example, from a ladder, to require much movement and expenditure of time and energy.
In order to minimize or reduce this problem, there have been provided in the prior art a number of hammers and attachments therefore serving to hold nails during starting, all as a one-hand operation. For example, applicant is aware of the below listed prior art:
______________________________________U.S. PatentsU.S. Pat. No. Patentee______________________________________ 35,885 Mills et al 193,967 Knight 794,310 Priestley 825,560 Smith1,029,934 J. R. Kidd1,209,583 Holmdahl1,247,683 Hritz et al1,365,778 Galligan1,387,920 Busse1,411,567 Fisher2,227,455 Lane2,574,304 B. Vigil2,722,251 F. F. Dillon2,983,297 J. M. Wilson4,270,587 Ludy______________________________________Foreign PatentsCountry Patent No. Patentee Date______________________________________Norway 72,002 Johannessen 4/1947Switzerland 566,846 Vigil 9/1975______________________________________
However, the devices of the prior patents are relatively expensive, even the hammer attachments, being necessarily of metal and involving expensive manufacturing procedures. Also, the prior art devices are relatively complex, bulky in size and heavy in weight to detract from their convenience in use. Also, even the prior art attachments are relatively difficult to attach or subject to inadvertent removal when not desired; and, prior art attachments are not capable of use with a variety of different sizes and types of hammers.
SUMMARY OF THE INVENTION
Accordingly, it is an important object of the present invention to provide a hammer attachment for holding nails during starting, which attachment both overcomes the above mentioned difficulties, being extremely light in weight and of minimum bulk for optimum convenience in use, capable of manufacture out of textiles for extreme economy of labor and materials, and which is uniquely adapted to fit hammers of greatly varing sizes, shapes and types so that a single one of such attachments is capable of great versitility in use.
Other objects of the present invention will become apparent upon reading the following specification and referring to the accompanying drawings, which form a material part of this disclosure.
The invention accordingly consists in the features of construction, combinations of elements, and arrangements of parts, which will be exemplified in the construction hereinafter described, and of which the scop will be indicated by the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a hammer including a nail holding attachment of the present invention.
FIG. 2 side elevational view of the hammer and attachment of FIG. 1 with the hammer inverted to show its other side and the attachment.
FIG. 3 is a side elevational view similar to FIG. 2 showing the attachment in a partially attached or detached condition.
FIG. 4 is a sectional elevational view taken generally along the line 4--4 of FIG. 3.
FIG. 5 a plane view showing the attachment of the present invention apart from the hammer.
FIG. 6 is a longitudinal sectional view taken generally along the line 6--6 of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more particularly to the drawings, and specifically to FIGS. 1 and 2 thereof, a hammer is there generally designated 10, and includes an elongate handle or helve 11, on one end of which is a transverse head, generally designated 12.
The hammer head 12 is there generally illustrated as of the claw type, which is commonly used in house building, but the hammer may be of other type, if desired.
In the illustrated embodiment the head includes a central sleeve or eye 15 for receiving the adjacent end of handle 11, and extending oppositely from the sleeve may be a claw 16 and a poll 17. As thus far described, the hammer 10 may be conventional.
Applied to the hammer 10 is the attachment of the present invention, being a nail holder snugly embracing the hammer and a generally designated 20.
The nail holder attachment 20 is shown in FIGS. 5 and 6 apart the hammer, and includes a generally ovaloid collar or loop 21 to one end of which is attached one end of a strap 22. The loop 21 may be fabricated of a pair of elastic strips 23, which may be essentially identical, having their opposite ends secured together, as by stiching, or the like, and combining to define an outline configuration approximating the sector of a sphere and having a central through opening, as at 24.
The strap 22 may advantageously also be fabricated of elastic tape and suitably secured, as at one end region 25 by stitching or other securing means to one end portion of the elongate loop 21. From its secured end 25 the strap 22 extends longitudinally of and outwardly from the ovaloid 21 to terminate in a free end portion 26.
Carried by the elongate loop 21, at its end remote from the strap 22, is a fastener element 27, which may advantageously be a patch of fastener fabric of the type sold as "VELCRO". The fastener fabric is shown on the upper or exposed surface of the loop 21 in FIG. 5; and, the strap end portion 25 may also be secured on the exposed or upper surface of the loop 21 seen in FIG. 5.
On the other side of the distal or remote end portion 26 of the strap 22, as seen in FIG. 3, better seen in FIG. 6, may be an additional patch 28 of fastener fabric, suitably secured by stitching or other securing means. That is, the fastener fabric patch 28 is adapted to mate in detachable securing engagement with the fastener fabric patch 27, in a manner appearing presently.
Secured on the upper or exposed surface of strap 22, overlying the inner end portion 25 may be a pocket patch 30 combining with the underlying strap end portion 25 to define a pocket or nail head receiver 31. The pocket patch 30 may be suitably secured, as by stitching or other securing means.
More specifically, the pocket patch 30 may be generally rectangular, having one edge 32 outward of the loop 21 unsecured to the strap 22 and formed with an inwardly tapering cut-out or V-shaped notch 33. By this construction, a nail is adapted to be received by the pocket 31 with the nail head beneath the pocket patch 30 and the nail shank frictionally engaged by the converging edges of cut-out 33.
The distal, opposite end of the strap 32 is similarly provided with a pocket patch 35 suitably secured in facing relation with the strap end portion 26 to define a nail receiving pocket 36. The pocket patch 35 may also be generally rectangular, having its outer edge 37 medially cut away to define a generally V-shaped notch or cut-out 38.
In order to assemble the nail holding attachment 20 to the hammer 10, the loop 21 is engaged in circumposed relation about the handle 11 and moved upwardly closely adjacent to the hammer head 12 surrounding the handle sleeve. This is done with the fastener fabric patch 27 and strap 22 outwardly and on opposite sides of the hammer head. Such an intermediate stage of assembly is shown in FIGS. 3 and 4. Assembly may be readily completed by merely wrapping the strap 22 outwardly about the hammer head 12, so that the strap has its opposite ends on opposite sides of the hammer head. Also, the fastener fabric patches 27 and 28 are in secured facing engagement with each other to effectively retain the attachment snuggly about the sleeve 15 and embracing the head. The elasticity of the loop straps 23, and of the strap 22 facilitate obtaining this snug embracing engagement of the attachment about the hammer head. In this condition, as seen in FIGS. 1 and 2 it will be apparent that the pockets 31 and 36 are on opposite sides of the hammer head with the pocket notches 33 and 38 extending in opposite directions longitudinally of the hammer handle. In this manner, the pocket 31 may define a receiver for a nail to be impaled in an overhead position, while the pocket 36 provides a receiver for a nail to be impaled in a lower position, as when a hammer head is downward.
It is believed apparent that the attachment 20 may be quickly and easily removed by mere reversal of the above described assembly procedure. That is, merely peeling the strap end portion 26, as seen in FIG. 2, away from the loop 21 to detach the fabric fasteners 27 and 28 will return the attachment to the condition shown in FIGS. 3 and 4. The loop 21 may then merely be slipped off of the handle 11 to entirely separate the attachment from the hammer.
From the foregoing, it will be appreciated that the hammer attachment of the present invention will effectively hold nails for starting in substantially any hammer position, is extremely simple and economical in construction, capable of use with substantially all types and sizes of hammers and otherwise fully accomplishes its intended objects.
Although the present invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it is understood that certain changes and modifications may be made within the spirit of the invention. | A hammer attachment comprising a loop engagable about a hammer handle closely beneath the hammer head, a strap engaged outwardly about the hammer head onto opposite sides of the head and there secured to opposite regions of the loop, and at least one nail head receiver on the strap for holding a nail to be started. | 1 |
TECHNICAL FIELD
[0001] The present invention relates to a cationic microfibrillated plant fiber and a method for manufacturing the same.
BACKGROUND ART
[0002] Various methods are known for microfibrillating plant fibers or the like (e.g., wood pulp) to obtain microfibrillated plant fibers (nanofibers) that are refined to have a nano-order fiber diameter. For example, Patent Literature 1 discloses that by microfibrillating a cellulose fiber having a specific fiber length, a microfibrillated cellulose having excellent water retentivity and a long fiber length can be obtained despite a small fiber diameter. Patent Literature 2 suggests a method for enhancing nanofibrillation, in which the adhesive property of unnecessary lignin, hemicellulose, and the like, contained in a cellulose-based fiber raw material is diminished by subjecting the fiber raw material to steaming treatment. Further, as a method for directly producing a cellulose nanofiber from lignocellulose by enhancing nanofibrillation, Patent Literature 3 suggests a method for treating lignocellulose in an aqueous-based medium containing a nitroxy radical derivative, alkali bromide, and an oxidizing agent.
[0003] Patent Literature 4 discloses a method for improving the water absorption property of fiber for use in disposable diapers and the like, in which a hydrophobized drug such as an anionic surfactant, cationic surfactant, or nonionic surfactant is added to a cellulose-based fiber, and then the mixture is subjected to mechanical stirring to provide the cellulose-based fiber with a high porosity. As in Patent Literature 4, although the production of microfibrils as small as microfibrillated plant fibers (nanofibers) is not intended, Patent Literature 5 suggests increasing the affinity with an anionic dye by introducing a cationic group into the surface of a cellulose-based fiber to cationically charge the fiber surface, and improving the water retentivity, shape retention property, and dispersibility of cellulose particles, while maintaining functions as the cellulose particles obtained by further refining the cellulose-based fiber.
CITATION LIST
Patent Literature
[0000]
PTL 1: Japanese Unexamined Patent Publication No. 2007-231438
PTL 2: Japanese Unexamined Patent Publication No. 2008-75214
PTL 3: Japanese Unexamined Patent Publication No. 2008-308802
PTL 4: Japanese Unexamined Patent Publication No. 1996-10284
PTL 5: Japanese Unexamined Patent Publication No. 2002-226501
SUMMARY OF INVENTION
Technical Problem
[0009] A main object of the present invention is to provide a novel cationized microfibrillated plant fiber and a method for manufacturing the same.
Solution to Problem
[0010] As described above, in producing a microfibrillated plant fiber from a plant fiber such as wood pulp, modifying a starting material or a defibration method to enhance nanofibrillation and subjecting a raw material fiber to a chemical treatment to improve water retentivity have been known. However, fiber that is highly refined even to a microfibrillated plant fiber has different levels of fiber dispersibility or surface damage depending on a defibration method or chemical treatment method, and this leads to a great difference in the properties, e.g., strength of a sheet or a resin composite obtained from the microfibrillated plant fiber. The present inventors conducted extensive research on a method for easily producing a microfibrillated plant fiber from a plant-fiber-containing material, wherein the obtained microfibrillated plant fiber has excellent strength. Consequently, they found that by employing a production method comprising the steps of (1) reacting hydroxyl groups in a material containing a cellulose fiber with a quaternary-ammonium-group-containing cationization agent to cationically modify the cellulose-fiber-containing material, and (2) defibrating the obtained cationically modified fiber in the presence of water, a plant fiber can be easily defibrated, and a microfibrillated plant fiber having particularly excellent strength when the fiber is formed into a sheet or a resin composite can be obtained.
[0011] In general, a microfibrillated plant fiber is slightly anionically charged because of reasons such as the reducing terminal being partially oxidized. Therefore, by merely subjecting plant fiber to cationic modification, bonding between fibers is enhanced by electrostatic interaction, which may increase strength. However, since the amount of the anionic group contained in the plant fiber is very small, its effect is poor. As a result of extensive study, however, the present inventors found that micro-fibrillation can significantly proceed by applying mechanical shear stress to a plant fiber that has been cationically modified.
[0012] The present invention was accomplished as a result of further research based on these findings. Specifically, the present invention provides a microfibrillated plant fiber, manufacturing method thereof, sheet containing the plant fiber, and thermosetting resin composite containing the plant fiber, as shown in the following Items 1 to 7.
[0000] 1. A cationic microfibrillated plant fiber cationically modified with a quaternary-ammonium-group-containing compound, the cationic microfibrillated plant fiber having an average diameter of 4 to 200 nm.
2. A cationic microfibrillated plant fiber having a degree of substitution of quaternary ammonium groups of not less than 0.03 to less than 0.4 per anhydrous glucose unit and an average diameter of 4 to 200 nm.
3. A method for manufacturing the cationic microfibrillated plant fiber of Item 1 or 2, the method comprising the steps of
(1) reacting hydroxyl groups in a material containing a cellulose fiber with a quaternary-ammonium-group-containing cationization agent to cationically modify the material containing a cellulose fiber, and
(2) defibrating a resulting cationically modified fiber in the presence of water to an extent that a fiber average diameter becomes 4 to 200 nm.
4. A sheet comprising the cationic microfibrillated plant fiber of Item 1 or 2.
5. A thermosetting resin composite comprising the cationic microfibrillated plant fiber of Item 1 or 2.
6. The thermosetting resin composite according to Item 5, wherein the thermosetting resin is an unsaturated polyester resin or a phenol resin.
7. A method for manufacturing a thermosetting resin composite, comprising the step of mixing the cationic microfibrillated plant fiber of Item 1 or 2 with a thermosetting resin.
Advantageous Effects of Invention
[0013] By employing the manufacturing method comprising the steps of (1) reacting hydroxyl groups in a material containing a cellulose fiber with a quaternary-ammonium-group-containing cationization agent to cationically modify the material containing a cellulose fiber, and (2) defibrating the obtained cationically modified fiber in the presence of water, the present invention can attain excellent effects such that a raw material is easily defibrated, and significantly high strength when the obtained microfibrillated plant fiber is formed into a sheet or a resin composite can be attained. Further, the microfibrillated plant fiber of the present invention has an average diameter as extremely small as about 4 to 200 nm, and it has excellent strength. Accordingly, the present invention is applicable to a wide variety fields including interior materials, exterior materials, and structural materials of transportation vehicles; the housings, structural materials, and internal parts of electrical appliances; the housings, structural materials, and internal parts of mobile communication equipment; the housings, structural materials, and internal parts of devices such as portable music players, video players, printers, copiers, and sporting equipment; building materials; and office supplies such as writing supplies.
BRIEF DESCRIPTION OF DRAWINGS
[0014] FIG. 1 is an electron microscope photograph of the cationic microfibrillated plant fiber obtained in Example 3 (magnification: ×10,000).
[0015] FIG. 2 is an electron microscope photograph of the cationic microfibrillated plant fiber obtained in Example 3 (magnification: ×20,000).
[0016] FIG. 3 is an electron microscope photograph of the cationic microfibrillated plant fiber obtained in Example 4 (magnification: ×50,000).
[0017] FIG. 4 is an electron microscope photograph of the cationic plant fiber obtained in Comparative Example 1 (magnification: ×10,000).
[0018] FIG. 5 is an electron microscope photograph of the cationic plant fiber obtained in Comparative Example 3 (magnification: ×250).
[0019] Hereinbelow, details are given on the present inventions, i.e., a cationic microfibrillated plant fiber, a method for manufacturing the plant fiber, and a sheet and a thermosetting resin composite obtained from the plant fiber.
[0020] One feature of the cationic microfibrillated plant fiber of the present invention is that the plant fiber is extremely thin, having an average diameter of about 4 to 200 nm, and the microfibrillated plant fiber is cationically modified with a quaternary-ammonium-group-containing compound.
[0021] In plant cell walls, a cellulose microfibril (single cellulose nanofiber) having a width of about 4 nm is present as the minimum unit. This is a basic skeleton material (basic element) of plants, and the assembly of such cellulose microfibrils forms a plant skeleton. In the present invention, the microfibrillated plant fiber is obtained by breaking apart the fibers of a plant-fiber-containing material (e.g., wood pulp) to a nanosize level.
[0022] The average diameter of the cationic microfibrillated plant fiber of the present invention is generally about 4 to 200 nm, preferably about 4 to 150 nm, and particularly preferably about 4 to 100 nm. The average diameter of the cationic microfibrillated plant fiber of the present invention is an average value obtained by measuring at least 50 cationic microfibrillated plant fibers in the field of an electron microscope.
[0023] The microfibrillated plant fiber of the present invention can be produced, for example, by a method including the following steps (1) and (2).
[0024] (1) Reacting hydroxyl groups in a material containing a cellulose fiber with a quaternary-ammonium-group-containing cationization agent to cationically modify the material containing a cellulose fiber, and
[0025] (2) defibrating the obtained cationically modified fiber in the presence of water to an extent that the fiber has an average diameter of 4 to 200 nm.
[0026] Examples of the material containing a cellulose fiber (cellulose-fiber-containing material), which is used as a raw material in step (1), include pulp obtained from a natural cellulose raw material such as wood, bamboo, hemp, jute, kenaf, cotton, beat, agricultural waste, and cloth; mercerized cellulose fiber; and regenerated cellulose fiber such as rayon and cellophane. In particular, pulp is a preferable raw material.
[0027] Preferable examples of the pulp include chemical pulp (kraft pulp (KP), sulfite pulp (SP)), semi-chemical pulp (SCP), semi-ground pulp (CGP), chemi-mechanical pulp (CMP), ground pulp (GP), refiner mechanical pulp (RMP), thermomechanical pulp (TMP), and chemi-thermomechanical pulp (CTMP), which are obtained by chemically and/or mechanically pulping plant raw materials; and deinked recycled pulp, cardboard recycled pulp, and magazine recycled pulp, which comprise these plant fibers as main ingredients. These raw materials may optionally be subjected to delignification or bleaching to control the lignin content in the plant fibers.
[0028] Among these pulps, various kraft pulps derived from softwood with high fiber strength (softwood unbleached kraft pulp (hereafter sometimes referred to as NUKP), oxygen-prebleached softwood kraft pulp (hereafter sometimes referred to as NOKP), and softwood bleached kraft pulp (hereafter sometimes referred to as NBKP) are particularly preferably used.
[0029] The lignin content in the cellulose-fiber-containing material used as a raw material is generally about 0 to 40% by weight, and preferably about 0 to 10% by weight. The lignin content is the value measured by the Klason method.
[0030] The cation modification reaction (reaction of hydroxyl groups in a cellulose-fiber-containing material with a quaternary-ammonium-group-containing cationization agent) in step (1) can be performed by a known method. The cellulose-fiber-containing material is formed by binding a large number of anhydrous glucose units, and each anhydrous glucose unit contains multiple hydroxy groups. For example, when glycidyl trialkyl ammonium halide is used as a cationization agent, the cationization agent and a catalyst, i.e., a hydroxylation alkali metal, are reacted with a cellulose-fiber-containing material, which is used as a raw material.
[0031] The quaternary-ammonium-group-containing cationization agent that acts on (reacts with) the cellulose-fiber-containing material is a compound that contains quaternary ammonium groups and a group reacting with hydroxyl groups in the cellulose-fiber-containing material. The group reacting with hydroxyl groups in the cellulose-fiber-containing material is not particularly limited as long as it is a reaction group that reacts with hydroxyl groups to form a covalent bond. Examples thereof include epoxy, halohydrin capable of forming epoxy, active halogen, active vinyl, methylol, and the like. Of these, epoxy and halohydrin forming epoxy are preferable in view of reactivity. Further, quaternary ammonium groups have a structure of —N + (R) 3 . (Note that R in the formula is an alkyl group, an aryl group, or a heterocyclic group, each of which may optionally have a substituent.) Various cationization agents are known as such cationization agents, and known cationization agents can be used in the present invention.
[0032] In the present invention, the molecular weight of the quaternary-ammonium-group-containing cationization agent is generally about 150 to 10,000, preferably about 150 to 5,000, and more preferably about 150 to 1,000. When the molecular weight of the cationization agent is 1,000 or less, defibration of the cellulose-fiber-containing material easily proceeds; a cationization agent having a molecular weight of 1,000 or less is thus preferable. Defibration easily proceeds presumably because a cationization agent permeates into the cellulose, and even the inside of the cellulose-fiber-containing material is fully cationized to increase the effect of electric resistance of cations.
[0033] Examples of the quaternary ammonium-containing cationization agent used in the present invention include glycidyl trimethylammonium chloride, 3-chloro-2-hydroxypropyl trimethyl ammonium chloride, and like glycidyl trialkyl ammonium halides, or halohydrin thereof.
[0034] The reaction of the cellulose-fiber-containing material and the quaternary-ammonium-group-containing cationization agent is preferably performed in the presence of a hydroxylation alkali metal and water and/or a C 1-4 alcohol. Examples of the hydroxylation alkali metal, which is used as a catalyst, include sodium hydroxide, potassium hydroxide, and the like. Examples of the water include tap water, purified water, ion exchange water, pure water, industrial water, and the like. Examples of the C 1-4 alcohol include methanol, ethanol, n-propyl alcohol, isopropyl alcohol, n-butanol, and the like. Water and C 1-4 alcohol can be used singly or as a mixture. When water and C 1-4 alcohol are used as a mixture, the composition ratio is suitably adjusted. It is desirable to adjust the degree of substitution of quaternary ammonium groups of the obtained cationic microfibrillated plant fiber to not less than 0.03 to less than 0.4 per anhydrous glucose unit.
[0035] The proportion of the cellulose-fiber-containing material and the cationization agent used in step (1) may be generally such that the cationization agent is contained in an amount of about 10 to 1,000 parts by weight, preferably about 10 to 800 parts by weight, and more preferably about 10 to 500 parts by weight per 100 parts by weight of the cellulose-fiber-containing material.
[0036] Further, the proportion of the hydroxylation alkali metal is generally about 1 to 7 parts by weight, preferably about 1 to 5 parts by weight, and more preferably about 1 to 3 parts by weight per 100 parts by weight of the cellulose-fiber-containing material. Further, the proportion of water and/or C 1-4 alcohol is generally about 100 to 50,000 parts by weight, preferably 100 to 10,000 parts by weight, and more preferably about 100 to 500 parts by weight per 100 parts by weight of the cellulose-fiber-containing material.
[0037] In step (1), the cellulose-fiber-containing material is reacted with the cationization agent generally at about 10 to 90° C., preferably at about 30 to 90° C., and more preferably at about 50 to 80° C. Additionally, the cellulose-fiber-containing material is reacted with the cationization agent for generally about 10 minutes to 10 hours, preferably 30 minutes to 5 hours, and more preferably about 1 to 3 hours. The pressure for performing step (1) is not particularly limited, and step (1) may be performed under atmospheric pressure.
[0038] The cellulose-fiber-containing material that is cationically modified in step (1) may be subjected to step (2) without further treatment; however, it is preferable that after cation modification in step (1), a component such as a alkali metal hydroxide salt that remains in the reaction system be neutralized with a mineral acid, organic acid, etc., and then be subjected to step (2). Further, in addition to the neutralization step, washing and purification may be performed by a known method. Additionally, the amount of water may be increased or decreased to obtain a fiber concentration appropriate for the subsequent defibration treatment in step (2).
[0039] However, in the present invention, the cellulose-fiber-containing material that is cationically modified should not be dried between step (1) and step (2). If the cellulose-fiber-containing material cationically modified in step (1) is dried, even when the dried product is defibrated in subsequent step (2), it becomes difficult to obtain a microfibrillated plant fiber that is defibrated to the nano level and has a high strength, as in the present invention. Since a cellulose molecule has a large number of hydroxyl groups, adjacent fibers of the cellulose-fiber-containing material that has undergone the drying step are bonded to each other by firm hydrogen bonding and are firmly agglomerated (for example, such agglomeration of fibers during drying is called “hornification” in paper and pulp). It is extremely difficult to defibrate fibers once agglomerated using mechanical power. For example, in Patent Literature 5, hornification occurs because drying is performed after cationization treatment. Accordingly, even if a material containing a hornificated cellulose fiber is mechanically broken by using any method, micro-order particles alone are merely formed.
[0040] Accordingly, in the present invention, the cellulose-fiber-containing material that is cationically modified in step (1) is defibrated in the presence of water in step (2). A known method can be employed as a method of defibrating the cellulose-fiber-containing material. For example, a defibration method can be used in which an aqueous suspension or slurry of the cellulose-fiber-containing material is mechanically milled or beaten using a refiner, high-pressure homogenizer, grinder, single- or multi-screw kneader, or the like. It is preferable to perform treatment by combining the aforementioned defibration methods, e.g., performing a single- or multi-screw kneader treatment after a refiner treatment, as necessary.
[0041] In step (2), the cellulose-fiber-containing material that is cationically modified in step (1) is preferably defibrated by using a single- or multi-screw kneader (hereinbelow, sometimes simply referred to as a “kneader”). Examples of the kneader (kneading extruder) include a single-screw kneader and a multi-screw kneader having two or more screws. In the present invention, either can be used. The use of the multi-screw kneader is preferable because the dispersion property of the microfibrillated plant fiber can be improved. Among multi-screw kneaders, a twin-screw kneader is preferable because it is readily available.
[0042] The lower limit of the screw circumferential speed of the single- or multi-screw kneader is generally about 45 m/min. The lower limit of the screw circumferential speed is preferably about 60 m/min., and particularly preferably about 90 m/min. The upper limit of the screw circumferential speed is generally about 200 m/min., preferably about 150 m/min., and particularly preferably about 100 m/min.
[0043] The L/D (the ratio of the screw diameter D to the kneader length L) of the kneader used in the present invention is generally from about 15 to 60, and preferably from about 30 to 60.
[0044] The defibration time of the single- or multi-screw kneader varies depending on the kind of the cellulose-fiber-containing material, the L/D of the kneader, and the like. When the L/D is in the aforementioned range, the defibration time is generally from about 30 to 60 minutes, and preferably from about 30 to 45 minutes.
[0045] The number of defibration treatments (passes) using a kneader varies depending on the fiber diameter and the fiber length of the target microfibrillated plant fiber, the L/D of a kneader, or the like; however, it is generally about 1 to 8 times, and preferably about 1 to 4 times. When the number of defibration treatments (passes) of pulp using a kneader is too large, cellulose becomes discolored or heat-damaged (sheet strength decreased) because heat generation simultaneously occurs, although defibration proceeds further.
[0046] The kneader includes one or more kneading members, each having a screw.
[0047] When there are two or more kneading members, one or more blocking structures (traps) may be present between kneading members. In the present invention, since the screw circumferential speed is 45 m/min. or more, which is much higher than the conventional screw circumferential speed, to decrease the load to the kneader, it is preferable not to include the blocking structure.
[0048] The rotation directions of the two screws that compose a twin-screw kneader are either the same or different. The two screws composing a twin-screw kneader may be complete intermeshing screws, incomplete intermeshing screws, or non-intermeshing screws. In the defibration of the present invention, complete intermeshing screws are preferably used.
[0049] The ratio of the screw length to the screw diameter (screw length/screw diameter) may be from about 20 to 150. Examples of the twin-screw kneader include KZW produced by Technovel Ltd., TEX produced by the Japan Steel Works Ltd., TEM produced by Toshiba machine Co. Ltd., ZSK produced by Coperion GmbH, and the like.
[0050] The proportion of the raw material pulp in the mixture of water and the raw material pulp subjected to defibration is generally about 10 to 70% by weight, and preferably about 20 to 50% by weight.
[0051] The temperature in the kneading is not particularly limited. It is generally 10 to 160° C., and particularly preferably 20 to 140° C.
[0052] As described above, in the present invention, the plant-fiber-containing material that is cationized may be subjected to preliminary defibration using a refiner, etc., before being defibrated in step (2). A conventionally known method can be used as a method of preliminary defibration using a refiner, etc. By performing preliminary defibration using a refiner, the load applied to the kneader can be reduced, which is preferable from the viewpoint of production efficiency.
[0053] The cationic microfibrillated plant fiber of the present invention can be obtained by the aforementioned production method. The degree of substitution of quaternary ammonium groups per anhydrous glucose unit is not less than 0.03 to less than 0.4, and the degree of crystallinity of the cellulose I is generally 60% or more. The lower limit of the degree of substitution of quaternary ammonium groups per anhydrous glucose unit is preferably about 0.03, and more preferably about 0.05. The upper limit of the degree of substitution is preferably about 0.3, and more preferably about 0.2. The degree of substitution varies depending on a defibration treatment method. To adjust the degree of substitution to the aforementioned range, the aforementioned defibration methods can be used. Among these, the use of a kneader, in particular a twin-screw kneader, is particularly preferable to adjust the degree of substitution to the desired numerical range. The degree of substitution of quaternary ammonium (cation) groups is the value measured by the method according to the Example.
[0054] The lignin content of the cationic microfibrillated plant fiber of the present invention is the same as the lignin content of the raw material, i.e., the cellulose-fiber-containing material, and is generally about 0 to 40% by weight, and preferably about 0 to 10% by weight. The lignin content is the value measured by the Klason method.
[0055] To obtain a microfibrillated plant fiber having high strength and a high elastic modulus in the present invention, a cellulose composing the microfibrillated plant fiber preferably includes a cellulose I crystal structure having the highest strength and the highest elastic modulus.
[0056] The cationic microfibrillated plant fiber of the present invention can be formed into a sheet-like shape. The molding method is not particularly limited. For example, a mixture (slurry) of water and a microfibrillated plant fiber, which is obtained in step (1) and step (2), is filtered by suction, and a sheet-like microfibrillated plant fiber is dried and hot-pressed on a filter to thereby mold the microfibrillated plant fiber into a sheet.
[0057] When the cationic microfibrillated plant fiber is formed into a sheet, the concentration of the microfibrillated plant fiber in the slurry is not particularly limited. The concentration is generally about 0.1 to 2.0% by weight, and preferably about 0.2 to 0.5% by weight.
[0058] The reduced pressure of the suction filtration is generally about 10 to 60 kPa, and preferably about 10 to 30 kPa. The temperature at the suction filtration is generally about 10 to 40° C., and preferably about 20 to 25° C.
[0059] A wire mesh cloth, filter paper, or the like, can be used as a filter.
[0060] A dewatered sheet (wet web) of the cationic microfibrillated plant fiber can be obtained by the aforementioned suction filtration. The obtained dewatered sheet is immersed in a solvent bath, as required, and then hot-pressed, thereby enabling obtaining a dry sheet of the microfibrillated plant fiber.
[0061] The heating temperature in hot pressing is generally about 50 to 150° C., and preferably about 90 to 120° C. The pressure is generally about 0.0001 to 0.05 MPa, and preferably about 0.001 to 0.01 MPa. The hot pressing time is generally about 1 to 60 minutes, and preferably about 10 to 30 minutes.
[0062] The tensile strength of the sheet obtained from the cationic microfibrillated plant fiber of the present invention is generally about 90 to 200 MPa, and preferably about 120 to 200 MPa. The tensile strength of the sheet obtained from the cationic microfibrillated plant fiber of the present invention sometimes varies depending on the basis weight, density, etc., of the sheet. In the present invention, a sheet having a basis weight of 100 g/m 2 is formed, and the tensile strength of the sheet having a density of 0.8 to 1.0 g/cm 3 and obtained from the cationic microfibrillated plant fiber is measured.
[0063] The tensile strength is a value measured by the following method. A dried cationic microfibrillated plant fiber sheet that is prepared to have a basis weight of 100 g/m 2 is cut to form a rectangular sheet having a size of 10 mm×50 mm to obtain a specimen. The specimen is mounted on a tensile tester, and the stress and strain applied to the specimen are measured while a load is applied. The load applied per specimen unit sectional area when the specimen is ruptured is referred to as “tensile strength.”
[0064] The tensile elastic modulus of the sheet obtained from the cationic microfibrillated plant fiber of the present invention is generally about 6.0 to 8.0 GPa, and preferably about 7.0 to 8.0 GPa. The tensile elastic modulus of the sheet obtained from the cationic microfibrillated plant fiber of the present invention sometimes varies depending on the basis weight, density, etc., of the sheet. In the present invention, a sheet having a basis weight of 100 g/m 2 is formed, and the tensile elastic modulus of the sheet having a density of 0.8 to 1.0 g/cm 3 and obtained from the cationic microfibrillated plant fiber is measured. The tensile strength is a value measured by the following method.
[0065] The cationic microfibrillated plant fiber of the present invention can be mixed with various resins to form a resin composite.
[0066] The resin is not particularly limited. For example, thermosetting resins, such as phenolic resin, urea resin, melamine resin, unsaturated polyester resin, epoxy resin, diallyl phthalate resin, polyurethane resin, silicone resin, and polyimide resin, can be used. These resins may be used singly or in a combination of two or more. Preferred are phenolic resins, epoxy resins, and unsaturated polyester resins.
[0067] The method of forming a composite of a cationic microfibrillated plant fiber and a resin is not particularly limited, and a general method of forming a composite of a cationic microfibrillated plant fiber and a resin can be used. Examples thereof include a method in which a sheet or a molded article formed of a cationic microfibrillated plant fiber is sufficiently impregnated with a resin monomer liquid, followed by polymerization using heat, UV irradiation, a polymerization initiator, etc.; a method in which a cationic microfibrillated plant fiber is sufficiently impregnated with a polymer resin solution or resin powder dispersion, followed by drying; a method in which a cationic microfibrillated plant fiber is sufficiently dispersed in a resin monomer liquid, followed by polymerization using heat, UV irradiation, a polymerization initiator, etc.; a method in which a cationic microfibrillated plant fiber is sufficiently dispersed in a polymer resin solution or a resin powder dispersion, followed by drying; and the like.
[0068] To form a composite, the following additives may be added: surfactants; polysaccharides, such as starch and alginic acid; natural proteins, such as gelatin, hide glue, and casein; inorganic compounds, such as tannin, zeolite, ceramics, and metal powders; colorants; plasticizers; flavors; pigments; fluidity adjusters; leveling agents; conducting agents; antistatic agents; UV absorbers; UV dispersants; and deodorants.
[0069] As described above, the resin composite of the present invention can be produced. The cationic microfibrillated plant fiber of the present invention has a high strength and can thus yield a resin composite with high strength. This composite resin can be molded like other moldable resins, and the molding can be performed by, for example, hot pressing in a mold. Molding conditions of resin appropriately adjusted, as required, can be used in the molding.
[0070] The resin composite of the present invention has high mechanical strength, and can thus be used, for example, not only in fields where known microfibrillated plant fiber molded articles and known microfibrillated plant fiber-containing resin molded articles are used, but also in fields that require higher mechanical strength (tensile strength, etc.). For example, the resin composite of the present invention can be effectively applied to interior materials, exterior materials, and structural materials of transportation vehicles such as automobiles, trains, ships, and airplanes; the housings, structural materials, and internal parts of electrical appliances such as personal computers, televisions, telephones, and watches; the housings, structural materials, and internal parts of mobile communication devices such as mobile phones; the housings, structural materials, and internal parts of devices such as portable music players, video players, printers, copiers, and sporting equipment; building materials; and office supplies such as writing supplies.
DESCRIPTION OF EMBODIMENTS
[0071] The present invention is described in further detail with reference to Examples and Comparative Examples. The scope of the invention is, however, not limited to these Examples.
Example 1
[0072] A slurry of softwood unbleached kraft pulp (NUKP) (an aqueous suspension with a pulp slurry concentration of 2% by weight) was passed through a single-disk refiner (produced by Kumagai Riki Kogyo Co., Ltd.) and repeatedly subjected to refiner treatment until a Canadian standard freeness (CSF) value of 100 mL or less was achieved. The obtained slurry was dehydrated and concentrated using a centrifugal dehydrator (produced by Kokusan Co., Ltd.) at 2,000 rpm for 15 minutes to a pulp concentration of 25% by weight. Subsequently, 60 parts by dry weight of the above-mentioned pulp, 30 parts by weight of sodium hydroxide, and 2,790 parts by weight of water were introduced into an IKA stirrer whose rotation number had been adjusted to 800 rpm, and the resulting mixture was stirred at 30° C. for 30 minutes. Thereafter, the temperature was increased to 80° C., and 375 parts by weight of 3-chloro-2-hydroxypropyltrimethylammonium chloride (CTA) on an active component basis was added thereto as a cationization agent. After the reaction was conducted for 1 hour, the reaction product was separated, neutralized, washed, and concentrated to thereby obtain a cationically modified pulp having a concentration of 25% by weight. Table 1 shows the degree of cationic substitution of the cationically modified pulp.
[0073] After the lignin content (% by weight) in the sample was measured by the Klason method, the degree of cationic substitution was calculated by measuring the nitrogen content (% by weight) of the sample by elemental analysis and using the following formula. The term “degree of substitution” used herein refers to the average value of the number of moles of substituent per mol of an anhydrous glucose unit.
[0000] Degree of Cationic Substitution=(162 ×N )/{(1400−151.6× N )×(1−0.01 ×L )}
[0074] N: Nitrogen content (% by weight)
[0075] L: Lignin content (% by weight)
[0076] The obtained cationically modified pulp was introduced into a twin-screw kneader (KZW, produced by Technovel Corporation) and subjected to defibration treatment. The defibration was performed using a twin-screw kneader under the following conditions.
[Defibration Conditions]
[0077] Screw diameter: 15 mm
Screw rotation speed: 2,000 rpm (screw circumferential speed: 94.2 m/min.)
Defibration time: 150 g of cationically modified pulp was subjected to defibration treatment under the conditions of 500 g/hr to 600 g/hr. The time from introducing the starting material to obtaining microfibrillated plant fibers was 15 minutes.
L/D: 45
[0078] Number of times defibration treatment was performed: once (1 pass)
Number of blocking structures: 0
[0079] Subsequently, water was added to the cationic microfibrillated plant fiber slurry obtained through defibration, and the concentration of the cationically modified microfibrillated plant fiber was adjusted to 0.33% by weight. The temperature of the slurry was adjusted to 20° C. After 600 mL of the slurry was placed into a jar and stirred with a stirring rod, filtration under reduced pressure (using a 5A filter paper produced by Advantec Toyo Kaisha, Ltd.) was promptly initiated. The obtained wet web was hot-pressed at 110° C. under a pressure of 0.003 MPa for 10 minutes, thereby obtaining a cationic microfibrillated plant fiber sheet of 100 g/m 2 . The tensile strength of the obtained sheet was measured. Table 1 shows the lignin content, the degree of cationic substitution, and each property value of the dry sheet. The method of measuring the tensile strength is as described above.
Example 2
[0080] A dry sheet was produced by carrying out cationic modification as described in Example 1, except that softwood bleached kraft pulp (NBKP) was used as the pulp, CTA was used in an amount of 180 parts by weight, and water was used in an amount of 2,730 parts by weight. Table 1 shows the lignin content, the degree of cationic substitution, and each property value of the dry sheet.
Example 3
[0081] A dry sheet was produced by carrying out cationic modification as described in Example 2, except that glycidyl trimethyl ammoniumchloride (GTA) was used as a cationization agent in place of CTA. Table 1 shows the lignin content, the degree of cationic substitution, and each property value of the dry sheet.
[0082] FIGS. 1 and 2 are electron microscope photographs of the cationic microfibrillated plant fiber obtained in Example 3. The diameters of 100 arbitrary cationic microfibrillated plant fibers shown in the SEM image at 10,000× magnification of FIG. 1 were measured; the number average fiber diameter was 87.02 nm. Further, the diameters of 50 arbitrary cationic microfibrillated plant fibers shown in the SEM image at 20,000× magnification of FIG. 2 were measured; the number average fiber diameter was 96.83 nm.
Example 4
[0083] A cationically modified microfibrillated plant fiber having a degree of cationic substitution of 0.185 was obtained by carrying out cationic modification as described in Example 2, except that sodium hydroxide was used in an amount of 7 parts by weight, GTA was used in an amount of 120 parts by weight, IPA was used in an amount of 2352 parts, and water was used in an amount of 588 parts.
[0084] FIG. 3 is an electron microscope photograph of the cationic microfibrillated plant fiber obtained in Example 4. The diameters of 100 arbitrary cationic microfibrillated plant fibers shown in the SEM image at 50,000× magnification of FIG. 3 were measured; the number average fiber diameter was 57.79 nm.
Comparative Example 1
[0085] A dry sheet was produced by carrying out cationic modification as described in Example 3, except that, at the time of cationic modification, CTA was added in an amount of 60 parts by weight, and water was added in an amount of 2,850 parts by weight. Table 1 shows the lignin content, the degree of cationic substitution, and each property value of the dry sheet.
[0086] FIG. 4 is an electron microscope photograph of the cationic plant fiber obtained in Comparative Example 1. The diameters of 50 arbitrary cationic plant fibers shown in the SEM image at 10,000× magnification of FIG. 4 were measured; the number average fiber diameter was 354.3 nm. This differs from the average diameter of the cationic microfibrillated plant fiber of the present invention, which is about 4 to 200 nm.
Comparative Example 2
[0087] A dry sheet was produced as described in Example 1, except that cationic modification was not carried out. Table 1 shows the lignin content and each property value of the dry sheet.
Comparative Example 3
[0088] A cationically modified plant fiber was obtained as described in Example 3, except that a twin-screw defibration treatment was not performed after cationic modification. Table 1 shows the lignin content, the degree of cationic substitution, and each property value of the dry sheet.
Comparative Example 4
[0089] Cationic modification was carried out as described in Example 3, except that a commercially available cellulose powder (KC Flock W-100G; average particle diameter: 37 μm; produced by Nippon Paper Chemicals Co., Ltd.) was used, and neutralization, dehydration, and drying were then performed. The dried product was crushed using a hammer mill, thereby obtaining a cationically modified plant fiber having a degree of cationic substitution of 0.052 and an average particle diameter of 35 μm. FIG. 4 is an electron microscope photograph of Comparative Example 4. The diameters of 50 arbitrary cationic plant fibers shown in the SEM image at 250× magnification of FIG. 4 were measured; the average diameter of the cationic plant fiber was 13.31 μm. This differs from the average diameter of the cationic microfibrillated plant fiber of the present invention, which is about 4 to 200 nm. Comparative Example 4 is a repetition of the Example of Japanese Unexamined Patent Publication No. 2002-226501.
[0000]
TABLE 1
Cationization
Tensile
Agent/
Tensile
Elastic
Proportion
Lignin
Degree of
Strength
Modulus
(relative
Content
Cationic
of Sheet
of Sheet
to pulp)
(%)
Substitution
(MPa)
(GPa)
Ex. 1
CTA/625%
6.0
0.032
128
7.1
Ex. 2
CTA/300%
0.0
0.031
141
6.9
Ex. 3
GTA/300%
0.0
0.048
139
6.9
Comp.
CTA/100%
0.0
0.021
79
4.8
Ex. 1
Comp.
—
76
5.4
Ex. 2
Comp.
GTA/300%
0.0
0.052
79
5.5
Ex. 3
[0090] As is clear from the results of Comparative Example 3, the cationically modified plant fiber sheet obtained without performing double-screw defibration after the treatment with GTA/300% had a strength and an elastic modulus of 79 MPa and 5 GPa, respectively, which are almost equal to those of untreated products. A comparison of the results of Example 3 and Comparative Examples 2 and 3 confirms the following: when the pulp (NBKP) is only treated with GTA, the tensile strength of the sheet does not improve, whereas when double-screw defibration is carried out after GTA treatment, the tensile strength of the sheet remarkably improves.
Example 5
[0091] The aqueous suspension of the cationic microfibrillated plant fiber produced in Example 2 was filtrated to obtain a wet web of the cationically modified microfibrillated plant fiber. This wet web was immersed in an ethanol bath for 1 hour and then hot-pressed at 110° C. under a pressure of 0.003 MPa for 10 minutes, thereby obtaining a bulky sheet of the cationically modified microfibrillated plant fiber. The filtration conditions were as follows:
[0092] Filtration area: about 200 cm 2
[0093] Reduced pressure: −30 kPa
[0094] Filter paper: 5A filter paper, produced by Advantec Toyo Kaisha, Ltd.
[0095] Subsequently, the obtained bulky sheet of the cationic microfibrillated plant fiber was cut to a size of 30 mm wide×40 mm long, dried at 105° C. for 1 hour, and the weight was measured.
[0096] The sheet was then immersed in a resin solution prepared by adding 1 part by weight of benzoyl peroxide (Nyper FF, produced by NOF Corporation) to 100 parts by weight of an unsaturated polyester resin (SUNDHOMA FG-283, produced by DH Material Inc.). The immersion was performed under reduced pressure (vacuum: 0.01 MPa; time: 30 minutes), thereby obtaining a sheet impregnated with unsaturated polyester resin. Subsequently, several identical sheets impregnated with unsaturated polyester resin were overlaid so that the molded article had a thickness of about 1 mm. After removing excess resin, the sheets were placed in a mold and hot-pressed (at 90° C. for 30 minutes) to obtain an unsaturated polyester composite molded product of the cationically modified microfibrillated plant fiber. The weight of the obtained molded product was measured, and the fiber content (% by weight) was calculated from the difference between the weight of the molded product and the dry weight of the sheet.
[0097] The length and width of the molded product were accurately measured with a caliper (produced by Mitutoyo Corporation). The thickness was measured at several locations using a micrometer (produced by Mitutoyo Corporation), and the volume of the molded product was calculated. The weight of the molded product was measured separately. The density was calculated from the obtained weight and volume.
[0098] A sample having a thickness of 1.2 mm, a width of 7 mm, and a length of 40 mm was produced from the molded product. The flexural modulus and flexural strength of the sample were measured at a deformation rate of 5 mm/min (load cell: 5 kN). An Instron Model 3365 universal testing machine (produced by Instron Japan Co., Ltd.) was used as a measuring device. Table 2 shows the fiber content, flexural modulus, and flexural strength of the obtained resin composite.
Example 6 and Comparative Examples 5 to 7
[0099] Molded products of Example 6 and Comparative Examples 5 to 7 were obtained as described in Example 5, except that the cationic microfibrillated plant fiber obtained in Example 3, the cationically modified pulp obtained in Comparative Example 1, the microfibrillated plant fiber without cationic modification obtained in Comparative Example 2, and the cationically modified pulp obtained in Comparative Example 3 were respectively used. Table 2 shows the fiber content, flexural modulus, and flexural strength of each resin composite obtained in Example 6 and Comparative Examples 5 to 7.
[0000]
TABLE 2
Unsaturated Polyester Resin
Pretreatment
Composite
Cationization
Degree
Fiber
Agent/Propor-
of
Con-
Flexural
Flexural
Plant
tion (relative
Substi-
tent
Modulus
Strength
Fiber
to pulp)
tution
(%)
(GPa)
(MPa)
Ex. 5
Ex. 2
CTA/300%
0.031
51.8
9.6
198
Ex. 6
Ex. 3
GTA/300%
0.048
56.4
9.9
222
Comp.
Comp.
CTA/100%
0.021
66.4
5.7
120
Ex. 5
Ex. 1
Comp.
Comp.
—
58.3
6.6
140
Ex. 6
Ex. 2
Comp.
Comp.
GTA/300%
0.052
57.6
3.1
101
Ex. 7
Ex. 3
Example 7 and Comparative Example 8
[0100] The dry sheet of the cationic microfibrillated plant fiber obtained in Example 3 and the dry sheet of the microfibrillated plant fiber obtained in Comparative Example 2 were dried at 105° C. for 1 hour, and each weight was measured.
[0101] Subsequently, these dry sheets were immersed (0.3 MPa) in a methanol solution (10% by weight) of phenolic resin (Phenolite IG-1002, produced by DIC Corporation), predried at room temperature, and vacuum-dried at 50° C. for another 6 hours; thus, a dry sheet impregnated with phenolic resin was obtained, and the weight was measured. The fiber content (% by weight) was calculated from the difference between the dry weights before and after the resin impregnation.
[0102] Each of the obtained dry sheets impregnated with phenolic resin was cut into a size of 30 mm wide×40 mm long. Then, several identical sheets were overlaid, placed in a mold, and hot-pressed (at 160° C. for 30 minutes under a pressure of 100 MPa), thereby obtaining a molded product of a composite of the cationic microfibrillated plant fiber and phenolic resin, as well as a molded product of a composite of the non-cationized microfibrillated plant fiber and phenolic resin.
[0103] The length and width of each of the molded products were accurately measured with a caliper (produced by Mitutoyo Corporation). The thickness was measured at several locations using a micrometer (produced by Mitutoyo Corporation), and the volume of each molded product was calculated. The weight of each molded product was measured separately. The density was calculated from the obtained weight and volume.
[0104] A sample having a thickness of about 1.6 mm, a width of 7 and a length of 40 mm was produced from each of the molded products, and the flexural modulus and flexural strength of each sample were measured at a deformation rate of 5 mm/min (load cell: 5 kN). An Instron Model 3365 universal testing machine (produced by Instron Japan Co., Ltd.) was used as a measuring device. Table 3 shows the fiber content, flexural modulus, and flexural strength of each of the obtained resin composites.
[0000]
TABLE 3
Pretreatment
Phenolic Resin Composite
Cationization
Degree
Fiber
Agent/Propor-
of
Con-
Flexural
Flexural
Plant
tion (relative
Substi-
tent
Modulus
Strength
Fiber
to pulp)
tution
(%)
(GPa)
(MPa)
Ex. 7
Ex. 3
GTA/300%
0.048
81.1
16.9
256
Comp.
Comp.
—
80.9
13.3
238
Ex. 8
Ex. 2 | The present invention provides a novel cationized microfibrillated plant fiber and a method for manufacturing the same. A cationic microfibrillated plant fiber that is cationically modified with a quaternary-ammonium-group-containing compound, and that has an average diameter of 4 to 200 nm. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. patent application Ser. No. 12/607,637, filed on Oct. 28, 2009, which is a divisional application of U.S. patent application Ser. No. 10/529,568, filed on Mar. 28, 2005, which issued as U.S. Pat. No. 7,617,961, which is a National Stage entry of PCT/US03/31653, filed on Oct. 6, 2003 under 35 U.S.C. §371(a), which claims the benefit of, and priority to, U.S. Provisional Patent Application Ser. No. 60/416,056, filed Oct. 4, 2002, now expired, the entire contents of each being incorporated by reference herein.
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure relates generally to a surgical tool assembly for manipulating and/or applying fasteners to tissue. More specifically, the present disclosure relates to a surgical tool assembly having a pair of jaws including a unique approximation mechanism to facilitate improved clamping and manipulation of tissue.
[0004] 2. Background of the Related Art
[0005] Surgical staplers and tool assemblies for clamping tissue between opposed jaw structure of a tool assembly and thereafter fastening the clamped tissue are well known in the art. These devices may include a knife for incising the fastened tissue. Such staplers having laparoscopic or endoscopic configurations are also well known in the art. Examples of endoscopic surgical staplers of this type are described in U.S. Pat. Nos. 6,330,965, 6,250,532, 6,241,139, 6,109,500 and 6,079,606, all of which are incorporated herein by reference in their entirety.
[0006] Typically, such staplers include a tool member or assembly having a pair of jaws including a staple cartridge for housing a plurality of staples arranged in at least two laterally spaced rows and an anvil which includes a plurality of staple forming pockets for receiving and forming staple legs of the staples as the staples are driven from the cartridge. The anvil and cartridge are pivotally supported adjacent each other and are pivotable in relation to each other between open and closed positions. In use, tissue is positioned between the jaws in the open position and the jaws are pivoted to the closed position to clamp tissue therebetween.
[0007] One problem associated with conventional staplers and tool assemblies is that as the anvil and cartridge pivot in relation to each other, closure occurs first at the proximal end of the jaws and thereafter at the distal end of the jaws. This sequence of jaw closure has the effect of moving tissue positioned between the jaws towards the distal end of the jaws, thus, forcing tissue from the jaws.
[0008] During laparoscopic or endoscopic procedures, access to a surgical site is achieved through a small incision or through a narrow cannula inserted through a small entrance wound in a patient. Because of the limited area available to access the surgical site, endoscopic staplers are sometimes used to grasp and/or manipulate tissue. Conventional staplers having an anvil or cartridge mounted to a fixed pivot point which are pivotable to a closed position are not particularly suited for grasping tissue because only a limited clamping force is produced at the distal end of the jaws.
[0009] Accordingly, a need exists for an endoscopic surgical stapling tool member or assembly having pivotal jaws which can be operated to effectively grasp, manipulate and/or fasten tissue, including with the end of the jaws, without, or while minimizing, distal movement of the tissue positioned between the jaws.
SUMMARY
[0010] In accordance with the present disclosure, a tool assembly having a pair of jaws is disclosed. Each of the jaws has a proximal end and a distal end and the first jaw is movable in relation to the second jaw between a spaced position and an approximated position. First and second cam followers are supported on the first jaw. An approximation member is movable in relation to the first jaw and includes at least one cam surface positioned to engage the first and second cam followers. The approximation member is movable in relation to the first jaw to move the at least one cam surface in relation to the first and second cam followers to effect movement of the first and second jaws from the spaced position to the approximated position. The at least one cam channel is configured to approximate the distal ends of the first and second jaws prior to approximation of the proximal ends of the first and second jaws. By approximating the distal ends of the first and second jaws first, tissue positioned between the jaws is not pushed forward within the jaws during closure of the jaws. Further, the jaws are better able to grip and manipulate tissue using the distal ends of the jaws.
[0011] Preferably, the first jaw includes an anvil and the second jaw includes a cartridge assembly housing a plurality of staples. In a preferred embodiment, the at least one cam surface includes first and second cam channels, and the approximation member includes a flat plate having the cam channels formed therein. The first jaw includes a longitudinal slot formed in its proximal end and the approximation member is being slidably positioned in the longitudinal slot. The first and second cam followers are supported on the proximal end of the first jaw and extend across the longitudinal slot adjacent the first and second cam channels. The first cam follower extends through the first cam channel and the second cam follower extends through the second cam channel. Preferably, the tool assembly is pivotally attached to a body portion by an articulation joint. The body portion may form the distal end of a surgical stapling device or a proximal portion of a disposable loading unit.
[0012] In another preferred embodiment, the tool assembly includes an anvil, a cartridge assembly housing a plurality of staples and a dynamic clamping member. The anvil and cartridge assembly are movable in relation to each other between spaced and approximated positions. The dynamic clamping member is movable in relation to the anvil and the cartridge assembly to eject the staples from the cartridge assembly. The tool assembly is pivotally attached to a body portion and is pivotable in relation to the body portion from a position aligned with the longitudinal axis of the body portion to a position oriented at an angle to the longitudinal axis of the body portion. An articulation and firing actuator extends at least partially through the body portion and the tool assembly. The articulation and firing actuator is operably associated with the dynamic clamping member and the tool assembly and is movable in relation thereto to selectively pivot the tool assembly in relation to the body portion and/or move the dynamic clamping member in relation to the tool assembly to eject the staples from the cartridge.
[0013] Preferably, the articulation and firing actuator includes a flexible band having a first end portion extending at least partially through the body portion and through the cartridge assembly, a central portion extending from the first end portion operably associated with the dynamic clamping member and a second end portion extending from the central portion through the cartridge assembly and at least partially through the body portion to a position adjacent the first end. The articulation and firing actuator is operably associated with the tool assembly such movement of either the first end portion or the second end portion of the flexible band proximally and independently of the other end portion effects pivoting of the tool assembly in relation to the body portion, and movement of both the first and second end portions of the flexible band simultaneously effects movement of the dynamic clamping member to eject the staples from the cartridge assembly. In a preferred embodiment, an approximation member is operably associated with the tool assembly and is movable in relation to the tool assembly to move the anvil and cartridge assembly from the spaced to the approximated position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Various preferred embodiments of the presently disclosed tool assembly for use with a surgical stapling device are disclosed herein with reference to the drawings, wherein:
[0015] FIG. 1 is a side perspective view of one preferred embodiment of the presently disclosed tool assembly in the approximated position;
[0016] FIG. 2 is a side view of the tool assembly shown in FIG. 1 ;
[0017] FIG. 3 is a side, exploded perspective view of the tool assembly shown in FIG. 1 ;
[0018] FIG. 4A is a schematic view of the jaws of the tool assembly shown in FIG. 1 at a first stage of jaw approximation;
[0019] FIG. 4B is a schematic view of the jaws shown in FIG. 4A at a second stage of jaw approximation;
[0020] FIG. 4C is a schematic view of the jaws shown in FIG. 4B in an approximated position;
[0021] FIG. 5 is a side perspective view of another preferred embodiment of the presently disclosed tool assembly in the approximated position;
[0022] FIG. 6 is a side, exploded perspective view of the tool assembly shown in FIG. 5 ;
[0023] FIG. 7 is a side perspective view of the approximation member of the tool assembly shown in FIG. 6 ;
[0024] FIG. 8 is a side perspective view of the dynamic clamping member of the tool assembly shown in FIG. 6 ;
[0025] FIG. 9 is a top partial cross-sectional view with portions broken away looking through a portion of the cartridge assembly and showing the articulation and firing actuator of the tool assembly shown in FIG. 6 ; and
[0026] FIG. 10 is a cross-sectional view with portions removed and portions added, as would be seen along section lines 10 - 10 of FIG. 9 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0027] Preferred embodiments of the presently disclosed tool assembly for a stapling device will now be described in detail with reference to the drawings in which like reference numerals designate identical or corresponding elements in each of the several views.
[0028] FIGS. 1-3 illustrate one preferred embodiment of the presently disclosed tool assembly shown generally as 10 for use with a surgical stapling device. Tool assembly 10 includes a pair of jaws including an anvil 12 and a cartridge assembly 14 and an approximation member 16 . Cartridge assembly 14 includes a support channel 18 for receiving a staple cartridge 14 a. Support channel 18 includes distal open channel portion 18 a and a proximal portion 18 b defining a truncated cylinder 18 c. Although not shown in detail, staple cartridge 14 a houses a plurality of staples and can include conventional pushers (not shown) for translating movement of a staple drive assembly that typically includes a sled (e.g., 131 in FIG. 6 ) to movement of the staples through openings or slots in a tissue engaging surface 25 of cartridge 14 a.
[0029] Anvil 12 has a tissue engaging surface 20 having a distal end 20 a and a proximal end 20 b and a proximal body portion 22 . A longitudinal slot 24 extends along the central longitudinal axis of anvil 12 through tissue engaging surface 20 and is dimensioned to slidably receive a portion of a drive assembly. The drive assembly typically includes a drive bar, a closure assembly, a sled, and a plurality of pushers. The drive assembly functions to eject staples from the cartridge and preferably also maintains a desired uniform tissue gap between the cartridge and the anvil during firing of the device. Proximal body portion 22 of anvil 12 is dimensioned to be generally pivotably received within truncated cylinder 18 c of proximal portion 18 b of support channel 18 such that tissue engaging surface 20 of anvil 12 is pivotable from a position spaced from tissue engaging surface 25 of cartridge 14 a to an approximated position in juxtaposed alignment therewith.
[0030] Tool assembly 10 includes an approximation member 16 having one or more cam channels 28 and 30 . Preferably, approximation member includes a pair of cam channels although a single cam channel having a pair of cam surfaces is envisioned. Approximation member 16 is dimensioned to be linearly slidable through proximal portion 18 b of channel 18 and through a slot 22 a formed in proximal body portion 22 of anvil 12 . A cam follower 32 extends through a bore 34 formed in proximal portion 22 of anvil 12 and through a hole 35 in proximal portion 18 b of support channel 18 and is positioned within cam channel 28 . A cam follower 36 extends through a second bore 38 formed in the proximal portion 22 of anvil 12 and through a hole 39 in proximal portion and is positioned within cam channel 30 . When approximation member 16 is advanced through slot 22 a in proximal portion 22 of anvil 12 , cam followers 32 and 36 move through cam channels 28 and 30 , respectively. Since approximation member 16 is confined to linear movement within slot 22 a, movement of approximation member 16 in a distal direction effects pivotal movement of anvil 12 from the open or spaced position to the closed or approximated position. The angles of the cam slots can be configured to provide a great variety of approximation motions to improve mechanical advantage and achieve specific results, e.g., grasping of tissue.
[0031] Referring also to FIGS. 4A-4C , cam channels 28 and 30 preferably are configured to pivot anvil 12 from an open position ( FIG. 4A ) towards cartridge assembly 14 in a controlled manner to initially facilitate grasping of tissue and thereafter provide for substantially parallel closure of the anvil and cartridge assembly. More specifically, cam channels 28 and 30 are preferably configured to position the distal end 20 a of tissue contact surface 20 of anvil 12 substantially in contact with cartridge 14 ( FIG. 4B ) during the initial portion of an actuating stroke of approximation member 16 . This facilitates grasping of tissue even very thin tissue. During a second portion of the actuating stroke of approximation member 16 , distal end 20 a of anvil 12 is moved away from cartridge assembly 14 to a resultant position in which tissue engaging surface 20 of anvil 12 is parallel or substantially parallel to tissue engaging surface 25 of cartridge assembly 14 . During the final portion of the actuating stroke of approximation member 16 , the anvil 12 and cartridge assembly 14 are brought together in parallel or substantially parallel closure to define a desired tissue gap ( FIG. 4C ). It is noted that any desired motion of anvil 12 can be achieved using the cam followers described herein. By moving anvil 12 in relation to cartridge assembly 14 from the spaced to the approximated position in the manner described above i.e., front or distal to back or proximal closure, the tendency for tissue to move forward within the jaws, as in conventional devices, is substantially eliminated.
[0032] Although approximation member 16 is illustrated as being in the form of a plate with two distinct cam channels, differently configured approximation members are envisioned. For example, a single cam channel may be provided to engage two cam followers. Further, the cam channels need not be confined but rather can be formed on the surface of a plate, bar or the like. In such a device, the anvil may be urged by a biasing member to the closed or clamped position.
[0033] Although one or more actuators has not been disclosed to advance the approximation member and/or fire staples from the cartridge assembly, it is envisioned that one or more of a variety of known pivotable, rotatable, or slidable actuators, e.g., trigger, knob, lever, etc., may be used to approximate the presently disclosed cartridge assembly and/or fire staples from the cartridge. It is also noted that the disclosed tool assembly may be or form the distal portion of a disposable loading unit or may be incorporated directly into the distal end of a surgical instrument, e.g., surgical stapler, and may include a replaceable cartridge assembly.
[0034] FIGS. 5-10 disclose another preferred embodiment of the presently disclosed tool assembly shown generally as 100 . Tool assembly 100 includes an anvil 112 and a cartridge assembly 114 , an approximation member 116 , and an elongated body portion 120 including an articulation joint generally referred to as 122 . Elongated body portion 120 may form the proximal end of a disposable loading unit or the distal end of a surgical stapling device. Tool assembly 100 also includes a combined articulation and firing actuation mechanism 124 for articulating tool assembly 100 about articulation joint 122 and ejecting staples from cartridge assembly 114 . Although the articulation joint illustrated as a flexible corrugated member with preformed bend areas, articulation joint 122 may include any known type of joint providing articulation, e.g., pivot pin, ball and socket joint, a universal joint etc.
[0035] Approximation member 116 is substantially similar to approximation member 16 and also includes cam channels 128 and 130 ( FIG. 7 ). Approximation member 116 further includes a pair of guide channels 126 . Guide channels 126 are dimensioned to receive guide pins 128 which extend through elongated body portion 120 and function to maintain approximation member 116 along a linear path of travel. Approximation member 116 is constructed from a flexible material, e.g., spring steel, which is capable of bending around articulation joint 122 . Alternately, it is envisioned that approximation member 116 may include a resilient rod, band or the like with cam surfaces formed thereon. Approximation member 116 operates in substantially the same manner as approximation member 16 and will not be discussed in further detail herein.
[0036] Cartridge assembly 114 includes a support channel 118 , a sled 131 and a dynamic clamping member 132 which, preferably, includes an upper flange 134 a for slidably engaging a bearing surface of the anvil and lower flange 134 b for slidably engaging a bearing surface of the cartridge. A knife blade 134 is preferably supported on a central portion 134 c of dynamic clamping member 132 to incise tissue. Knife blade may be secured to dynamic clamping member 132 in a removable or fixed fashion, formed integrally with, or ground directly into dynamic clamping member 132 . Sled 131 is slidably positioned to translate through cartridge 114 in a known manner to eject staples from the cartridge. Sled 131 or the like can be integral or monolithic with dynamic clamping member 132 . Sled 131 is positioned distal of and is engaged and pushed by dynamic clamping member 132 . The position of 131 is to effect firing or ejection of the staples to fasten tissue prior to cutting the stapled tissue. Flange 134 b preferably is positioned within a recess 138 formed in the base of cartridge 114 . Flange 134 a is preferably positioned within a single or separate recess formed in anvil 112 . Again, flanges 134 a and 134 b need not be positioned in a recess but can slidably engage a respective surface of the anvil and cartridge. Dynamic clamping member 132 preferably is positioned proximal of sled 130 within cartridge assembly 114 . Dynamic clamping member 132 functions to provide, restore and/or maintain the desired tissue gap in the area of tool assembly 100 adjacent sled 130 during firing of staples.
[0037] It is preferred that the anvil and preferably the dynamic clamping member be formed of a material and be of such a thickness to minimize deflection of the anvil and dynamic clamping member during firing of the device. Such materials include surgical grade stainless steel. The anvil is preferably formed as a solid unit. Alternatively, the anvil may be formed of an assembly of parts with conventional components.
[0038] Referring to FIGS. 6 , 9 and 10 , articulation and firing mechanism 124 includes a tension member 140 which can have loops 124 or other connection portions or connectors for connection to suitable connection members of one or more actuators or of an actuation mechanism. Although illustrated as a flexible band, tension member 140 may be or include one or more of any flexible drive member having the requisite strength requirements and being capable of performing the functions described below, e.g., a braided or woven strap or cable, a polymeric material, a para-aramid such as Kevlar™, etc. Kevlar™ is a trade designation of poly-phenyleneterephthalamide commercially available from DuPont. A pair of suitable fixed or rotatable members, preferably rollers 142 a and 142 b, are secured at the distal end of cartridge assembly 114 . Rollers 142 a and 142 b may be formed or supported in a removable cap 114 b ( FIG. 6 ) of cartridge assembly 114 . Alternately, cap 114 b may be formed integrally with staple cartridge 114 a or cartridge channel 118 . Rollers 142 a and 142 b can also be secured to or formed from cartridge support channel 118 . Tension member 140 extends distally from elongated body 120 of tool assembly 100 , distally through a peripheral channel 142 in staple cartridge 114 a , around roller 142 a, proximally, preferably, alongside central longitudinal slot 144 formed in cartridge 114 a, through a slot 200 , preferably a transverse slot, in or around a proximal portion of dynamic clamping member 132 , distally around roller 142 b, and again proximally through a channel 146 formed in cartridge 114 a to a proximal portion of elongated body 120 . Alternately, two tension members can be employed, each of which may be secured to dynamic clamping member 132 . As illustrated in FIG. 10 , channels 142 and 146 can be at least partly defined by an inner and/or outer wall of cartridge 114 a and/or by cartridge support channel 118 . Unlike as shown, channels 142 and 146 should be in a consistent, i.e., same, functionally same or corresponding location on both sides of the staple cartridge. Thus, it is envisioned that there would be two peripheral channels 142 , or two channels 146 .
[0039] In use, when a first end or portion 150 of tension member 140 is retracted by suitable means in the direction indicated by arrow “A”, as viewed in FIG. 9 , tool assembly 100 will articulate about pivot member 122 a in the direction indicated by arrow “D”. When second end or portion 152 of tension member 140 is retracted in the direction indicated by arrow “B”, tool assembly 100 will articulate in the direction indicated by arrow “C”. When both ends of tension member 140 are retracted simultaneously, tension member 140 will advance dynamic clamping member 132 distally through slot 144 in cartridge 114 a to advance dynamic clamping member 132 and sled 130 through cartridge 114 a and by engaging pushers, eject staples from the cartridge and incise tissue in the tissue gap. In order to prevent dynamic clamping member 132 from advancing through slot 144 when the tool assembly is being articulated, i.e., when only one end of tension member 140 is retracted, a lockout device (not shown), e.g., a shear pin, may be provided to prevent movement of the dynamic clamping member or delay it until a predetermined force has been applied to the dynamic clamping member. It is envisioned that multiple tension members, e.g., bands, can be employed, respectively, to perform individual or a combination of functions. For example, a pair of tension members can be employed, one to articulate, and the other to approximate, clamp and fire. The tension members can be fixed to the dynamic clamping member or a knife carrying member or to a combination dynamic clamping member, knife member and/or sled member.
[0040] The above-described tool assembly may be incorporated into a disposable loading unit such as disclosed in U.S. Pat. No. 6,330,965 or attached directly to the distal end of any known surgical stapling device. Although a handle assembly for actuating the approximation member and the combined articulation and firing mechanism have not been specifically disclosed herein, it is to be understood that the use of a broad variety of different actuating mechanisms and handle configurations are envisioned including toggles, rotatable and slidable knobs, pivotable levers or triggers, pistol grips, in-line handles, remotely operated systems and any combination thereof. The use of an above-described tool assembly as part of a robotic system is envisioned.
[0041] It will be understood that various modifications may be made to the embodiments disclosed herein. For example, although this application focuses primarily on the use of surgical staples, other fastening devices, such as two-part fasteners, may be included in this device. In a device in which two-part fasteners are used, each of the anvil staple forming pockets may be configured to receive one part of the two-part fastener. Further, it is envisioned that the teachings provided in this disclosure may be incorporated into surgical devices other than stapling devices including graspers. Therefore, the above description should not be construed as limiting, but merely as exemplifications of preferred embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto. | The present disclosure describes a surgical device with a body portion defining a longitudinal axis, a tool assembly including an anvil, a cartridge assembly housing a plurality of staples, a dynamic clamping member movable relative to the tool assembly to eject the staples, and an articulation and firing actuator extending at least partially through the body portion and the tool assembly. The tool assembly is pivotally attached to the body portion for movement from a position aligned with the longitudinal axis to a position oriented at an angle thereto. The articulation and firing actuator extends at least partially through the body portion and the tool assembly, is operably associated with the dynamic clamping member and the tool assembly, and is movable in relation thereto to selectively pivot the tool assembly relative to the body portion and move the dynamic clamping member relative to the tool assembly to eject the staples. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/718,494, filed Sep. 19, 2005, and having the same title and inventor(s) as above.
FIELD OF THE INVENTION
[0002] The present invention relates to a beverage holding device and, more specifically, to such a device that is compact for storage, may be used on uneven surfaces and presents ample visible surface area for promotional marking, among other beneficial features.
BACKGROUND OF THE INVENTION
[0003] Many people enjoy outdoor environments for various group or individual activities, for example, picnics, receptions, athletic events or merely relaxing in the sun. The outside environment for these activities may include lawn, lawn alternatives, beach or other landscapes that have uneven or non-uniform surfaces. While consuming beverages in these environments, it is often challenging to find a stable, sufficiently flat location to rest one's beverage container, often resulting in precarious balancing of one's beverage and having it fall over. Even if one is successful in finding a sufficiently flat surface, the locations are often random and/or less stable increasing the likelihood that a beverage may be accidentally knocked over.
[0004] The prior art includes several beverage holding devices. These include devices disclosed in three representative U.S. Pat. Nos. 2,063,328 issued to Morcom; 5,028,023 issued to Allen; and 6,533,140 to Freeman.
[0005] The device of the '328 patent is disadvantageous for many reasons including that the compact or retracted configuration has an awkward shape that does not facilitate packing en masse and is easily damaged. Furthermore, it is configured for use only on flat, uniform surfaces and does not accommodate different sized beverage containers.
[0006] The device of the '023 patent is disadvantageous for many reasons including that the large flat bottom is not well-configured to accommodating non-uniform surfaces, essentially requiring a large flat surface on which to be placed. Furthermore, it does not appear to accommodate different sized containers, may actually attach to a container requiring the bulky holding device and container to be lifted to take a drink, and it does not present good surface visibility for promotional information.
[0007] The device of the '140 patent is disadvantageous for many reasons including that it is not compactible, does not accommodate different sized containers and does not present good visibility surface area for promotional information.
[0008] A need thus exists for a beverage holding device that may be stowed and transported in a compact configuration yet expand to securely hold beverage containers, particularly on uneven and/or non-uniform surfaces. A need further exists that presents ample visible surface area for promotional marking and/or accommodates different sized beverage containers.
SUMMARY OF THE INVENTION
[0009] Accordingly, it is an object of the present invention to overcome the shortcomings of prior art.
[0010] It is also an object of the present invention to provide a beverage container holding device that is compact for storage when not in use; accommodates use on uneven, non-uniform surfaces; has ample visible surfaces for promotional marking; provides some adjustability for accommodating (securely holding) different sized containers and/or provides minimal contact points with a beverage container such that condensation from a beverage container does not cause the beverage container to stick to the holder or damage the holder.
[0011] These and related objects of the present invention are achieved by use of a beverage container holding device as described herein.
[0012] The attainment of the foregoing and related advantages and features of the invention should be more readily apparent to those skilled in the art, after review of the following more detailed description of the invention taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of a beverage holding device in accordance with the present invention.
[0014] FIG. 2 is a perspective view of the beverage holding device of FIG. 1 holding a beverage container in accordance with the present invention.
[0015] FIGS. 3-6 is a series of drawings that illustrate fabrication of the device of FIG. 1 in accordance with the present invention.
[0016] FIGS. 7-8 illustrates an alternative embodiment of the present invention utilizing three support members.
[0017] FIGS. 9-11 are a perspective, a side and a top view of another embodiment of a beverage container holding device in accordance with the present invention.
[0018] FIG. 12 illustrates a side end view of an alternative support member for use with a beverage container holding device in accordance with the present invention.
[0019] FIGS. 13-19 are a series of diagrams illustrating construction of a beverage holding device from a single piece of material in accordance with the present invention.
DETAILED DESCRIPTION
[0020] Referring to FIG. 1 , a perspective view of a beverage holding device 10 in accordance with the present invention is shown. Device 10 may include four support members 15 - 18 that are movably mounted to one another. While the support members may be provided as individually coupled members in one embodiment, they are provided in the embodiment of FIG. 1 as pairs coupled by fastening member 52 . For example, and as discussed in more detail below, cut piece 11 may be folded to provide support members 15 and 16 while cut piece 12 may be folded to provide support members 17 and 18 . Piece 11 has folds at 6 and 7 , while piece 12 has folds at 8 and 9 . Support members 15 - 18 are preferably movable along their respective folds and about fastening mechanism 52 .
[0021] A side wall structure 21 , 22 is preferably provided between each pair of support members 15 - 16 and 17 - 18 respectively. Each side wall preferably includes two sections 25 , 26 and 27 , 28 that are movable about their respective folds 8 , 9 .
[0022] Each support member 15 - 18 is preferably configured 2% to support surfaces, a bottom support 31 - 34 and a lateral support 35 - 38 . These surfaces 31 - 38 in addition to side wall sections 25 - 28 may contact a beverage container in use.
[0023] Since the support members are movable with respect to each other, different sized beverage containers may be supported by device 10 . For example, bringing support members 15 and 17 and support members- 16 and 18 toward each other, side walls 21 - 22 (and lateral supports 35 - 38 ) are brought closer together, enabling device 10 to securely hold a narrower beverage container. By moving support members 15 - 18 to their furthest away positions, the largest sized beverage container can be accommodated.
[0024] Support members 15 - 18 may be configured along their bottom edge with one or more portions removed. For example, in the embodiment of FIG. 1 arch portions 13 are removed from the bottom of each support member. The removal of these portions defines outer legs 14 and inner legs 19 in each support member. The provision of legs, whether added as supplemental members or defined by cutaway portions or other means, provides increased stability and ease-of-use on uneven or non-uniform surfaces such as lawns and the like. It should be recognized that other leg structures could be provided without departing from the present invention. Furthermore, while leg structures are shown in device 10 of FIG. 1 , the bottom edge of support members 15 - 18 could be flat or legless; such an embodiment is well suited for use in sand and like substrates.
[0025] Referring to FIG. 2 , a perspective view of beverage holding device 10 holding a beverage container 60 in accordance with the present invention is shown. FIG. 2 illustrates that a beverage container may be positioned in device 10 on the bottom support surfaces (only 31 and 33 are visible) and laterally by any combination of lateral support surfaces 35 - 38 and side wall sections 25 - 28 . Note that a beverage container may rest wholly on bottom supports 31 - 34 without contacting the lateral support structure, though the latter is quite useful in guarding against accidental knock-over and use on uneven and/or sloped surfaces.
[0026] Referring to FIGS. 3-6 , a series of drawings is presented that illustrate fabrication of device 10 in accordance with the present invention. FIG. 3 is a side elevation view of piece 11 or 12 that is preferably cut from a sheet of suitable material. Characteristics of suitable material include being lightweight, foldable and durable. In one preferred embodiment, the material is cardboard, which may be coated or laminated to avoid condensation absorption and provide promotional information, etc. There is also an inherent property in some cardboards to expand from a fold which may be used in the present invention to achieve a beverage holder that “spring” from a compressed position towards the position shown in FIG. 1 .
[0027] Other materials include, but are not limited to, some plastics or rubberized plastics, etc., and more substantial hinged embodiments may also be configured, the hinges permitting use of materials that do not permit resilient folding.
[0028] The perimeter of piece 11 , 12 is preferably cut as shown and a additional cut 5 to separate the side wall 21 , 22 from the bottom support surfaces 31 , 34 is made. The piece is then folded as shown in FIG. 4 at folds 6 , 8 and 7 , 9 . The two cut and folded pieces 11 - 12 are then positioned as shown in FIG. 5 and joined with fastening mechanism 52 to produce the device 10 as shown in FIG. 1 . When joined and pressed flat (in the opposite sense of FIG. 3 ) device 10 will appear as shown in FIG. 6 . When made of a suitable cardboard or the like, the inherent “spring” or resilience in the material causes the device stored in the position shown in FIG. 6 to spring open to a position as shown in FIG. 1 .
[0029] Device 10 may be stored in the position shown in FIG. 6 or that shown in FIG. 3 . It should also be recognized that device 10 is ready for use from its compact position and does not require any tearing along perforations or assembly as evident in prior art beverage holding devices.
[0030] FIGS. 7-8 illustrates an alternative embodiment of the present invention utilizing three support members 115 , 117 , 118 . This device 110 may be fabricated using a single piece 112 , similar to piece 12 of FIGS. 1-5 , and attaching it via fastener 152 to a “half-piece” or a single support member 115 , similar to support member 15 of FIGS. 1-5 . This effectively achieves a tripod beverage holding device preferably with one set of side walls 127 , 128 . When piece 112 is folded towards compression and support section 115 is folded back onto compressed piece 112 , then the side view appears as illustrated in FIG. 8 . In this configuration, device 110 has a side view that is half the size of device 10 , though it is thicker by one support member ( 115 ).
[0031] Referring to FIGS. 9-11 , a perspective, side and top view of another embodiment of a beverage container holding device 210 in accordance with the present invention is shown. Device 210 illustrates substantially flat bottoms on support members 215 - 218 . Substantially flat bottoms may function well on sandy substrates.
[0032] FIG. 12 illustrates a side end view of an alternative support member 315 for use with devices 10 , 110 , 210 or other. Support member 315 may have a bottom edge that is bent or otherwise shaped for form a fin or the like 319 that resists penetration into sandy surfaces, so that a beverage container holding device does not descend more than desired, perhaps obscuring the visible promotional surfaces.
[0033] Referring to FIGS. 13-19 , a series of diagrams illustrating construction of a beverage holding device 410 from a single piece of material in accordance with the present invention is shown. The single piece of material 411 may be cardboard or any other suitable substance including paper-based and non-paper-based materials. Paper-based materials are advantageous in that they are readily recyclable and/or biodegradable. The single piece of material is cut to the shape shown to form or outline sections 401 - 408 . Horizontal cuts 414 and 415 preferably extend into sections 402 - 403 and 406 - 407 , respectively. Piece 411 is preferably scored above these horizontal cuts at 412 and 413 to enhance bending and demarcate side wall sections 425 - 428 (shown below). Tab 409 extends to the right of piece 411 .
[0034] Piece 411 is folded substantially in half at point A. Sections 401 - 404 are then folded at points B,C and D, while sections 405 - 408 are folded at points E,F and G, to form the structure shown in FIG. 15 . The inner most portion of section 405 is glued to the distal end of section 401 (opposite it) and tab 409 is also glued to the distal end of section 401 . Corners 417 and 418 are pushed toward center 419 to form the intermediate structure shown in FIG. 16 , and further until the corners 417 and 418 approach or contact each other at center 419 (as shown in FIG. 17 ). Folded in this manner, sections 401 - 408 create support members 415 - 418 . Side wall sections 425 - 426 are shown pulled out in FIG. 17 , while side wall sections 427 - 428 are not and thus appear flush with the remainder of sections 402 - 403 .
[0035] FIG. 18 illustrates beverage holding device 410 with support members 415 - 418 folded out into more of an X shape and with both side wall pairs 425 - 426 and 427 - 428 folded out. The position of device 410 as shown in FIG. 18 is substantially that of device 10 of FIG. 1 as it would appear when viewed from above.
[0036] The paired sections 407 - 408 , 405 - 406 , 403 - 404 and 401 - 402 that respectively form legs 415 - 418 may be glued or otherwise fastened to each other or, as in one preferred embodiment, not be glued or otherwise fastened, except for the fastening provided at the distal end of section 401 as discussed with respect to FIG. 15 . Reduced fastening reduces the number of fabrication steps.
[0037] FIG. 19 illustrates a side elevation view of device 410 in the position shown in FIG. 17 .
[0038] While sections 401 - 408 are shown with a flat bottom is should be recognized that the bottom of the sections may be fastened to define legs such as those disclosed in device 10 of FIG. 1 , etc.
[0039] While the invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modification, and this application is intended to cover any variations, uses, or adaptations of the invention following, in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice in the art to which the invention pertains and as may be applied to the essential features hereinbefore set forth, and as fall within the scope of the invention and the limits of the appended claims. | A lightweight and compactable beverage container holding device. The beverage container holding device may be made of a single piece or multiple pieces of material and is preferably foldable or otherwise collapsible into a reduced size for shipping or storage. The device preferable supports use on non-uniform surfaces, provides ample visible surface area for promotional marking and may have minimal points of contact with a beverage container. The device may be configured to accommodate different size beverage containers. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application comprises a continuation-in-part of my copending application Ser. No. 675,026, filed Apr. 8, 1976, now abandoned, entitled INSTRUMENT PANEL ASSEMBLY.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to signaling systems which may include instrument panel assemblies having means for permitting selective testing of the operability of the indicating means and/or alarm means thereof.
2. Description of the Prior Art
In instrument panel assemblies of the prior art, a plurality of indicating lamps or the like may be mounted to a panel for indicating different conditions of associated equipment. Illustratively, in a vehicle, the instrument panel may include a plurality of indicating lamps arranged to indicate abnormal conditions, such as high oil temperature, etc.
In the commercial automobile field, such indicator lamps are considered to be somewhat unreliable relative to protecting the associated equipment in that a burnout or loose connection of the particular indicator lamp causes a failure of indication to the driver of a malfunction of the apparatus of the vehicle. Illustratively, where the indicator lamp provided to signal a low oil level condition burns out, the driver of the vehicle may not be properly apprised of such condition, causing serious and costly damage to the engine.
In U.S. Pat. No. 3,745,547 of Walter Robert Hadank, a lamp supervisory circuit is shown having a test switch which is connected through a plurality of indicating lamps. The control includes a supervisory circuit which is connected through a plurality of diodes to a corresponding plurality of indicating lamps. The control includes a supervisory circuit which operates to indicate a component failure in one of the branch circuits of the lamp supervisory circuit. An alarm is provided for indicating when one of the lamps fails so as to avoid a failure of the indicating system to provide the desired indicating function.
Irving F. Weiss discloses, in U.S. Pat. No. 3,040,243, a test circuit for an indicator system having means for activating all the indicators of a control panel simultaneously to ascertain their operating condition.
Allan Bennett, in U.S. Pat. No. 3,631,393, shows a vehicle lamp failure warning system having a first lamp circuit for illuminating the lamp and a second lamp circuit which is completed when the lamp is extinguished but has a resistance sufficiently high to insure that the lamp is not illuminated.
Tobias Wagner discloses a motor vehicle control light system in U.S. Pat. No. 3,320,586 including a signaling device mounted at the rear of the vehicle where it may be seen by other drivers so as to advise as to the intentions of the driver of the vehicle.
In U.S. Pat. No. 3,975,708, Joe F. Lusk et al show a vehicle condition monitoring system providing status information regarding the operability of headlights or taillights and the condition of the following trailer. The system may also be used to check the tire pressure and brake drum temperature. A memory circuit is provided for storing a fault condition and a diagnostic unit may be used subsequently to detect the condition of the memory circuit.
SUMMARY OF THE INVENTION
The present invention comprehends the provision in an instrument panel assembly of an improved means for facilitated testing of the indicator means of the instrument panel.
More specifically, the invention comprehends the provision of a test switch and suitable control means associated with the different indicating means and the test switch to permit a concurrent test indication of the operability of the individual indicating means.
More specifically, the invention comprehends providing such a test circuit utilizing a plurality of electrical devices permitting only a unidirectional flow of current so as to avoid false concurrent energization of the individual indicating devices as a result of the connection of any one of the indicating devices by the normal control means to indicate a single malfunction.
In the illustrated embodiment, the indicating means comprises a plurality of indicator lamps and the current controlling means comprises a corresponding plurality of diodes connected one each to the respective lamps and to a control switch. The circuit is arranged so that upon closing of the control switch, each of the operable indicator lamps will be illuminated, thereby immediately identifying to the user any inoperable lamp to permit its replacement and thereby avoid a failure of indicating of a malfunction of the apparatus being supervised by the instrument panel.
The invention further comprehends the provision of a signaling system for use in a vehicle or the like including one or more alarms for providing information as to malfunctioning of corresponding components of the vehicle. The alarms may be associated one each with different ones of the instrument panel indicator lamps so as to be operated in parallel therewith whereby the system provides not only an indication of malfunctioning of the vehicle component by way of the instrument panel indicator lamp, but, at least in certain instances, by separate alarm.
More specifically, the signaling system may be arranged to provide a plurality of different alarms as an indication of a malfunctioning of one or more of the components of the vehicle, to provide a single alarm as an indication of a malfunctioning of one or more of different components of the vehicle, and to provide only an indicator lamp indication on the instrument panel as an indication of malfunctioning of one or more further different components of the vehicle.
More specifically, the invention comprehends the provision of such a signaling system in a vehicle having an oil system for lubricating the engine of the vehicle, a hydraulic system for operating hydraulically operable means of the vehicle, and means for generating electricity in the vehicle operation. The signaling system may include first, second and third indicating lamps connected in parallel, a first control switch in series with the first indicating lamp, a second control switch in series with the second indicating lamp, and a third control switch in series with the third indicating lamp, a first alarm, and a second alarm, at least one of the control switches being associated with at least one of the engine oil system, hydraulic system, and generating means to be closed as an incident of a malfunction thereof, circuit means for connecting the first and second alarms in parallel with the first indicating lamp for concurrent operation thereof upon closing of the first control switch, and concurrently connecting the first alarm in parallel with the second indicating lamp for concurrent operation of only the first alarm and second indicating lamp upon closing of the second control switch, the third control switch controlling the operation of the third indicating lamp independently of operation of the alarms.
At least one of the alarms may comprise an intermittent alarm, such as a flashing light and/or an intermittent audio signal.
The system is arranged so that the test switch may test not only the operability of the indicator lamps, but concurrently the operability of the associated alarms.
In the illustrated embodiment, diodes are connected in the circuit means for preventing cross flow between the different alarms and indicator lamps. Further, in the circuit means, diodes may be connected to prevent cross flow between the different indicator lamps and alarms upon closing of the test switch.
Thus, the instrument panel assembly and signaling system of the present invention are extremely simple and economical of construction while yet providing the highly desirable features discussed above.
BRIEF DESCRIPTION OF THE DRAWING
Other features and advantages of the invention will be apparent from the following description taken in connection with the accompanying drawing wherein:
FIG. 1 is a side elevation of a vehicle in which an instrument panel assembly of the present invention may be installed;
FIG. 2 is a front elevation of the instrument panel;
FIG. 3 is a vertical section taken substantially along the line 3--3 of FIG. 2;
FIG. 4 is a schematic wiring diagram illustrating the improved lamp testing circuit of the instrument panel assembly;
FIG. 5 is a fragmentary schematic wiring diagram illustrating the use of a battery as the power source; and
FIG. 6 is a schematic wiring diagram illustrating a signaling system embodying the invention further including a plurality of alarms associated with different ones of the indicator lamps.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the exemplary embodiment of the invention as disclosed in FIGS. 1-5 of the drawing, a instrument panel generally designated 10 is adapted for use in a vehicle, such as a loader, generally designated 11, and more specifically may be arranged to be mounted in the cab 12 thereof adjacent the steering wheel 13 for monitoring of the vehicle components by the driver when the vehicle is in use. Such instrument panels conventionally include a plurality of indicators 14 having a corresponding plurality of indicator lamps 15 which are selectively illuminated such as for indicating malfunctioning or other conditions of the vehicle components.
The instrument panels may include other instrumentation, such as instrumentation 16 shown in FIG. 2. The present invention, however, is directed to an improved means for testing the lamps 15 of the indicators 14 to effectively avoid a failure of indication as by a burnout or malfunction of the indicator lamps.
Referring now to FIGS. 3 and 4, instrument panel 10 comprises an assembly having a front panel portion 17 through which indicator lamps 15 may be selectively viewed. The indicator lamps are connected in a circuit generally designated 18 and are arranged to be energized therein from a power source, which illustratively may include a transformer 19 which may have a low voltage secondary 20 connected at one end to ground 21. The other end of transformer secondary 20 may be connected to each of the indicator lamps 15 so as to provide a parallel connection therebetween. Each of the indicator lamps, in turn, may be controlled by a suitable normally open switch 22 connected between the respective lamps 15 and ground 21.
As indicated briefly above, the present invention comprehends an improved test circuit generally designated 23 for testing the lamps 15 when desired by the user.
More specifically, test circuit 23 includes a normally open switch 24 having its moving contact 24a connected to ground 21 and its fixed contact 24b connected to a parallel arrangement of a plurality of diodes 25 connected one each to between the respective indicator lamps 15 and control switches 22. In illustrating the invention, two such lamps and associated control diodes are shown, it being understood that the invention comprehends the provision of any number of such lamp and diode combinations in parallel.
More specifically, each lamp 15 is connected to its associated control switch by a connection 26. Diodes 25 are connected one each to the respective connections 26 so as to be connected in series one each with the respective lamps. The diodes, in turn, are connected to a common connection 27 to which fixed contact 24b of switch 24 is connected.
As shown in FIG. 5, the power supply to control circuit 18 may comprise a direct current power supply, such as a conventional battery, 28 connected between ground 21 and the common connection 29 to each of the indicator lamps 15.
As shown in FIG. 3, diodes 25 may be mounted on a panel 30 carried on the rear of instrument panel 17.
When it is desired to test the operability of the indicator lamps 15, the user need merely close control switch 24, which, as shown in FIG. 2, may be provided with a manual actuator 31, disposed for facilitated selective manipulation by the user such as at a lower portion 32 of the instrument panel 10. Closing of switch 24 completes a circuit through each of the operable lamps 15 and diodes 25, through the switch to ground 21. Thus, each operable lamp 15 is concurrently energized so as to provide an immediate indication to the user of the operability of the lamps. Any lamp which is not so illuminated upon the closing of switch 24 may be readily replaced by the removal of thelens 33 of the indicator 14 with which the defective lamp is associated, from forwardly of the instrument panel 10. In the event the replacement of the bulb does not effect illumination thereof upon retesting of the circuit by reclosing switch 24, the user is apprised of a malfunctioning of that particular portion of the control circuit 18 so that suitable servicing can be effected to remedy the defect.
Diodes 25 prevent spurious parallel operation of the lamps as by the closing of any one single control switch 22 as a result of the parallel connection of each of the lamps to the single test 24. Thus, each of the diode as 25 broadly comprehends a unidirectional current element which prevents backfeed from one lamp 15 circuit to another lamp 15 circuit while yet permitting facilitated rapid testing of the individual lamps by one single pole, normally open switch.
Thus, the instrument panel assembly test means of the present invention is extremely simple and economical of construction while yet providing an improved rapid testing of the indicating lamps of the instrument panel, thereby avoiding the serious problem of failure of the individual lamps to properly indicate a malfunction of the vehicle component because of a burnout or other inoperable condition of the particular lamp circuit portion.
Referring now more specifically to the embodiment of FIG. 6, a modified form of signaling system, or circuit, generally designated 40 is shown to include a plurality of indicator lamps 41, 42, 43, 44, 45 and 46, which may be provided as a portion of a modified instrument panel assembly. As shown in FIG. 6, each of the lamps is connected to one side of the power supply of the vehicle 11 and, more specifically, may be connected to a power supply lead 47 which, in turn, may be connected to the alternator-generator 48 of the vehicle through a current limiting device 49, which illustratively may comprise a lamp so as to function in the manner of a fuse in protecting the circuit 40.
As will be obvious to those skilled in the art, the indicator lamps may be utilized for providing indicating signals relative to any one of a plurality of different functions of the vehicle. To illustrate such utilization of the indicator lamps, indicator lamp 41 is shown to be connected through a first control switch 50 to the grounded side of the generator 48, with switch 50 being controlled, for example, by a control device 51 responsive to the temperature of the transmission oil of the vehicle so as to close the switch when the transmission oil temperature rises to a preselected level.
Further illustratively, indicator lamp 42 may be connected through a switch 52 to ground and may be controlled illustratively by a control device 53 responsive to the engine oil pressure in the vehicle so as to close switch 52 when the engine oil pressure drops below a preselected level.
Indicator lamp 43 may be connected through a switch 54 to ground with switch 52 being illustratively controlled by a control device 55 responsive to the temperature of the cooling means of the engine so as to close switch 54 and operate indicator lamp 43 when the cooling temperature rises above a preselected level.
Indicator lamp 44 may be connected through a switch 56 to ground, switch 56 illustratively being controlled by a control device 57 responsive to the temperature of hydraulic fluid utilized in the operation of the vehicle.
Indicator lamp 45 may be connected through a switch 58 to ground, switch 58 illustratively being controlled by a control device 59 responsive to the voltage output of the alternator 48 so as to close switch 58 and operate indicator lamp 45 when the power supply voltage is below a preselected level.
Indicator lamp 46 may be connected through a switch 60 to ground, switch 60 being controlled by a control device 61 responsive to the setting of the parking brake of the vehicle so as to close switch 60 and energize indicator lamp 46 when the parking brake is set.
The invention comprehends the provision of a plurality of additional alarms for use in parallel with different ones of the indicator lamps discussed above. Thus, as shown in FIG. 6, a flasher 62, which may be of conventional construction, is connected to a parallel connection of a buzzer 63 and a warning lamp 64 from power supply lead 47. Buzzer 63 is connected through a first diode 65 to switch 50 and through a second diode 66 to switch 54 so that when either of switches 50 or 54 is closed not only is the corresponding indicator lamp 41 or 43 energized, but also buzzer 63 is concurrently intermittently energized through its connection to power supply lead 47 through flasher 62.
As further shown in FIG. 6, warning lamp 64 is connected in series with the parallel connection of diodes 65 and 66 through a third diode 67 so that warning lamp 64 is concurrently intermittently energized with the intermittent energization of buzzer 63 by the closing of either switch 50 or 54 as discussed above.
As further shown in FIG. 6, lamp 64 is connected through a fourth diode 68 to switch 56 and through a fifth diode 69 to switch 52. Thus, when either of switches 56 or 52 is closed, not only is the indicator lamp 44 or 42 associated therewith energized, but also the warning lamp 64 is intermittently energized to provide a further improved indication of the specific malfunctioning sensed by the associated control device.
It may be noted that switches 58 and 60 are not connected to either of the buzzer 63 or warning lamp 64 so that closing thereof effects only the energization of the associated indicator lamp 45 or 46. Thus, it may be seen that the invention comprehends the provision of a plurality of different indicator arrangements in the circuit 40 so that a concurrent energization of an associated intermittently operated buzzer and warning lamp is effected upon energization of one or more of the indicator lamps, concurrent intermittent energization of the warning lamp only is effected upon energization of one or more different ones of the indicator lamps, and one or more of the indicator lamps may be energized without any concurrent additional warning signal being provided.
As discussed above relative to circuit 18, the invention further comprehends the provision of a plurality of diodes connected between the switches and their respective associated indicator lamps and in series with a test switch generally designated 70 to ground. More specifically, as shown in FIG. 6, the connection between lamp 41 and switch 50 is connected through a first test diode 71 to switch 70, the connection between switch 52 and lamp 42 is connected through a second test diode 72 to switch 70, the connection between switch 54 and lamp 43 is connected through a third test diode 73 to switch 70, the connection between switch 56 and lamp 44 is connected through a fourth test diode 74 to switch 70, the connection between switch 58 and lamp 45 is connected through a fifth test diode to switch 70, and the connection between switch 60 and lamp 46 is connected through a sixth test diode 76 to switch 70.
Thus, closing of switch 70 effectively connects each of the indicator lamps from power supply lead 47 directly to ground through the test diodes so as to cause energization of all operative indicator lamps. At the same time, the closing of switch 70 causes energization of the intermittently operated buzzer 63 and warning lamp 64 through connections thereof to test diodes 71, 72, 73 and 74, respectively, thereby concurrently providing an indication of the operability of the buzzer and warning lamp as well as the individual indicator lamps. Similarly, a malfunction of the flasher 62 may be indicated by a concurrent nonenergization of the buzzer and warning lamp upon closing of the test switch 70.
The test diodes effectively preclude cross flow of current between the differrent indicator lamps, buzzer and warning lamp in the same manner as such cross current flow is prevented in the circuit of the first above described embodiment.
Each of the diodes of circuit 40 may be mounted on a single panel, such as panel 30 of FIG. 3, which, in turn, may define a plug-in assembly for facilitated servicing and replacement of the control.
The indicating means of the present invention provides a facilitated indication of the operating condition of the key elements of the vehicle so as to provide improved low cost and low maintenance operation thereof. Thus, in the illustrated embodiment of the vehicle, the control devices provide monitoring of different conditions of the vehicle elements, such as the pressure of the oil in the oil system generally designated 77 of the vehicle engine 78, condition of the hydraulic oil in the hydraulic system 79 for operating the hydraulic devices, such as piston devices 80 of the loader bucket 81, etc.
The facilitated testing of the indicating means further effectively assures proper indication of the malfunctioning of the vehicle components intended to be indicated by the different indicator lamps. The use of the buzzer and lamp in parallel with different ones of the indicator lamps further provides a warning relative to malfunctioning of certain ones of the indicator lamps as the circuit effects an operation of the additional buzzer and warning lamp means notwithstanding burnout of the associated indicator lamps. Thus, operation of either or both of the buzzer and warning lamp without concurrent operation of a indicator lamp serves as an additional means for warning the vehicle operator of the burnout of an indicator lamp and thereby indicating the need for testing the indicating circuit means as discussed above.
The foregoing disclosure of specific embodiments is illustrative of the broad inventive concepts comprehended by the invention. | An instrument panel assembly having a plurality of indicating elements and a test switch for concurrently indicating the operability of the individual indicating elements. A plurality of electrical devices is connected in association with the test switch and indicating elements so as to prevent false concurrent operation of the indicating elements. The assembly may include circuitry for causing an intermittent alarm as an additional test indication during the testing of one or more of the indicating elements. | 7 |
FIELD OF THE INVENTION
[0001] The present invention pertains to a wear assembly for securing a wear member to an excavating bucket or the like.
BACKGROUND OF THE INVENTION
[0002] Wear members in the form of adapters, shrouds, and the like are ordinarily secured to the front edge of an excavating bucket. Such wear members are commonly subjected to harsh conditions and heavy loading. Accordingly, the wear members wear out over a period of time and need to be replaced. The wear members are made to withstand the rigors of a digging operation and still be capable of replacement when worn. Whisler-style locking arrangements have long been in use for mechanically attaching wear members to the lip of a bucket. Such locks generally consist of a wedge and a C-shaped clamp or spool. While the wedge is typically hammered into the assembly, U.S. Pat. Nos. 4,433,496 and 5,964,547 disclose arrangements wherein the wedge is drawn into place under pressure from a screw. U.S. Patent Application Publication No. 2004/0216336 discloses a lock where the wedge is a conical threaded member that is turned to drive the wedge into and out of the assembly.
[0003] FIG. 19 discloses one example of a conventional Whisler shroud 21 attached to a lip 16 . As seen in the drawing, the lip includes a digging edge 25 , an inner surface 27 and an outer surface 29 . A hole 31 , which is elongated axially, extends through the lip at a location rearward of the digging edge. Hole 31 has a generally straight front wall 33 and a rear wall 35 that includes a step 37 . The step includes a tapered surface 39 that tapers away from inner surface 27 as it extends rearward away from digging edge 25 .
[0004] Shroud 21 wraps around the front end 25 of lip 16 with an inner leg 41 extending along inner surface 27 and an outer leg 43 extending along outer surface 29 . Inner leg 41 includes an through-hole 47 which generally aligns with hole 31 when the shroud 21 is put on the lip. The hole 31 and opening 47 collectively define a passage 49 into which is received a lock 51 adapted to releasably hold the shroud 21 to the lip 16 . Through-hole 47 includes a step 53 adjacent wear surface 55 of inner leg 41 . As with step 37 in hole 31 , step 53 includes a tapered surface 57 that tapers away from inner surface 27 as it extends rearward away from the digging edge 25 . In this way, tapered surfaces 39 , 57 diverge rearwardly at generally equal inclinations relative to a central axis of the lip 16 .
[0005] Lock 51 includes a wedge 61 and a clamp or spool 63 . Spool 63 has a C-shaped configuration with a generally vertical body 65 and two axially extending arms 67 , 69 . Upper arm 67 is adapted to fit within step 53 , while lower arm 69 is adapted to fit within step 37 . Each arm 67 , 69 is formed with an inclined inner wall 71 , 73 that conforms and sets against a respective tapered surface 39 , 57 . The front surface of body 65 defines a ramp surface 75 that is inclined forward (relative to vertical) as it extends downward in passage 49 . Wedge 61 has front and rear converging walls 81 , 83 . Converging wall 83 abuts ramp surface 75 during installation and use in order to produce a tight fit of lock 51 in passage 49 . As shown in FIG. 19 , converging wall 83 and ramp surface 75 are formed with interlocking ridges 85 to ensure a stable and sure contact between the surfaces.
[0006] For installation, shroud 21 is first fit on lip 16 so that through-hole 47 generally aligns with hole 31 . Spool 63 is then placed within the defined passage 49 with arms 67 , 69 inserted into steps 37 , 53 . On account of the incline of tapered wall 57 and inner wall 71 , the spool tends to slide forward and downward through passage 49 if not held in place. As a result, the spool at times can slip through the lip and fall to the ground requiring the worker to retrieve it from under the bucket. This can be a difficult process particularly if installation is being done at night. In addition, crawling under the bucket can place the worker in a potentially hazardous position.
[0007] The spool 63 must therefore be held in place while the wedge 61 is inserted into the assembly. In order to withstand the rigors of the digging operation, the wedge must be fit very tightly into passage 49 . A large hammer is required to install the wedge into the assembly, which places the worker in a potentially hazardous position for injury from pieces that may fly off during hammering.
[0008] As wedge 61 is forced into passage 49 , arms 67 , 69 are pushed rearward over tapered walls 39 , 57 . This causes shroud 21 to be pulled tight against digging edge 25 and inner leg 41 to be pinched against lip 16 . This tight fit is intended to resist heavy and diverse loading that may be applied to the wear member. The large forces applied to the spool arms can result in spreading of the arms. Such spreading reduces the grip of the lock on the wear member and can at times lead to failure of the lock.
SUMMARY OF THE INVENTION
[0009] The present invention pertains to an improved wear assembly for securing wear members to excavating equipment or the like.
[0010] The present invention regards a lock assembly for securing a wear member to a base. For example, the inventive lock is useful in securing a shroud or other wear member to a lip of an excavating bucket to avoid problems experienced in the prior art.
[0011] In one aspect of the invention, an improved spool is used with a wedge to hold the wear member in place. The spool is formed with at least one laterally extending arm at its upper end in lieu of an axial arm such as used in a conventional C-shaped spool. In this way, the spool can be easily supported in the assembly as the wedge is installed. The spool does not fall through the opening and no special care is needed to prevent it from falling. As a result, installation of the wear assembly is easier and less hazardous. In addition, the lateral support reduces the risk that the spool will suffer spreading.
[0012] In a preferred construction, an upper lateral arm extends outward from each side of a spool body to generally define a T-shaped configuration. The spool with upper lateral arms can be used with a variety of lower arms, such as an axial arm, lower lateral arms or other supports adapted to engage a lower leg or lower portion of the lip. In any of the combinations, the inner walls of the upper and lower arms are preferably inclined outward in a rearward direction to apply the rearward pinching force generally provided in Whisler-style locks.
[0013] Similarly, in another aspect of the invention, the wear member is formed with an opening having at least one spool support for receiving and holding a spool with a lateral arm. Preferably, the wear member is formed with a side recess as the spool support to each side of the lock-receiving opening. As noted above, this new construction enables the wear member to be assembled on the lip or other equipment more easily and with less risk to the user.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is an axial cross-sectional view of a wear assembly in accordance with the present invention secured to a lip of a bucket.
[0015] FIG. 2 is an enlarged, partial cross-sectional view of the wear assembly.
[0016] FIG. 3 is a partial top view of the wear assembly.
[0017] FIG. 4 is a perspective view of the wear assembly with an axial cross-section.
[0018] FIG. 5 is a side view of a spool in accordance with the present invention.
[0019] FIG. 6 is a front perspective view of the spool.
[0020] FIG. 7 is a rear perspective view of the spool.
[0021] FIG. 8 is a perspective view of a wedge in accordance with the present invention.
[0022] FIG. 9 is a perspective view of a lock assembly in accordance with the present invention.
[0023] FIG. 10 is a perspective view of a wear member in accordance with the present invention.
[0024] FIG. 11 is an enlarged, partial perspective view of the through-hole in the wear member.
[0025] FIG. 12 is an upper perspective view of an alternative wear assembly of the present invention without the wedge.
[0026] FIG. 13 is a bottom perspective view of the alternative wear assembly without the wedge.
[0027] FIG. 14 is an exploded perspective view of the alternative wear assembly without the wedge.
[0028] FIG. 15 is a perspective view of the alternative wear assembly with the spool partially installed into the wear assembly.
[0029] FIG. 16 is a perspective view of the alternative wear member.
[0030] FIG. 17 is a bottom perspective view of a portion of a lip adapted to be used with the alternative wear assembly.
[0031] FIG. 18 is an axial cross-sectional view of a second alternative wear assembly in accordance with the present invention.
[0032] FIG. 19 is an axial cross-sectional view of a wear assembly of the prior art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] The present invention pertains to a wear assembly 100 in which a wear member 102 is releasably attached to excavating equipment 103 ( FIGS. 1-4 ). In this application, wear member 102 is described in terms of a shroud that is attached to a lip of an excavating bucket. However, wear member 102 could be in the form of other kinds of products (e.g., adapters, wings, etc.) attached to other equipment. Moreover, relative terms such as forward, rearward, up or down are used for convenience of explanation with reference to the drawings; other orientations are possible.
[0034] In one embodiment ( FIGS. 1-4 ), shroud 102 fits on a conventional lip 16 . Although the lip in FIG. 1 is slightly different than in FIG. 19 , for convenience, the same numbers are used to identify the lip and its features. The particular lip construction is not critical for the invention, and an assembly in accordance with the present invention can be used with a wide range of lips.
[0035] Lock 104 includes a wedge 106 and a spool or clamp 108 to releasably secure shroud 102 to lip 16 ( FIGS. 1-9 ). Spool 108 includes a body 110 , at least one and preferably two upper arms 112 , and a lower arm 114 . Lower arm 114 is formed in the same manner as lower arm 69 in a conventional spool; i.e., lower arm 114 extends axially rearward from body 110 . Lower arm 114 also has an inclined inner surface 116 that sets against tapered wall 39 formed in the lip. However, unlike a conventional spool, spool 108 includes at least one laterally extending upper arm 112 to engage shroud 102 . In the preferred construction, an upper lateral arm 112 extends outward from each side 118 of body 110 in a transverse direction so as to define a generally T-shaped configuration with body 110 .
[0036] In the preferred construction, wedge 106 has a rounded, conical shape with a helical thread 120 formed on its exterior surface 122 , preferably in the form of a helical groove. The wedge is formed generally in accordance with the wedge disclosed in co-pending U.S. Patent Application Publication No. 2004/0216336 and U.S. patent application Ser. No. 10/824,490, which are both incorporated herein by reference. Spool 108 includes a front ramp surface 126 , inclined to vertical, to abut exterior surface 122 of wedge 106 . Ramp surface 126 preferably includes a trough 128 with a concave surface that generally conforms to the curve of wedge 106 , but other concave configurations could be used to provide the desired support to the wedge. Other shaped ramp surfaces may also be used so long as the abutment of the wedge and spool is sufficient and stable in the assembly during use. The trough may extend substantially along the entire length of body 110 or only part way. In either case, a thread formation 130 is provided on ramp surface 126 , and in this embodiment, within trough 128 , to mate with thread 120 of wedge 106 . Thread formation 130 may extend the entire length of trough 128 as shown or along only a part of the length.
[0037] Wear member 102 is formed with a front working end 134 , an inner leg 136 and an outer leg 138 ( FIGS. 1-4 and 10 - 11 ). As with known shrouds, inner leg 136 is preferably longer than outer leg 138 , but other arrangements could be used (see, e.g., FIG. 18 where the legs are the same length). Inner leg 136 includes a through-hole 140 that generally aligns with hole 31 in lip 16 to collectively define a passage 141 . However, unlike conventional shrouds 21 , through-hole 140 includes at least one and preferably two spool supports 142 extending along sides 144 ( FIGS. 10 and 11 ). In a preferred construction, spool supports 142 are recesses or steps that extend partially through inner leg 136 within through-hole 140 . In the preferred construction, each spool support or recess 142 includes a bearing surface 146 and a stop 148 in a generally V-shaped configuration, though other shapes could be used. Bearing surface 146 is preferably inclined away from lip 16 as it extends rearward away from digging edge 25 but other configurations could be used. The inclination of bearing surface 146 relative to the lip is preferably the same as tapered or inclined wall 39 in lip 16 , albeit in the opposite direction. Stop 148 is preferably inclined away from the lip in the forward direction. As one example, bearing surface 146 sets about 18 degrees relative to lip 16 , and about 90 degrees relative to stop 148 ; although a wide variation of each angle could be used.
[0038] Each lateral arm 112 of spool 108 is received into a corresponding spool support or recess 142 of shroud 102 ( FIGS. 1-4 ). In the preferred construction, each upper arm 112 includes a bearing surface 152 and a stop 154 to complement and engage bearing surface 146 and stop 148 of the recess 142 into which it is received ( FIGS. 3 , 4 , 10 and 11 ). Bearing surface 152 is inclined to generally conform to the inclination of bearing surface 146 in shroud 102 , and stop 154 to generally conform to the inclination of stop 148 , although other shapes are possible. When spool 108 is installed into passage 141 , bearing surface 152 of spool 108 sets against bearing surface 146 of shroud 102 , and stop 154 against stop 148 . The engagement of surfaces 146 , 152 and 148 , 154 prevent the spool from falling through the passage 141 . The V-shaped configuration of bearing surfaces 146 , 152 and stops 148 , 154 also hold spool 108 in place as wedge 106 is inserted.
[0039] To install lock 104 , spool 108 is first placed into passage 141 such that lower arm 114 is set in step 37 and upper arms 112 are set in spool supports or recesses 142 . The recesses 142 hold the spool in its proper position for receiving the wedge without any additional holding by a worker or anything else. As a result, the spool no longer falls through the lip to the ground. Additionally, workers are not forced into hazardous conditions when installing the locks.
[0040] Following insertion of spool 108 , wedge 106 is installed into passage 141 between front wall 33 of hole 31 and ramp surface 126 of spool 108 . In the preferred construction, wedge 106 includes a tool engaging structure 156 such as a socket for a wrench. Thread formation 120 of wedge 106 is engaged with thread formation 130 of spool 108 , and the wedge rotated about its axis 158 to draw the wedge into passage 141 . As the wedge is driven into the opening, spool 108 is pushed rearward such that bearing surfaces 152 press against bearing surfaces 146 , and inner surface 116 presses against tapered wall 39 . The upper and lower arms 112 , 114 of spool 108 , then, function to push shroud 102 rearward into a tight fit with lip 16 and to pinch inner leg 136 against the inner surface 27 of lip 16 for a secure attachment of the wear member to the bucket. The positioning of the upper arms 112 closer to the vertical axis of the spool also reduces the tendency for the upper and lower arms to spread apart during use; that is, this new orientation of the upper arms reduces the couple tending to spread the arms in conventional spools such that upper and lower arms 112 , 114 of spool 108 experience less deformation in use.
[0041] Spool 108 preferably includes a cavity 160 in trough 128 ( FIG. 6 ). A retainer 162 preferably formed of a rubber, foam or other elastomer is fit within the cavity to press outward against the exterior surface 122 of wedge 106 . The retainer provides resistance to prevent loosening of the wedge as the bucket is used in digging operations. Of course, other retainers could also be used to prevent loosening.
[0042] In an alternative embodiment ( FIGS. 12-17 ), spool 108 a is formed with lower lateral arms 114 a as well as upper lateral arms 112 a. The lip 16 a is, then, formed with lower spool supports 37 a ( FIG. 17 ) rather than the conventional axial step 37 ( FIG. 19 ). Upper lateral arms 112 a can retain the same structure as arms 112 . Spool 108 a is turned ninety degrees for installation into passage 141 a ( FIGS. 14 and 15 ). Specifically, spool 108 a is initially turned so that lower lateral arms 114 a extend generally parallel to the rearward extension of inner leg 136 a of wear member 102 a, i.e., forward and rearward relative to passage 141 a. In this way, the spool can be inserted into passage 141 a until the lower arms can be set in side steps 37 a. Side steps 37 a are formed in the outer surface of lip 16 to have the same construction as side steps 142 described above for shroud 102 . Shroud 102 a is formed with asymmetrical side steps or recesses 142 a, 142 a ′ to accommodate turning of spool 108 a when placing lower arms 114 a into side steps 37 a ( FIGS. 12 , 14 and 15 ). Specifically, step 142 a preferably has a longer axial shape than step 142 a ′, and no stop, to accommodate the swinging of the front upper lateral support 112 a (during installation) into step 142 a. Step 142 a ′ has a bearing surface and stop essentially the same as steps 142 .
[0043] Other modifications can also be made to the lip, lock or wear member. As examples only, the lower leg of the wear member can be extended and provided with a recess(s) for receiving the lower arm(s) or the spool instead of the lip structure ( FIG. 18 ), such as in U.S. Patent Application Publication No. 2004/0216334, which is incorporated herein by reference. The shapes of the upper and lower spool supports along with the configuration of the bearing surfaces and stops could be altered. A hammered wedge could be used with a spool in accordance with the present invention instead of a rotating wedge. A wedge driven by a separate screw member or composed of multiple parts that apply an expansion force could also be used with a spool utilizing the novel lateral arms. Additionally, various inserts (such as between the front wall of the hole in the lip and the wedge) could be included in the through-holes to improve the locking or wear of the assembly. | In a wear assembly for securing wear members to excavating equipment, a spool is used with a wedge to hold the wear member in place. The spool is formed with at least one laterally extending arm at its upper end in lieu of an axial arm such as used in a conventional C-shaped spool. In this way, the spool can be easily supported in the assembly as the wedge is installed. The spool does not fall through the opening and no special care is needed to prevent it from falling. The spool also holds itself in place when the wedge is driven into the passage. As a result, installation of the wear assembly is easier and less hazardous. In addition, the lateral support reduces the risk that the spool will suffer spreading. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to an auditory ossicle prosthesis designed for replacing or bridging at least one element in the human auditory ossicle chain with a sound transmitting prosthesis body which at one end has a first coupling element designed as a head plate for mechanical connection of the prosthesis to the tympanic membrane and which at the other end has a second coupling element either designed for mechanical connection of the prosthesis to a second element of the human auditory ossicle chain, in particular to the stapes footplate, or for being inserted directly into the inner ear, whereby a stabiliser element is provided which is designed for fixation of the auditory ossicle prosthesis in its implanted state on a level with the plane of the tympanic membrane and for stabilising the position of the implanted auditory ossicle prosthesis in the middle ear, whereby the stabiliser element is adapted for permanent and stable securing at a section of the prosthesis body adjacent to the first coupling element and comprises a fixation part for anchoring the stabiliser element at one or more places of the ear canal wall.
Devices of this type are described in EP 0 231 162 A1, U.S. Pat. No. 4,130,905, WO 2010/150016 A1 and DE 20 2008 003887 U1.
Similar devices are, for example, described in DE 10 2007 041 539 B4 or US 2009 149 697 A1.
Ossicle prostheses are used in cases in which the ossicles of the human middle ear are missing or damaged, either entirely or partially, to conduct sound from the tympanic membrane to the inner ear. The ossicle prosthesis has two ends. Depending on the specific circumstances, one end of the ossicle prosthesis is fastened to the tympanic membrane, for instance, using a top plate, and the other end of the ossicle prosthesis is fastened, e.g., to the stapes of the human ossicular chain, or it is inserted directly into the inner ear. In many cases, with the known ossicle prostheses, sound conduction between the tympanic membrane and the inner ear is limited, because most known ossicle prostheses do not fully replace the natural anatomical formations of the ossicular chain.
After the prosthesis has been surgically implanted in the middle ear and the tympanic membrane has been closed, the recovery phase begins. Scars form during this period, and they produce unforeseeable forces, which can cause the prosthesis to move out of its initially localized position within the middle ear.
U.S. Pat. No. 4,169,292 A describes a—comparatively exotic—artificial middle ear prosthesis for replacing the complete ear structure from the bony ear canal up to the oval window of the vestibule including a tube to replace at least part of the bony ear canal, an annulus to connect an artificial ear drum to the tube, a complex structure to replace the hammer and anvil of a human patient and a piston means connected to the complex structure to replace at least part of the stirrup. This very complex type of middle ear prostheses requires, however, very extensive operational effort for being implanted, in particular the provision of an artificial ear canal. On the other hand does this type of prostheses not allow for being directly mechanically coupled to the tympanic membrane or anyone of the ossicles.
SUMMARY OF THE INVENTION
In contrast thereto, it is an object of the present invention is to improve a generic auditory ossicle prosthesis of the type described initially, using a particularly simple and compact design and the simplest technical means possible, in a cost-favorable manner by ensuring on the one hand that the auditory ossicle prosthesis stays spatially fixed within very small variations in its initial position after implantation inside the middle ear cavity, in particular providing effective protection against post-operative dislocation, tilting or tipping of the prosthesis and, on the other hand, that the sound transmission properties of the prosthesis are not deteriorated by the mechanical stabilization measures.
According to the present invention, this object is attained in a manner that is surprisingly simple and effective in that the stabiliser element is Y-shaped, whereby the fixation part comprises two hooked anchoring elements adapted for securing the fixation part in artificially drilled holes in the ear canal wall starting from a common bifurcation point at the body of the stabiliser element and branching towards their hooked free ends at an angle with respect to each other.
It is a surprising fact discovered by the inventors, that a fixation of the auditory ossicle prosthesis by using the stabiliser element in accordance with the present invention does just not considerably debase the sound transmission through the prosthesis which one would a-priori expect considering the usual implications of any mechanical fixation. Normally, the stiffening of a device induced by fixing it at one or more points will inevitably reduce its capability of freely swinging and oscillating thereby of course deteriorating the sound transmission properties of the device in its fixated state. This is, however, not true for a device according to the present invention, which is mainly due to the choice of a stabilization point on a level with the plane of the tympanic membrane. Thus, the auditory ossicle prosthesis—despite being spatially fixated by anchoring at one or more points of the ear canal wall—still retains its ability to swing freely following the acoustic amplitudes tapped from the tympanic membrane and thereby transmitting the sound to the inner ear region.
In preferred embodiments of the auditory ossicle prosthesis according to the invention, the first coupling element is designed as a clip-like, umbrella-like or U-shaped part for mechanically coupling the prosthesis to a first element of the human auditory ossicle chain, in particular to the manubrium.
The second coupling element can be designed for mechanical connection of the prosthesis to the stapes head or as a piston for being inserted directly into the inner ear.
Further, the stabiliser element can be adapted for permanent and stable securing at the first coupling element.
Preferably, the stabiliser element is completely or partly made of titanium because of its bio-compatible properties.
Alternatively or in addition, the stabiliser element may comprise at least parts made of a material with memory effect, in particular of Nitinol.
In further preferred embodiments the auditory ossicle prosthesis according to the invention is assembled from different modular components allowing for a greater ad hoc flexibility during the implantation operation which is per se known e.g. from EP 2 072 026 B1 or US 2009 164 010 A1.
Other beneficial embodiments are characterised in that the stabiliser element comprises at least one predetermined breaking point or a portion of a material thickness less than the material thickness of the prosthesis body which allows for an easy mechanical decoupling of the stabiliser element from the prosthesis at any time after the implantation. Moreover; a particularly thin design of the stabiliser element contributes to excellent swinging properties and thus to good sound transmission qualities.
In a class of embodiments of the auditory ossicle prosthesis according to the invention, the stabiliser element comprises a clipping element for securing the stabiliser element at the first coupling element or at a section of the prosthesis body adjacent to the first coupling element.
An alternative class of embodiments is characterised in that the stabiliser element comprises an elongated portion functionally replacing the natural malleus handle.
In modifications of these embodiments which are easy to manufacture, the elongated part may be shaped as a piston.
Other modifications of these embodiments are characterised in that the auditory ossicle prosthesis comprises a receiving section designed for supporting the stabiliser element in the implanted state of the auditory ossicle prosthesis.
These modifications can be further improved by a receiving section comprising a hook shaped portion provided at the first coupling element.
Embodiments of the auditory ossicle prosthesis according to the present invention are very advantageous in which the fixation part comprises more hooked anchoring elements adapted for securing the fixation part in more artificially drilled holes in the ear canal wall.
Variants of the above-described embodiments are ergonomically particularly favorable in which the hooked anchoring elements comprise reinforced free end portions.
From the preceding discussion it is clear that also a stabiliser element per se being designed for fixating an auditory ossicle prosthesis in its implanted state on a level with the plane of the tympanic membrane and for stabilising the position of the implanted auditory ossicle prosthesis in the middle ear, whereby the stabiliser element is adapted for permanent and stable securing at the first coupling element or at a section of the prosthesis body adjacent to the first coupling element and comprises a fixation part for anchoring the stabiliser element at one or more places of the ear canal wall, falls within the scope of the present invention, as long as the stabiliser element is Y-shaped, whereby the fixation part comprises two hooked anchoring elements adapted for securing the fixation part in artificially drilled holes in the ear canal wall starting from a common bifurcation point at the body of the stabiliser element and branching towards their hooked free ends at an angle with respect to each other.
Further features and advantages, of the present invention result from the detailed description of embodiments of the invention presented below with reference to the figures in the drawing which shows the details that are essential to the present invention. Further features and advantages of the present invention also result from the claims. The individual features may be realized individually, or they may be combined in any possible manner in different variants of the present invention.
Embodiments of the present invention are depicted in the schematic drawing and are described in greater detail in the description that follows. The embodiments of auditory prostheses in FIGS. 3 a through 5 b are only illustrative and not claimed per stabiliser element as invention. Also, the surgical methods referred in the description are not part of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a shows a schematic, spatial depiction of a first embodiment of the invention with a total auditory ossicle prosthesis having a first coupling element designed as a head plate for laying on the tympanic membrane, a second coupling element formed as a piston for being inserted directly into the inner ear and a stabiliser element for anchoring in the ear canal wall.
FIG. 1 b shows a view of the embodiment of FIG. 1 a from above in a direction perpendicular to the plane of the head plate.
FIG. 2 a shows a view in greater detail of the stabiliser element of FIG. 1 b with a piston-shaped elongated part.
FIG. 2 b shows a view of the stabiliser element of FIG. 2 a seen from the side.
FIG. 2 c shows a view of a stabiliser element like in FIG. 2 a , but with a predetermined breaking point.
FIG. 2 d shows a view of the stabiliser element of FIG. 2 c seen from the side.
FIG. 2 e shows a schematic, spatial depiction of a stabiliser element with clipping element for securing the stabiliser element at the first coupling element of the prosthesis or at a section of the prosthesis body adjacent to the first coupling element.
FIG. 3 a shows a view of the total auditory ossicle prosthesis of FIG. 1 a in a schematic, spatial depiction.
FIG. 3 b shows a view of the prosthesis of FIG. 3 a seen from the side.
FIG. 3 c shows a view of an embodiment of a partial auditory ossicle prosthesis with a head plate and a plunger-like second coupling element in a schematic, spatial depiction.
FIG. 3 d shows a view of the prosthesis of FIG. 3 c seen from the side.
FIG. 3 e shows a view of an embodiment of a partial auditory ossicle prosthesis with a head plate and a sliced bell as a second coupling element in a schematic, spatial depiction.
FIG. 3 f shows a view of the prosthesis of FIG. 3 e seen from the side.
FIG. 4 a shows a schematic, spatial depiction of a further embodiment of the invention with a partial auditory ossicle prosthesis having a first coupling element designed as clip for gripping an end of the stabiliser element, a second coupling element formed as a sliced bell for being mounted on the stirrup and the stabiliser element according to FIG. 2 a.
FIG. 4 b shows a view of the embodiment of FIG. 4 a from above in a direction perpendicular to the plane of the head plate.
FIG. 5 a shows a view of the partial auditory ossicle prosthesis of FIG. 4 a in a schematic, spatial depiction.
FIG. 5 b shows a view of the prosthesis of FIG. 5 a seen from the side.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiments of an auditory ossicle prosthesis 10 ; 20 depicted in a schematic, spatial manner in FIGS. 1 a , 1 b , 4 a and 4 b of the drawing, are designed for replacing or bridging at least one element in the human auditory ossicle chain with a sound transmitting prosthesis body 13 ; 13 ′; 13 ″; 23 which at one end has a first coupling element 11 ; 21 designed either as a head plate for mechanical connection of the prosthesis to the tympanic membrane or as a clip-like, umbrella-like or U-shaped part for mechanically coupling the prosthesis to a first element of the human auditory ossicle chain, in particular to the manubrium, and which at the other end has a second coupling element 12 ; 12 ′; 12 ″; 22 either designed for mechanical connection of the prosthesis to a second element of the human auditory ossicle chain, in particular to the stapes head or to the stapes footplate, or designed as a piston for being inserted directly into the inner ear.
The present invention is characterised in that a stabiliser element 14 ; 14 ′; 24 is provided which is designed for fixation of the auditory ossicle prosthesis 10 ; 20 in its implanted state on a level with the plane of the tympanic membrane and for stabilising the position of the implanted auditory ossicle prosthesis 10 ; 20 in the middle ear, whereby the stabiliser element 14 ; 14 ′; 24 may comprise titanium and/or a material with memory effect, in particular of Nitinol and is adapted for permanent and stable securing at the first coupling element 11 ; 21 or at a section of the prosthesis body 13 ; 13 ′; 13 ″; 23 adjacent to the first coupling element 11 ; 21 and comprises a fixation part 14 . 2 ; 14 . 2 ′; 24 . 2 for anchoring the stabiliser element 14 ; 14 ′; 24 at one or more places of the ear canal wall.
As also shown in the embodiments of figures is through 2 e , 4 a and 4 b , the fixation part 14 . 2 ; 14 . 2 ′; 24 . 2 can comprise one or more hooked anchoring elements 16 ; 16 ′; 26 having reinforced free end portions 17 ; 17 ′; 27 adapted for securing the fixation part 14 . 2 ; 14 . 2 ′; 24 . 2 in one or more artificially drilled holes in the ear canal wall. In particular, the stabiliser element 14 ; 14 ′; 24 may be Y-shaped, whereby the fixation part 14 . 2 ; 14 . 2 ′; 24 . 2 comprises two hooked anchoring elements 16 ; 16 ′; 26 starting from a common bifurcation point 14 . 3 ; 14 . 3 ′; 24 . 3 at the body of the stabiliser element 14 ; 14 ′; 24 and branching towards their hooked free ends at an angle with respect to each other.
In the embodiments of the invention shown in figures is through 2 d , 4 a and 4 b , the stabiliser element 14 ; 14 ′ comprises an elongated part 14 . 1 ; 14 . 1 ′ shaped as a piston and functionally replacing the natural malleus handle. Accordingly, embodiments of the auditory ossicle prosthesis 10 as shown in FIGS. 1 a , 1 b and 3 a through 3 f can comprise a receiving section 15 with a hook shaped portion provided at the first coupling element 11 designed for supporting the elongated part 14 . 1 ; 14 . 1 ′ of the stabiliser element 14 ; 14 ′ in the implanted state of the auditory ossicle prosthesis 10 .
In further embodiments of the invention, like in those shown in FIGS. 4 a through 5 b , the first coupling element 21 can have a clip-like design for being fixed on the elongated part 14 . 1 of the stabiliser element 14 . In these embodiments, the stabiliser element 14 and in particular its piston-like elongated part 14 . 1 may carry a sound transmitting coupling link to the tympanic membrane, which will in most practical cases comprise a tailor-made element made from the patient's natural cartilage.
Another class of embodiments of the invention can comprise a stabiliser element 24 as depicted in FIG. 2 e having a clipping element 24 . 1 for securing the stabiliser element 24 at the first coupling element of the auditory ossicle prosthesis or at a section of the prosthesis body 13 ; 13 ′; 13 ″; 23 adjacent to the first coupling element.
FIGS. 2 c and 2 d show a variant of the stabiliser element 14 ′ according to the invention comprising at least one predetermined breaking point 18 ′. The same effect can be achieved in other embodiments—not shown in the drawings—having a portion of a material thickness less than the material thickness of the prosthesis body 13 ; 13 ′; 13 ″; 23 .
In still further embodiments of the invention not depicted in the present drawings, the auditory ossicle prosthesis according to the invention may be assembled from different modular components.
The auditory ossicle prosthesis 10 ; 20 according to the present invention is generally designed as a MRP (=Malleus Replacement Prosthesis) for a better stability.
The absence of the malleus handle can affect hearing results after ossiculoplasty. To enhance middle ear prosthesis stability, recreation of an absent malleus can be important.
In close conjunction with Robert Vincent MD from Beziers, France (Causse Ear Clinic), KURZ has developed a new concept of Tympanoplasty.
The MRP (Malleus Replacement Prosthesis) is a titanium neo-malleus which is implanted underneath the tympanic membrane at any position in the bony rim. It is attached via a Y-shaped titanium wire with two hooks. These hooks are inserted into two holes, which are drilled with a 0.6 mm burr into the external canal wall. The surgeon introduces the MRP and can connect almost any Partial- or Total-Replacement Prosthesis due to the malleable MRP.
The primary advantage of this new concept is to keep the neo-malleus in proper position during the initial healing period, reducing the risk of tilting.
Benefits:
Higher stability of ossicular chain reconstruction Pure titanium for highest biocompatibility Easy and safe procedure A truly versatile prosthesis which can be used in most cases
The MRP implantation requires drilling two holes to create space for the MRP hooks. The direction for drilling the holes is determined by the status of the EAC (=external auditory canal). When there is enough bone at the posterior superior part of the EAC the holes are drilled approximately at 09 and 11 o'clock for a right ear and 1 and 3 o'clock for a left ear to leave room for the first and second hook respectively. When there is not enough residual posterior-superior bony canal wall it is possible to drill the holes through the posterior-inferior bony canal wall. Thus, the position of the titanium neo-malleus will be exactly opposite to the position of a normal malleus handle.
MRP can be used in all cases of malleus absence (Austin-Kartush Groups C and D). There might be a persistent atticotomy and not enough residual bone at the posterior-superior part of the EAC. Therefore the MRP should be implanted in the posterior-inferior part of the EAC (6 to 8 o'clock).
Two holes are drilled through the EAC wall at 6 and 8 o'clock from side to side with a 0.6 mm diamond dust burr to create space for the hooks of the MRP. The distance between the two EAC holes is equal to the distance between the hooks of the MRP. Drilling of the holes requires highly regulated speed with constant irrigation to prevent burning or pressure necrosis of the bone. The hooks of the MRP are inserted into the holes. This configuration prevents MRP displacement and avoids contact between the neo-malleus and the canal wall.
While the MRP is held in position by the hooks the thin titanium link between the handle and the hooks enables the surgeon to easily accommodate the position of the neo-malleus to all anatomical variations. The neo-malleus is slightly moved superiorly and is placed in proper position overlying the stapes Capitulum.
It is possible to insert any type of partial or total prosthesis at the same stage (onestage procedure) which will be positioned from the stapes capitulum or footplate to the handle of the MRP. The PORP is placed onto the stapes capitulum. The groove of the prosthesis head is then placed underneath the handle of the MRP.
As with a titanium middle ear prosthesis it is advised to cover the system with a layer of cartilage.
In the following, results of scientific research work performed by Robert Vincent, Causse Ear Clinic, Colombiers (France) pertaining to MRP (=MALLEUS REPLACEMENT PROSTHESES) are presented:
Introduction
The presence or absence of a malleus handle affects results in ossiculoplasty particularly in the absence of a stapes superstructure. Numerous authors have emphasized the importance of the malleus in successful ossiculoplasty (1-4). Re-creation of the malleus has been used by several authors to enhance middle ear prosthesis stability (5-7).
During the period of January 1991 to June 2010, 1764 consecutive ossiculoplasty procedures were performed by the author (RV) in the same tertiary referral centre. Of these, 178 cases (10%) cases were performed with malleus absent and stapes present and 74 cases (4%) with malleus and stapes both absent. Of these 74 cases, 18 were operated with a bone anchored malleus prosthesis (MRP) implantation from December 2009 to July 2010.
This study aimed to determine the effectiveness of the MRP which was designed to replace a missing malleus. Any type of partial or total ossicular chain replacement prosthesis can be coupled to the MRP which will enhance the stability of PORPs and TORPs.
Material and Method:
This is a prospective study of 18 patients (18 ears) who were operated from Dec. 12, 2009 to Jun. 28, 2010 with MRP implantation. All cases were revision tympanoplasty cases for CSOM without active cholesteatoma.
One patient was also implanted with a MRP for revision otoslerosis with eroded incus and malleus. This patient is excluded from this preliminary study.
Assessment of hearing status was conducted before and 3 months after surgery. The mean age was 41 years (age range 16-66 yr). Sex Ratio was 72% female (13 cases) and 28% male 28% (5 cases).
The ossicular chain status was explored at the time of surgery and cases were assigned on 4 groups according to the status of the ossicular chain. Austin's classification of ossicular defects as modified by Kartush was used to define the ossicular status encountered (8, 9).
Austin-Kartush group D (malleus and stapes absent): 15 cases Austin-Kartush group C (malleus absent, stapes present): 1 case—Austin-Kartush group B (malleus present, stapes absent): 1 case—Austin-Kartusk group F (stapes fixed, malleus absent): 1 case
All cases were revision tympanoplasty cases and the cause of failure was identified as displaced prosthesis in all cases. None of these cases required tympanic membrane grafting during the procedure. All cases had intact, healthy middle ear mucosa with no active cholesteatoma or inflammation.
Of these 18 cases, 9 Austin-Kartush group cases (50%) were operated with a simultaneous implantation of a MRP and a TORP which was positioned from the MRP to the stapes footplate during the same operation (one-stage procedure). The remaining 9 cases (50%) were implanted with a MRP only (first-stage procedure) and will be operated for a second stage procedure 3 to 6 months later with a TORP placement from the MRP to the stapes footplate.
The main cause of failure which was identified at the time of surgery was prosthesis displacement in 15 cases and prosthesis extrusion in 3 cases.
All data were tabulated using the Otology-Neurotology Database (ONDB) (AS Multimedia Inc., Cassagne, France) (10). This is a commercially available software package developed at our centre, designed to comply with the American Academy of Otolaryngology guidelines for reporting clinical and audiometric results (11).
Surgical Technique for MRP Implantation:
All procedures were performed by the same surgeon (RV) and a transcanal approach was used in all cases. Two tunnels were drilled through the EAC (=external auditory canal wall) from side to side with a 0.6 mm diamond dust burr to leave room for the two hooks of the MRP. The distance between the 2 EAC tunnels were equal to the distance between the two hooks of the two tunnels of the MRP.
The drilling of the two tunnels required highly regulated speed with constant irrigation to prevent burning or pressure necrosis of the bone.
The choice of the position of these two tunnels were dictated by the status of the EAC. In 17 cases (94%) they were drilled approximately at 11 and 09 o'clock for a right ear and 1 and 3 o'clock for a left ear to leave room for the first and second hook respectively. Thus, the position of the titanium neo-handle of the MRP was slightly more posterior to a normal malleus handle. In one case (6%) there was not enough residual posterior-superior bony canal wall to allow for drilling out the tunnels which were then drilled at 5 and 6 o'clock. Thus, the position of the titanium neo-handle was exactly opposite but parallel to the position of a normal malleus handle.
The two hooks of the MRP were inserted in the two tunnels and the titanium handle was positioned over the stapes footplate. This configuration prevents MRP displacement and avoids contact between the neo-handle and the canal wall. Each hook of the MRP is inserted within its corresponding tunnel and the titanium handle is positioned over the stapes footplate.
While the MRP was kept in position by the 2 hooks the thin titanium link between the handle and the hooks enabled the surgeon to easily accommodate the position of the neo-handle to all anatomical conditions.
It was possible to slightly move the handle laterally, inferiorly or superiorly. The foremost advantage of this prosthesis is to keep the neo-handle in proper position overlying the stapes footplate in all cases.
In 9 cases a TORP was planed to be inserted in the same stage (one-stage procedure). The distance between the neo-malleus of the MRP and the stapes footplate was determined with an elongated stapes measuring rod. The TORP shaft was cut at the appropriate length and the TORP was positioned from the neo-handle to the stapes footplate. The distal tip of the TORP's shaft is centered to the stapes footplate and the MRP's neo-handle is easily introduced within the groove of the TORP's head.
A thin layer of tragal cartilage was interposed over the MRP in all cases covering both the two hooks and the neo-handle.
Audiometric Assessment
Audiometric evaluation included preoperative and postoperative air-bone gap (ABG), air conduction (AC) thresholds, and bone-conduction (BC) thresholds. Only AC and BC results that were obtained at the same time postoperatively were used for calculation of ABG and pure-tone averages (PTAs). We used a four-frequency PTA for AC and BC thresholds (0.5, 1, 2 and 4 kHz) obtained at 3 months follow-up for the one-stage procedure cases (9 case). The preoperative and postoperative BC and AC levels at 4 kHz were also assessed. Audiometry was reported according to American Academy of Otolaryngology-Head and Neck Surgery Guidelines (11) except for thresholds at 3 kHz which were substituted in all cases with those at 4 kHz.
Preliminary Results
Of the 18 cases in which MRP was implanted, 9 cases (50%) were operated with a simultaneous implantation of a MRP and a TORP which was positioned from the MRP to the stapes footplate during the same operation (one-stage procedure).
Preliminary postoperative hearing results were studied for these 9 one-stage procedure cases.
Of the 9 one-stage procedure cases, 5 cases (55.5%) had postoperative audiological data available at 3 months follow-up. Of these 5 cases, one patient had more than 5 previous failed surgeries, 2 patients had 4 previous failed surgeries and 2 patients had one previous failed operation. The main cause of failure which was identified at the time of surgery was prosthesis displacement in 7 cases and prosthesis extrusion in 2 cases.
Hearing result of these 5 cases are presented in Table 1. There was no case of postoperative sensorineural hearing loss in the series and no prosthesis extrusion nor tympanic membrane reaction was observed postoperatively.
TABLE 1
Postoperative hearing results at 3 months in
5 cases (Simultaneous MRP + TORP implantation)
Variable
MRP + TORP (n = 5)
ABG < 10 dB-%
100 (5 cases)
Mean BC-dB
16.3
Mean AC-dB
23
Mean ABG-dB
6.7
SNHL-dB
0
BC, Bone conduction;
AC, air conduction;
ABG, air-bone gap;
SNHL, sensorineural hearing loss
The postoperative air bone gap (ABG) (averaged over 0.5, 1, 2 and 4 kHz) was closed to 10 dB in all cases (5 cases, 100%). The postoperative mean ABG was 6.7 dB compared to 39.5 dB preoperatively. The mean postoperative bone conduction (BC) was 16.3 dB compared to 18.8 dB preoperatively. The mean postoperative air conduction (AC) was 23 dB compared to 58 dB preoperatively.
Discussion
Re-creation of the malleus has been used in the past (5-7). Without an intact malleus, Wehrs (6) suggested the use of an homologous drum and malleus, which usually requires staging for a stable reconstruction. Black (7) introduced a technique of neo-malleus ossiculoplasty by using an autograft neo-malleus strut and an assembly rather than columella in cases in which the malleus was unavailable for assembly techniques.
More recently we described an original technique of silastic banding in a consecutive series of 100 cases with missing malleus and intact stapes superstructure (Austin-Kartush group C) (12). Ossiculoplasty was performed with a TORP positioned from the stapes footplate to the under surface of the tympanic membrane, using a silastic band to stabilize the prosthesis.
Our preliminary hearing results with the MRP implantation in cases of missing malleus and stapes are encouraging and compare favourably with the results reported by other authors in case of missing malleus (Table 2).
TABLE 2
Hearing results in case of missing malleus in literature review
Austin-
Postop
Postop
Kartush
ABG < 10
mean
Series
Group
Material
n
dB (%)
ABG
Moretz (1)
C
PORP
6
0
24
C
TORP
4
0
24
Vincent (10)
C
TORP
96
66
12
Austin (13)
C
Partial
23
12
27
autograft
Black (14)
C
PORP
13
15
—
Goldenberg (15)
C
PORP
7
14
23
Current series
D
TORP
5
100
6.7
ABG, air-bone gap
Table 3 shows the postoperative comparative hearing results of the author (RV) at 3 months follow-up in case of absence of malleus (Austin-Kartush groups C and D) according to the type of prosthesis used and assembly. Our best short-term hearing results were obtained with the MRP implantation coupled to a TORP: 100% of ABG closure to within 10 dB compare to 57% in Austin-Kartush group C cases with PORP implantation from tympanic membrane (TM) to stapes head (S), 58% in Austin-Kartush group C cases with TORP implantation from TM to footplate (F) and Silastic banding technique and 35.7% in Austin-Kartush group D cases with TORP implantation from TM to F.
TABLE 3
Personal results. Postoperative comparative results at 3 months
in case of absence of malleus: Austin Kartush groups C and D.
Austin-Kartush group
Austin-Kartush group D
Prosthesis
PORP
TORP + Silastic
TORP
MRP + TORP
Banding
Assembly
TM/S
TM/F
TM/F
TM/F
Available data
7
106
28
5
ABG < 10 dB-%
57 (4 cases)
58 (61 cases)
35.7 (10 cases)
100 (5 cases)
ABG < 20 dB-%
86 (6 cases)
77 (81 cases
50 (14 cases)
100
Mean BC-dB
28.4
24.2
30.5
16.3
Mean AC-dB
41
37
53.5
23
Mean ABG-dB
12.6
12.9
23
6.7
SNHL-dB
0
0
0
0
BC, Bone conduction;
AC, air conduction;
ABG, air-bone gap;
SNHL, sensorineural hearing loss;
TM/S, tympanic membrane to stapes head assembly;
TM/F, tympanic membrane to footplate assembly.
Moreover these preliminary results tend to show better results when a prosthesis is implanted from the titanium handle of the MRP then from the normal malleus handle. This may be related to the vibratory properties of the MRP. This factor is currently under research study at the Otolaryngology Department of Hannover Medical University (Prof Med Thomas Lenarz, Dr Med Gentiana Wenzel). The results of this research study may dramatically increase the indication of use of the MRP in the future.
Because of the osseointegration of Titanium, the MRP may become fixed with time to the bony canal wall as the bone may grow on to the surface of the two hooks in the tunnels. However thanks to the vibratory properties of the MRP which may be related to its specific design the vibratory properties of the neo-handle may remain stable and efficient. This is also under current study at the Otolaryngology Department of Hannover Medical University.
CONCLUSION
The MRP was developed to improve on results of cases with absent malleus that had been previously managed with columellae or neo-malleus technique or silastic banding in case of stapes present.
With the MRP a new malleus handle is re-created which can be used with any type of PORP or TORP which can be positioned under the neo-handle in a single or two-stage procedure. This decreases the risk of displacement of PORP and TORP.
The amount of time required to place a MRP will vary depending on the experience of the practitioner, the quality and quantity of the bone of the external auditory canal and the difficulty of the individual situation but the surgical technique is simple and reliable.
The preliminary results of this current series has demonstrated successful ABG closure in 100% of case. However, considering the short period of follow-up of the present series it will be important to prospectively observe outcomes after longer period of follow-up.
BIBLIOGRAPHY
1—Moretz W. Ossiculoplasty with an intact stapes: superstructure versus footplate prosthesis placement. Laryngoscope 1998; 108:1-12
2—Dornhoffer J, Gardner E. Prognostic factors in ossiculoplasty: a statistical staging system. Otol Neurotol 2001; 22:299-304
3—Albu S, Babighian G, Trabalzini F. Prognostic factors in tympanoplasty. Am J Otol 1998; 19:136-40
4—Black R. Ossiculoplasty prognosis: The SPITE method of assessment. Am J Otol 1992; 13:544-51
5—Fisch U. Tympanoplasty, Mastoidectomy, and Stapes Surgery. New York: Thieme Medical Publishers, 1994
6—Wehrs R. The homograft tympanic membrane after 12 years. Ann Otol Rhinol Laryngol 1982; 91:533-7
7—Black B. Neomafleus ossiculoplasty. Otol Neurotol 2002; 23:636-42
8. Austin D F. Ossicular reconstruction. Otolaryngol Clin North Am 1972; 5:145-60.
9. Kartush J M. Ossicular chain reconstruction: Capitulum to malleus. Otolaryngol Clin North Am 1994; 27:689-715.
10—Vincent R, Sperling N, Oates J, Jindal M. Surgical findings and long-term hearing results in 3050 stapedotomies for primary otosclerosis: a prospective study with the Otology Neurotology Database. Otol Neurotol 2006; 27:S25-47
11. American Academy of Otolaryngology-Head Neck Surgery Foundation, Inc. Committee on Hearing and Equilibrium guidelines for the evaluation of results of treatment of conductive hearing loss. Otolaryngol Head Neck Surg 1995; 113:186-7.
12. Vincent R, Sperling N M, Oates J, Osborne J. Ossiculoplasty with intact stapes and absent malleus: the Silastic banding technique. Otol Neurotol 2005; 26:846-852.
13—Austin D. Transcanal tympanoplasty: A 15-year report. Trans Am Acad Ophtalrnol Otolaryngol 1976; 82:30-8 | An auditory ossicle prosthesis ( 10 ) with a sound transmitting prosthesis body ( 13 ) has first and second coupling elements ( 11, 12 ) provided at opposite ends. A stabilizer element ( 14 ) fixes the prosthesis on a level with the plane of the tympanic membrane and stabilizes the position of the prosthesis in the middle ear. A fixation part ( 14.2 ) anchors the Y-shaped stabilizer element at one or more places of the ear canal wall. The fixation part includes two hooked anchoring elements ( 16 ) that secure the fixation part in artificially drilled holes in the ear canal wall. The auditory ossicle prosthesis has a particularly simple and compact design and stays spatially fixed within very small variations in its initial position after implantation inside the middle ear cavity, providing effective protection against post-operative dislocation, tilting or tipping and without deteriorating sound transmission properties of the prosthesis. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a bulk loaded change dispensing apparatus, and more particularly to a large capacity machine for dispensing change in exchange for paper currency.
2. The Prior Art
Change dispensing machines for changing a single dollar bill and a five dollar bill are known, and have utility in applications where a limited amount of change is required. In other applications, however, where large amounts of change or tokens are required, such as concentrated locations of coin receiving machines, the conventional change making machines are inadequate because of their limited capacity. It is therefore desirable to provide a change dispensing machine having a much greater capacity, so that longer periods of time may be allowed between servicing the machine to replenish its change inventory, thereby conserving the efforts of service personnel. In an environment in which there is a continuous demand for large amounts of change, such as in a gambling casino, a large capacity change making machine serves the purpose of providing change needed for efficient casino operation, and replenishment of the change inventory can be scheduled at infrequent periods during times of low demand.
It is also desirable to provide dispensing apparatus which can be easily and quickly loaded in a bulk form, without the need to insert individual coin rolls or tubes into separate compartments; and which is amenable to visual inspection of the inventory for the auditing purposes or the like.
SUMMARY OF THE INVENTION
It is a principal object of the present invention to provide a large capacity change bulk loaded dispensing machine with a capacity of thousands of coins which may be dispensed in exchange for paper currency of various denominations.
Another object of the present invention is to provide the change dispensing machine with sufficient capacity so that even under conditions of continuous use, its inventory needs to be replenished only occasionally.
Another object is to provide such a machine with a dispensing magazine which does not require intervening partitions of any kind among the coin tubes.
In one embodiment of the present invention there is provided a change dispensing machine having a magazine containing a plurality of layers of coin rolls or tubes, each of the layers being made up of a plurality of rows and columns of tubes, with a stripping device for unloading each layer one row at a time to a transport mechanism, which feeds the tubes seriatim to a dispensing mechanism where they are dispensed as required. The large magazine capacity of the machine of the present invention makes it possible to store and dispense a large quantity of coins or coin-like tokens without the need for frequent replenishment of the supply of the machine.
The change dispensing machine of the present invention makes it possible to replace or supplement cashiers or other clerks whose sole function is to make change, and the change making service is not interrupted by the need for frequently replenishing the inventory of change to be dispensed.
These and other objects and advantages of the present invention will become manifest by a review of the following description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference will now be made to the accompanying drawings in which:
FIG. 1 is a perspective view of an illustrative embodiment of the present invention;
FIG. 2 is a vertical cross-sectional view of the apparatus of FIG. 1;
FIG. 3 is a front view of the magazine portion of the apparatus of FIG. 2;
FIG. 4 is a side view of a portion of the apparatus of FIG. 3, taken along the line IV--IV;
FIG. 5 is a plan view of a portion of the apparatus taken along line V--V in FIG. 2;
FIG. 6 is a side view of a portion of the apparatus of FIG. 5;
FIG. 7 is a side elevational view of part of the transport portion of the apparatus of FIG. 5;
FIG. 8 is an end view of the apparatus shown in FIG. 7, taken along line VIII--VIII;
FIG. 9 is a view similar to FIG. 8, showing the tilt tray in operated position;
FIG. 10 is a side view of the dispensing ramp of the present invention, with the dispensing escapement shown in closed position;
FIG. 11 is a top view of the apparatus of FIG. 10;
FIG. 12 is a side elevational view of a portion of the apparatus of FIG. 10, with the dispensing escapement open; and
FIGS. 13-15 are views illustrating an arrangement for securing temporary cover sheets in place about the magazine.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, a change making machine in accordance with the present invention is shown in perspective view. The change machine has an exterior case 10, with a bill receiver mechanism 12, and a coin dispensing compartment or tray 14. The currency receiving mechanism 12 has a slot which is adapted to receive an item of paper currency (a bill) and present it to a validating mechanism 16 (FIG. 2) mounted within the case 10. The validing unit 16 determines the genuineness of the currency fed into the machine, and its denomination, and controls the dispensing mechanism to dispense the appropriate number of coin tubes or rolls to the dispensing tray 14. On or more coin rolls are dispensed onto the tray 14 through a slot 18 by means described hereinafter. The number of coin rolls which are dispensed depends on the denomination of the bill inserted into the machine at the currency receiving station 12.
FIG. 2 is a side view of the case 10, showing the relative locations of the unit 16, and other components of the machine. A magazine 20 is provided for storing a multiplicity of coin tubes in a plurality of horizontal layers, each layer being made up of a plurality of rows and columns of the tubes. The rows extend across the width of the magazine, and the columns extend from front to back. The topmost layer of coin tubes is stripped from the magazine, one row at a time, by pushing the entire layer rearwardly ejecting the rearmost row onto a tilt tray 44, which tips the tubes into an upright position on a horizontal conveyor belt 50, which carries the tubes laterally to an elevator mechanism 23 powered by a drive chain 76. The tubes are then lifted by the elevator to an upper portion 24 of the machine, from which the tubes are rolled down a ramp 26 to a dispensing unit 90, which dispenses them one at a time into the receiving tray 14.
A microprocessor 22 is provided within the case 10, for controlling operation of the currency validator 16, and for operating the dispensing mechanism in response to recognition of a genuine currency bill of given denomination.
FIG. 3 illustrates a front view of the magazine 20. A support plate 30 is provided for supporting the bottom layer 32 of coin rolls, in the magazine, and a plurality of stops 34 on the upper surface of the plate 30 maintain the coin columns in alignment with each other and in equally spaced arrangement. A second layer is supported on the first layer 32, with each coin roll of the second layer being supported on two adjacent rolls of the first layer. The second layer has one fewer coin rolls than the first layer. The third layer rests on the second layer, and has the same configuration as the first layer, and subsequent layers repeat the arrangement, so that each layer is substantially horizontal. Side walls 36 confine the end tubes of each row.
FIG. 4 shows vertically aligned columns in a plurality of layers, and it can be seen that the upper surface of the plate 30 has a plurality of zones arranged in a ratchet shape, to allow the coin tubes of each column to engage each other so that the upper extremity of the front end of each coin tube is somewhat higher than the upper extremity of the rear end of the adjacent tube in the column. This facilitates stripping the coin tubes from the magazine. The extreme forward and rearmost zones are horizontal, to facilitate loading the magazine, and to facilitate endwise motion of the coin tubes onto the tilt tray 44.
The tubes are stripped by a pusher bar or stripper 40, disposes forwardly of the topmost layer 38, the bottom extremity 42 of the pusher bar 40 being aligned with the forward row of the top layer 38. The pusher bar 40 moves rearwardly, pushing the entire upper layer 38, for a distance of one row until the last row of the upper layer is ejected onto the tilt tray 44. A stop 46 adjacent the rear end of the second layer prevents the second layer from being moved rearwardly by the pusher bar 40. The tilt tray 44 is tilted rearwardly to deliver the tubes to a transport conveyor, and each time the tilt tray 44 is cleared, the pusher bar 40 moves rearwardly an additional distance corresponding to the length of a coin tube, thereby pushing a new row of coin tubes onto the tray 44. When all of the rows of a layer have been pushed onto the tilt tray 44, the pusher 40 retracts forwardly to its initial position (shown in FIG. 4), and then is lowered into operative position in relation to the next layer which has become the new top layer. The tray 44 and the transport conveyor is lowered as the pusher 40 is lowered.
As shown in FIGS. 3 and 6, a lead screw 51 is provided for moving the pusher bar on stripper 40, and the transport conveyor up and down. A pair of guides 49 are mounted in fixed position within the case 10, and they guide the vertical motion of a carriage which supports the pusher 40 and its associated mechanism, as well as the transport conveyor mechanism.
The magazine 20 is supported by base members 54, which are each supported in rolling relationship on a base plate 56 by roller assemblies 58.
The roller assemblies each have steel balls adapted to roll along individual grooves on the upper surface of the bottom plate 56, so that the entire magazine area may be pulled forward, together with a forward section 10a of the case 10, in order to allow replenishing of the magazine, or replacement of the entire magazine with a full unit.
The tilt tray 44 is mounted on a pivot stud 45 (FIG. 6) at each side of the case 10, and is adapted to be rotated from its horizontal position to a vertical position. The rotation of the tray transfers coin rolls 48 onto the upper surface of the conveyor belt 50 located at the rear of the tray 44. The conveyor belt 50 is supported by pulley 52 and 53 (FIG. 7), and forms a transport conveyor for transporting the coin rolls 48 from the area behind the tilt tray 44. The pulley 53 is driven by a motor 55 through a worm gear drive.
FIG. 5 illustrates the condition of the apparatus after the tilt tray 44 has rotated the coin rolls 48 into position on the conveyor belt 50, and after the tilt tray 44 is subsequently returned to its horizontal position.
A stop member 57 is secured to the upper surface of the conveyor belt 50, and maintains the last coin roll 50a in upright position, as the entire row is transported, sliding between the rear wall 39 and a wall 62 (FIG. 6) which is integrally formed with the tilt tray 44.
A flap 61 is hinged to the wall 39, and is interposed in the path of the coin rolls as they are transported by the conveyor belt 50. The flap 61 holds back the coin rolls in the row, but is adapted to pivot about the hinge 64 so as to allow the end most roll to pass, as the conveyor belt 50 is advanced. The flap 61 then springs back to retain the next coin roll in upright position on the conveyor belt. A spring 63 (FIG. 7) biases the flap 61 toward its closed position.
When a coin roll has passed beyond the flap 61, the bottom end of the roll is only partially supported on the conveyor belt 50, so that the coin roll rotates forwardly to a horizontal position, falling onto a ramp 66. The ramp 66 slopes downwardly toward the front of the machine (FIG. 6), and allows the coin tube to roll forward, until it is in position to be received by one of a series of carriers 68, of the elevator mechanism 23.
The forward portion of the ramp 66 slopes downwardly, and coin rolls are adapted to roll onto the platforms 72 of individual tube carriers 68 as they move upwardly past the ramp 66. Each tube carrier 68 holds but a single coin tube. The platform 72 of each carrier is secured to a back plate 74, which is attached to one of the links of the chain 76. An elongated U-shaped bracket 78 is adjustably secured to a frame member 79 by means of a screw 80, and retaining members 81 secured to the bracket 78 retain the edges of the plate 74 in position on its carrier 78 and is lifted by the chain 76.
As shown in FIGS. 2 and 6, the chain 76 passes vertically upwardly over a sprocket 82, and then downwardly in a path around sprockets 86 and 87, and then vertically again. Because the transport conveyor cooperates with the vertical leg of the elevator, the carriage carrying the transport conveyor feeds the elevator over a range of vertical positions, as successive layers are stripped from the magazine.
A ramp 88 is positioned adjacent the upper sprocket 82, and the coin rolls are adapted to leave the carriers of the elevator and roll downwardly on the ramp 88, as shown in FIG. 6.
Associated with the forward end of the ramp 88 is a hollow circular dispensing member 90. One side 91 of the cylinder is open, to enable a roll to enter the interior of the dispensing cylinder 90 from the ramp 88. FIG. 10 illustrates the dispensing cylinder in position to receive a coin roll from the ramp 88. The dispensing cylinder 90 is supported for rotation on a shaft 92, and a motor 94 is adapted to rotate the shaft 92 through a worm gear drive. As the dispensing cylinder 90 rotates, the open side 91 is rotated toward the lowest coin tube, permitting the coin tube to roll downwardly on a ramp 94 until it reaches the dispensing tray 14.
Though the sequence described above, each coin roll is stripped from the magazine 20 onto the tilt tray 44, from which is it tilted onto the conveyor belt 50, and tilted again onto the ramp 66 which allows the coin roll to roll down to position to be lifted by the elevator. At the top of the elevator the coin roll rolls down ramp 88 to the dispensing cylinder 90 and subsequently down the ramp 94 to the dispensing tray 14. Although these operations are sequential with respect to each individual coin tube, some of these operations are carried on simultaneously, so that a continuous supply of coin rolls is assured on the ramp 88. Accordingly, each time the dispensing cylinder 90 is rotated one revolution, one coin roll is dispensed into the receiving tray 14. Apparatus is provided for insuring that the elevator mechanism 23 operates continuously as long as there are less than seven rolls available for dispensing in position on the ramp 88, and the transport conveyor 50 operates whenever there is no roll available on the ramp 66 waiting for pick up by the elevator mechanism. A mechanism is also provided for determining when no more coin rolls remain supported by the conveyor belts 50, to reverse the direction of drive of the conveyor, preparatory to a new row of coin rolls being tipped from the tilt tray 44 onto the conveyor belt. A mechanism is also provided for reloading the tilt tray with a row of coin rolls immediately after it has been tilted, so the tilt tray remains ready to tilt a row of coin rolls onto the conveyor belt 50 as soon as it has been emptied. Similarly, a mechanism is provided for retracting the pusher 40 as soon as the last row of coin rolls has been removed from a layer of the magazine, and lowering the pusher 40, tilt tray 44 and conveyor belt 50, to enable the pusher 40 to remove a row of coin tubes from the next successive layer. By overlapping the sequences involving the movements of the coin tubes, it is possible to assure a continuous supply of coin tubes to the receiving tray 14 even though the individual feeding operations are intermittent.
The case 10 (FIG. 1) has a front part 10a and a rear part 10b, the front part being hinged at one side to the rear part, so it can be swung open to allow replacement or replenishment of the magazine. The magazine can roll forwardly on roller assemblies 58 when the when the machine is opened for replenishing the inventory. The base members 54 support a plurality of columns 96, to which are secured cross pieces 98 which support the magazine support plate 30. The side walls 36 are also secured to the support columns 92, so the entire magazine represents a rigid U-shaped structure, which are open at the front and back when in plate in the machine. The pusher 40 is raised above the highest layer of the magazine when the magazine is pulled forwardly for reloading. Preferably the case portions 10a and 10b are held together by a key operated locking mechanism.
The lead screw 51, by which the transport conveyor is lowered, is journalled at its upper and lower ends in brackets 100 and 102, (FIG. 6) which are secured to the interior of the case 10b. The bracket 102 supports a motor 104 which drives the screw 51 through a gear mechanism 106. A housing 108 is threadably received on the screw 51, and supports a U-shaped carriage member 60 so that the carriage 60 is raised and lowered as the screw 51 is turned. A second housing 109, also secured to the carriage 60, is also in threaded engagement with the screw 51. The carriage 60 has an upper horizontal leg 110 and a lower horizontal leg 112. The lower leg supports the sprockets for the transport conveyor belt 50. The upper leg supports a beam 114 on each side of the machine which extends forwardly from the carriage 60 to the front of the magazine. The front ends of the beam 114 are joined with a member 116, which supports a bracket 118 journalling the forward end of a screw 120, which drives the pusher 40. The rear end of the screw 120 is journalled in a bearing 122 supported on the carriage member 60. The upper leg 110 also supports a motor 124 which is connected to the screw 120 through gears 126 and 128, the latter being fixed to the end of the screw 120. A housing 130 is threadably mounted on the screw 120 and supports the pusher 40, so that the pusher can be moved forward and back as the screw 120 is rotated.
A bracket 132 is supported on the underside of the leg 110, on one side of the housing 130, and a corresponding bracket (not shown) is supported below the leg 110 on the other side of the housing 130. The two brackets support a light source (not shown) and photo detector, such as a photocell 132a, respectively, so that when the housing 130 is in its rearward position, light from the light source cannot reach the photocell 132a, thereby generating a signal indicating the position of the housing 130.
On the bracket 118, a further bracket 134 is supported on one side of the housing 130 with a corresponding bracket (not shown) on the other side of the housing 130. These brackets are also provided with a light source 134a and photocell 134a, respectively, for identifying the forward position of the bracket 130, when the pusher 40 is forwardly of all of the coin rolls in the magazine.
The bracket 118 has another bracket 118a which has a feeler member 136 pivotally supported on a shaft 137. The feeler passes through an aperture in the central part of the pusher bar 40, and has a vane 139 which, as shown in FIG. 6, is interposed in the path between a light souce and a photocell 138, supported on walls 141 secured to the rear surface of the pusher bar 40. The feeler 136 rests on top of the topmost layer of coin tubes. When the stripper 40 is being lowered into position relative to the top row of coin tubes, the light path is unobstructed until the feeler reaches the top layer and rotates the vane 139 into the light path. This operation assures that the stripper is at the correct height to strip the top layer.
The bracket 100 supports a bracket 140 on which a limit switch 142 is mounted, having an actuator 144. The actuator 144 is adapted to engage the housing 109, when the carriage supporting the transport conveyor and the pusher are in their lowest position. Another bracket 145 is secured to the upper portion of the inside of the case and mounts a limit switch 147, with an actuator 149. The actuator 149 is adapted to engage the upper surface of the bracket 108, when the carriage has been moved to its upper most position, when the pusher 40 is above the topmost layer of a fully loaded magazine.
The tilt tray 44 has a tab formed integrally at each end thereof, which is supported on the pivot stud 45, allowing the tilt tray to be pivoted between its horizontal and vertical position. A U-shaped bracket 150 (FIG. 5) is secured to one end of the carriage 60, for supporting the pivot stud 45, as shown in FIG. 7. It also supports a bracket 152, which has an upper leg 154 and a lower leg 156. A photocell or light source 158 is secured to the upper end 154, in alignment with a light source or photocell 160 secured to a bracket 162 at the other side of the magazine (FIG. 5). This establishes a light beam which is interrupted by a row of coin rolls when they are pushed into position onto the tilt tray 44. The forward end of the tilt tray 44 is secured to a wire link 164 by which the tilt tray is raised and tilted into its vertical position. At its upper end, the wire link 164 is wrapped for part of a revolution around a pulley 166, and the end of the link 164 is secured to the pulley, and the pulley is fixed to a shaft 168. The shaft 168 is rotated by a rotary solenoid 170, so that the link 164 may be pulled upwardly, when the solenoid 170 is energized, thus tilting the tilt tray 44 to its vertical position. A spring 172, interconnected between the forward end of the tilt tray 44 and the lower arm 112 of the carriage 60, returns the tilt tray 44 to its horizontal position when the solenoid 170 is de-energized.
A flap 167 is secured to the bottom of the tilt tray 44, and is interposed between a light source 169 and a photocell 171, both of which are supported on a bracket 173, which is mounted on the U-shaped member 150. When the tilt tray 44 is in its horizontal position, the flap 167 is interposed in the light path between the source and photocell 169 and 171, whereas a second flap 175, connected to the rear wall 62 of the tilt tray, is interposed between the same light source and photocell when the tilt tray is in its vertical position, as shown in FIG. 9. Accordingly, the same photocell and light source combination furnishes separate signals when the tilt tray is in either of its two positions. A pair of funnel members 174 are secured to the upper surface of the tilt tray 44, adjacent the left and right sides of the magazine, to funnel coin rolls into position on the tilt tray 44 and prevent them from rolling in either direction on the tilt tray. Each funnel member 174 is formed of sheet metal and is secured to the tilt tray 44 by means of an L-shaped bracket portion 176 integral with the funnel member 174.
Secured at its lower end to the leg 112 of the U-shaped member 39 is a curved plate 212 (FIGS. 6 and 8) which extends toward the magazine, and then upwardly, its free end terminating at a level just below the tilt tray 44. The plate 212 acts to straighten the rows of coin tubes as the carriage is lowered, particularly those in the second highest layer, and blocks the movement of the second layer as the stripper strips the top layer onto the tilt tray. The coin rolls in the magazine are maintained in uniform orientation prior to being pushed onto the tilt table 44.
On the bottom leg 156 of the bracket 152, a limit switch 220 is provided, which cooperates with a bracket 222 secured to the belt 50. The belt is shown in FIG. 7 in the position in which it is ready to receive a new row of coin tubes from the tilt tray 44, and in that position, the stop bracket 222 is engagement with another limit switch 224, secured to a bracket 226 mounted to the lower arm 112 of the carriage 60. The switch 224 thus identifies the ready position of the belt 50. When the belt 50 has been advanced to cause all of the coin rolls to be removed from the transport conveyor, it is brought into engagement with the limit switch 220, which thus signals the empty position of the belt 50.
The pulleys 52 and 53 which support the belt 50, are supported by brackets 244 and 246 secured to the upper leg 112 of the carriage 60. The motor 55 turns, by means of a worm gear 250, the shaft of the sprocket 53 to drive the belt 50.
A light source and photocell combination 240 are provided to establish a light beam just above the ramp 66, to indicate the presence of a coin tube in position on the ramp. One of the pair 240 (FIG. 6) is secured to the bracket 162 (FIG. 5) below the lamp or photocell 160, and the other (not shown) is mounted beneath the lower leg 112 of the carriage 60. A light beam between the two is broken by the first coin roll on the ramp 66, which is not in position on a carrier 68, as illustrated in FIG. 6.
Another pair of light source and photocell 241 are located on the same brackets, but establish a light beam adapted to be broken when each coin tube is lifted by its carrier 68. The breaking of this light beam indicates the removal of a coin tube from the ramp 66, and signals the conveyor to be advanced to feed one additional coin tube to this ramp.
Similarly a pair of light source and photocell 250 and 252 are on opposite sides of the ramp 88, supported on the side walls 254. The light beam established between these two units is broken by the forth coin tube in the ramp 88. This light beam, when broken, insures that there are at least three coin tubes present on the ramp 68, which together provide sufficient weight to ensure that the lowest tube on the ramp fully enters the dispensing cylinder 90 for dispensing. Initial dispensing is delayed until at least three tubes are present on the ramp for that reason. A second pair of light source and photocell 251 establishes a light beam broken by the seventh tube on the ramp 68, and the elevator operates continuously until this condition is reached.
The shaft 92 has an extension 260, to which is secured a vane 262. The vane is adapted to interrupt a light beam between a pair of light source and photo detector 264 and 266, to indicate the position of the shaft 92. The light beam therefore indicates when a complete revolution of the escapement mechanism 90 has been effected.
A door 270 is supported for rotation on a shaft 272, in position above the ramp 94. When a coin roll is released from the dispensing cylinder 90, a coin tube, in rolling down the ramp 94, swings the door 270 open, pivoting it counterclockwise as illustrated in FIGS. 10 and 12. A vane 274 is secured to the door 270, and is adapted to interrupt a light beam between light source and photocell pair 276 and 278. The position of the vane 274 which interrupts the light beam is illustrated in FIG. 12. The opening of the door 270 is indicated by a signal caused when the light beam between 276 and 278 is interrupted.
From the various pairs of photocells and light sources, timing signals are developed which are used by the microprocessor 22 to control proper sequential operation of the parts of the apparatus. In addition, the light source and photocell pair 276 and 278, produce a signal when the door 270 is raised manually, and not by a coin roll as illustrated in FIG. 12. This can be used to sound an alarm signal indicating an unauthorized entry attempt.
Referring to FIGS. 13-15, an arrangement is shown for a temporary cover for the magazine. Since the magazine is adapted to hold 2,000 to 3,000 coin tubes, it represents, when full, considerable monetary value. For that reason it is desirable to provide some security against theft, while the magazine is outside the dispensing machine. The amount of security required is minimal, however, because the loaded magazine is typically maintained in a secure area when not in place in the dispensing machine.
As shown in FIGS. 13, which is a plan view of the magazine, each of the side walls 36 has a bracket secured thereto which has an upper horizontal flange 302, and front and rear flanges 304 and 306, respectively. Vertical slots are defined by the flanges, so that a rear plate 308 and a front plate 310 can be slipped downwardly into the slots, covering the front and rear of the magazine. With the front and rear plates in place, a top plate 312 can be slipped into the slots formed below the flanges 302, as shown in FIG. 14, overlying the top ends of the front and rear plates, and preventing them from being removed. The top plate has a front panel 314 which extends down over the top of the front plate 310, ending in a tongue 316 which can be locked with a padlock or the like to a tongue 318 secured by rivets or the like to the front plate behind the panel 314. Preferably, the front plate 310 is made of transparent material such as Lexan or other transparent plastic, to allow an inventory check or an auditing check without requiring the removal of the covers. The total content of the magazine can be easily determined from outside inspection, merely by counting the layers of coin tubes, and multiplying by the number in each layer.
The function of the microprocessor 22 is to monitor the various photo detectors and limit switches, and to initiate operations as required, and as indicated by the signals from the photocells, to insure that a continuous series of coin tubes are present on the dispensing ramp 88. Some of the photo detectors and limit switches are used to establish that each operation is completed before a succeeding operation can begin. For example, the pusher 40 must be withdrawn to its forward extremity, in front of the magazine, before it can be lowered preparatory to a subsequent pushing operation. As it is well within the purview of those skilled in the art to program a microprocessor to carry out the operations described above in proper sequence, as described, the microprocessor and its program need not be described in detail herein.
The microprocessor is also preferably employed to control operation of the currency validator 16, and to determine that a valid bill has been received by the machine, and to rotate the dispensing cylinder 90 an appropriate number of revolutions, in response to the sensed denomination of the currency which has been received. Apparatus for validating and determining up to two denominations of currency is commercially available from several sources, and therefore need not be specifically described herein. The prefered apparatus is disclosed in the application Ser. No. 276,684, filed on even date herewith.
It will be apparent that various modifications and additions may be made in the apparatus of the present invention, without departing from the essential features of novelty thereof, which are intended to be defined and secured by the appending claims. | A bulk loaded coin dispensing machine maintains a supply of coins to be dispensed in a bulk loaded magazine made up of a plurality of layers of coin rolls or tubes, each layer having plural rows and columns of coin tubes resting directly on each other, without intervening portions among the tubes. Coin tubes are stripped from the magazine a row at a time, and then carried by a transport conveyor and an elevator to a dispensing mechanism. The magazine carrier is movable independently of the stripper, conveyor and elevator to allow inventory replacement, and the stripper and conveyor are vertically adjustable in accordance with the decreasing height of the magazine as the coin rolls are dispensed. The stripper, conveyor, elevator and dispenser are operable asynchronously under control of a microprocessor. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. provisional patent application Ser. No. 60/685,632 filed May 26, 2005 and of common title and inventorship, the contents which are incorporated herein by reference in entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to classifying, separating, and sorting solids generally, and more specifically in one manifestation to a device using aqueous suspension, sifting, and stratifying to wash and classify aggregate.
2. Description of the Related Art
Cleaning and classifying aggregate matter is an old technology with many applications in modern society. A primary application is in the production of suitable aggregate for the fabrication of high-quality concrete products. As is known in the concrete industry, many characteristics of concrete can be greatly enhanced through the addition of appropriate aggregate materials. The aggregate additives are incorporated in relative quantities based upon particular size ranges, so that a typical mix will include some combination of both sand and one or more sizes of larger stones. Through appropriate size and even shape selection, the concrete can be designed to have the best characteristics for a given application.
However, in order for the aggregate additives to provide the intended benefits without undesirable disadvantages, the aggregate needs to be both clean and properly classified into size ranges. Humus, clay, wood and paper, and even softer and lower density rock such as shale can very adversely affect the performance of a concrete product. These undesirable materials can deleteriously alter such characteristics as compression strength, spalling, and wear or abrasion resistance, chemical resistance, and other characteristics. Consequently, it is very desirable to remove such materials prior to the aggregate matter being incorporated into a concrete mix.
There are many additional applications for washed and classified aggregate, including but not limited to road, building and other construction, landscaping, mining, sand blasting and casting, and even filtration. The different applications may have more or less stringent requirements for both size ranges and cleanliness of product, which may often vary not only by the application, but also by a given job requirement. Consequently, while aggregate for concrete mixes are discussed for exemplary purposes herein, it will be understood that other applications are contemplated as well.
In order to produce suitable aggregate, many facilities depend entirely upon large agitated screens. These screens will typically be loaded with a quantity of aggregate mix, and then shaken or vibrated relatively violently. Matter which is smaller than the screen opening will pass through the screen, where it will typically be caught upon the next screen, which will normally have an even smaller opening size. With sufficient agitation, all of the smaller particles will pass through the screen, while the larger particles will be blocked by the screen. By cascading several screens, it is possible to classify the aggregate mix into particular rock and gravel sizes. Unfortunately, this approach generates a great deal of dust during the agitation of the screens, and so water sprays are often used to keep the dust down. In some instances, the water spray may also assist with the removal of silt or humus, though quite frequently it will be desirable to keep the mist fine and light enough to only serve as dust control. More water may actually interfere with the screening, and may permit clay, for exemplary purposes and not limited thereto, to stick directly to desirable rock. Consequently, without a full washing, the spray can interfere with the separating process. As a result, the classified aggregate produced by this method tends to be relatively dirty, and may require further washing for the more demanding applications.
The use of a water mist also limits the environment where the apparatus may be applicable. As residents of northern climates will recognize, it is not practical to spray a mist during colder, sub-freezing weather. Consequently, the mist dust control is dependent upon warmer weather, undesirably limiting the screening and classifying to the warmer seasons. Further, the mist will rapidly evaporate from the surfaces of the aggregate. This evaporation may lead to very undesirable losses in the very arid climates, again limiting the application and generally preventing misting in arid climates or during times of drought. Since sensitivity of machinery to weather is almost always disadvantageous, causing interruptions in work projects and disruption of schedules, it is consequently desirable to reduce the sensitivity of the apparatus to climate.
Because the screens rely upon lifting and dropping of the aggregate upon the screen, the process requires substantial machinery to have high throughput of matter. In other words, it takes a great deal of energy to repetitively lift and drop the aggregate, and that in turn means large motors and strong frames and supports. Moreover, the extra energy is usually dissipated in the screens, resulting in substantial erosion of the screens and frequent replacement.
Yet another drawback of the agitated screen is the inability of the process to separate out the hardness or density of the materials being sifted. In other words, it is difficult to separate wood and sticks from rocks, and also low-density rocks such as shale from higher density harder rocks. Consequently, when using a sifting process, a separate and additional machine and process is required to further clean and separate undesirable matter.
SUMMARY OF THE INVENTION
Exemplary embodiments of the present invention solve inadequacies of the prior art by providing a rotary screen with counter-flowing water. The water may be either fresh, or filtered on site using a filter, sedimentation pond or other suitable means. With appropriate design, a sand classifier may be integrated directly into the apparatus, and cooperate with the rotary screen and counter-flowing water. The design may be either fixed or mobile, and when mobile provided with a wheel-set such as a trailer, or be provided as a fully functional vehicle.
In a first manifestation, the invention is a rotary aggregate washing and classification system. The system comprises in combination a material inlet for receiving material therein, a reservoir containing a fluid therein, at least one screen mesh, and a sand classifier within the reservoir. The at least one screen mesh has at least one screen opening size, is coupled to the material inlet suitably to receive material therefrom, and passes at least partially through the reservoir, thereby forming a passage for material smaller than the at least one screen opening size to pass through while larger material is prevented from passing through. The at least one screen mesh is operative to separate larger material from smaller material. The sand classifier is located within the reservoir and receives smaller material after the smaller material passes through the at least one screen mesh and is cooperative with a flow within the fluid and with smaller material, to grade smaller material into at least two coarseness increments.
In a second manifestation, the invention is an aggregate washing and classification system. In the system, a material inlet receives material. A reservoir contains a fluid. At least one screen mesh has at least one screen opening size, and is coupled to the material inlet suitably to receive material therefrom. The screen mesh passes at least partially through the reservoir, and thereby forms a passage for material smaller than the at least one screen opening size to pass through while material larger than the at least one screen opening size is prevented from passing through, whereby the at least one screen mesh is operative to separate larger material from smaller material. At least one rock bin has a top which receives graded material that has passed through the at least one screen mesh, a bottom, a fluid inlet distal from the rock bin top, a fluid discharge adjacent the rock bin top, and a means to discharge graded material from the rock bin to a location external to the rotary aggregate washing and classification system. The rock bin at least temporarily stores rocks therein and also conducts fluid received at the fluid inlet to the rock bin top for discharge therefrom.
In a third manifestation, the invention is a method of washing and sorting aggregated materials to separate useful rocks and sands from debris. According to the method, aggregated materials are introduced through a passageway inlet into a passageway at least partially defined by a perforated wall and at least partially flooded with a fluid contained in a receptacle. A first fraction of aggregated materials is separated from a second fraction by passing the first fraction through the perforated wall, while retaining the second fraction within the passageway. The second fraction of aggregate materials is moved within the passageway to a passageway discharge distal to the passageway inlet. The first fraction of aggregate materials is transferred into a temporary storage bin. The temporary storage bin is streamed with a relatively purer fluid than passageway fluid. The relatively purer fluid stream is then conducted from temporary storage bin to passageway discharge and into the passageway, thereby washing impurities from the first fraction of aggregate materials into the passageway fluid.
OBJECTS OF THE INVENTION
A first object of the invention is to provide an efficient and effective method and apparatus for washing and classifying an aggregate. A second object of the invention is to remove as much undesirable matter from an aggregate mix as reasonably possible. Another object of the present invention is to quickly and efficiently classify the aggregate mix into appropriate size ranges. An ancillary object is to permit release of relatively precise proportions of the various size ranges, to facilitate the formation of an aggregate mix to specification. A further object of the invention is to perform the desired washing and classification with high throughput, while not requiring as large a machine as was heretofore needed and while keeping wear to a minimum. An additional object of the invention is to reduce sensitivity to the environment, to permit the machine to operate at lower temperatures and in water-scarce areas. Yet another object of the present invention is to enable the apparatus for washing and classifying to be portable without significant disassembly or labor, such that the apparatus may readily be transported as a trailer or load upon a vehicle from location to location.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, advantages, and novel features of the present invention can be understood and appreciated by reference to the following detailed description of the invention, taken in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates a first preferred embodiment rotary aggregate washing and classification system designed in accord with the teachings of the present invention from side sectional view.
FIG. 2 illustrates a second preferred embodiment rotary aggregate washing and classification system designed in accord with the teachings of the present invention from side sectional view.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Manifested in the preferred embodiment of the invention illustrated in FIG. 1 , the present invention provides a rotary aggregate washing and classification system 10 which is operative to receive, wash and separate aggregate into useful components and waste. Aggregate, as is known in the industry, may typically include not only rock, gravel and sand but may also contain contaminants such as wood, leaves, paper, plastic, shale, clay, and other undesirable constituents. Most desirably, the undesirable constituents will be separated from the rock, sand and gravel. The rock, gravel and sand will each be further separated into size classifications, for later use as is known in the industry.
Rotary aggregate washing and classification system 10 is comprised by several main components. These include inlet 20 , rotary screen and auger 30 , rock receiver 40 , sand classifier 50 , and water flow control 60 . Inlet 20 is operative to receive aggregate in an “as-delivered” state, which may come directly from an adjacent gravel pit, or which may be delivered from a distance, such as by truck or rail. As will be described herein below, one of the advantages of the present invention is the mobility which is inherent. The preferred rotary aggregate washing and classification system 10 may be readily transported from location to location, thereby facilitating the processing of aggregate from smaller gravel pits without requiring the aggregate to be transported to another processing facility. Consequently, in many instances the source for aggregate passing into inlet 20 will be a loader, shovel or other equipment within the gravel pit. Depending upon the quality and size of the source matter, in some cases the matter may be passed through a crusher prior to introduction into inlet 20 . To better control the rate of feed into inlet 20 , it may also be desirable to meter the source matter onto a conveyor belt or the like, or use other suitable means to maintain a steady feed of source matter into inlet 20 . Finally, it may also be desirable to add water into either the aggregate or to inlet 20 together with the aggregate, which will assist with ensuring proper flow of matter without undesirable clogging.
Aggregate is first received within aggregate inlet funnel 21 , and then passes into a narrower neck region 22 . At the lower end of neck region 22 , the aggregate will first be exposed to water within rotary aggregate washing and classification system 10 , which will desirably be maintained at a level illustrated in the figures as water line W. The aggregate will then continue to drop into holding region 23 , prior to passing into rotary screen and auger 30 . A sloped infeed surface 24 helps to ensure gravity-driven automatic feeding into rotary screen and auger 30 . In operation, the primary water outlet for water that has passed through rotary aggregate washing and classification system 10 is water outlet 25 . As will be described in more detail herein below, fresh water is pumped into rotary aggregate washing and classification system 10 through water inlets 44 - 46 , and may circulate an indeterminate number of times within rotary aggregate washing and classification system 10 . The water will ultimately pass out of water outlet 25 . Since water outlet 25 is located immediately adjacent to aggregate inlet funnel 21 , as aggregate passes through neck region 22 into submersion, lighter materials such as wood, leaves, paper and other undesirable trash will float up and eventually pass into water outlet 25 with water flow 82 . In addition, materials such as very fine silt which remain fully suspended in the water will also be carried out with flow 82 . With appropriate flow rates and patterns, even matter closer in density to the desired sand, rock and aggregate product may be separated at the inlet, including such matter as shale and clay.
Most preferably, inlet 20 will never be fully filled, as this might undesirably trap lighter materials in the aggregate. Instead, turbulence within water adjacent to neck 22 is often quite desirable, which will assist with the separation of materials which float. Specific arrangements of in-feed belts carrying matter, feed and flow rates, and other factors may be adjusted to optimize a given apparatus for a particular source matter, to most efficiently process that material.
Aggregate, which has now desirably been separated from wood, paper, leaves and the like, will next be drawn into rotary screen and auger 30 from adjacent holding region 23 . In operation, motor 39 will drive and rotate shaft 38 relative to the outer wall of rotary aggregate washing and classification system 10 . Shaft 38 is in turn coupled to auger shaft 37 , which carries auger 32 , such as an Archimedes screw, thereon. Supported circumferentially about auger 32 are a set of screens 33 - 36 , which get progressively coarser as aggregate passes from holding region 23 to the eventual rock outlet 31 . Support for auger 32 and screens 33 - 36 may include various types of known and suitable bearings.
Screens 33 - 36 will most preferably be manufactured from a durable and abrasion resistant material such as, but not limited to, polymers and various metals and metal-alloys, either plated or unplated, and coated or otherwise. In one preferred embodiment, screens 33 - 36 may be fabricated from expanded metal, which may be coated, plated or otherwise protected from corrosion and wear, such as with a polyurethane, PVC or any other suitable material. Further, in the case of the expanded metal and with other materials as suitable and desired, it is known that the forming process causes the metal to twist out of the plane of the web of metal. So, small segments of the metal are each angularly offset from tangent about the center, each small segment offset in the same direction. In this special case, it may be further desired to orient the angular offset such that it approaches a vertical angle sometime after passing through the six o'clock position, such as when approximately adjacent to the seven or eight o'clock position, when viewed from rotational axis and when rotating in that view clockwise. While not being bound to a particular theory, this is believed to permit the appropriately sized and cleaned product to drop through the screen as the aggregate is being lifted against the force of gravity, where otherwise the angular offset would tend to hold material into the screen during the upward movement of the screen.
Rotary motion is coupled from auger shaft 37 through any suitable means to auger 32 and screens 33 - 36 , such as one or more stub shafts or the like that, for exemplary purposes only and not limited thereto, may extend radially between auger shaft 37 and either or both auger 32 and screens 33 - 36 . The benefit of a relatively small axial auger shaft 37 is that it provides strength and rigidity in the axial direction, while, if smaller than the inner diameter of auger 32 , permitting flow of water through the center of auger 32 . This flow of water directly through the core, which may be counter to the direction of aggregate movement, is preferable for some applications.
Auger 32 is rotated by the action of motor 39 , as already described, and will in turn carry aggregate through rotary screen and auger 30 from adjacent holding region 23 , gradually raising the aggregate to levels closer to and eventually above water line W. In this way, any rocks large enough to avoid passing through final screen 36 will finally be dropped out of open end 31 . Such larger rocks may be sorted further if desired, but in some instances will alternatively be passed through a crusher or the like, and then the resulting aggregate will once again be introduced back into aggregate inlet funnel 21 . While only one rotary screen and auger 30 is illustrated, it will be apparent to those reasonably skilled in the art that a plurality of rotary screen and auger units may be combined in one machine, or that a plurality of separate augers 32 may be provided within a common, circumscribing screen. Furthermore, the direction of rotation of the augers, either individually or with respect to each other, is not critical to the operation of the invention, so long as the material is satisfactorily transported, as is known in the material handling arts. Consequently, the augers may be either counter-rotating or rotating in the same direction.
As the aggregate traverses rotary screen and auger 30 , sand and gravel will pass through screen 33 , while the smallest rock will not be dropped out until encountering screen 34 . Generally circumscribing the lower side of screen 34 is the first of three rock chambers 41 - 43 within rock receiver 40 . These chambers are used to collect and store the rocks, until later discharged through a side or bottom door (not illustrated). In one conceived embodiment, each separate rock chamber will further be provided with a false bottom, a scale monitoring the load upon the false bottom, and electrical controls, to permit both monitoring of the fill levels within each rock chamber, and also to permit discharge of selected amounts of rock therefrom through automated or computer control.
As an alternative to the use of doors or gates, it is further contemplated herein that additional augers may be provided which couple into one or more of the chambers 41 - 43 . These additional augers may be used to remove product from the chambers when desired, such as through a proportional metering, or may alternatively be operative continuously to discharge the product. The augers, including rotary screen and auger 30 , may also be provided with scoops at the ends thereof to couple product into slides, chutes or the like, as may be desired.
Along the bottom of rotary aggregate washing and classification system 10 is a preferred sand classifier 50 , which has a number of funnels 51 - 54 and associated outlets 55 - 58 which are used to selectively release sand therefrom. Once again, outlets 55 - 58 may be replaced by, or additionally provided with discharge assists such as additional augers, chutes and skids, or other suitable apparatus, similar to that already discussed with regard to chambers 41 - 43 . Operation of sand classifier 50 is provided by water flow control 60 , which controls the flow of water within rotary aggregate washing and classification system 10 to operate sand classifier 50 in a manner such as is known in the prior art as a horizontal flow, gravitational separator.
Sand passing through finer screen 33 will drop into a water flow stream having a flow direction illustrated by arrow 71 , and limited by baffle 62 . As the water and sand approach baffle 63 , the water flow will divide, as shown by arrows 72 and 73 , with flow 72 carrying most of the larger sand and gravel. Finer silt that remains suspended will be carried within flow 74 or flow 76 to an inlet to pump 61 defined by baffle 64 . The outlet for pump 61 is defined by flow 77 , which will be greatly accelerated relative to the other adjacent flow path. This acceleration will carry not only flow path 77 , but also gravel suspended within flow 75 , horizontally along flow path 78 , passing over funnels 51 - 54 in order. Larger gravel will drop first, falling into funnel 51 , with finer gravel being carried into funnel 52 . Since baffle 62 has a slight slope, flow 79 will be moving slower than flow 78 was. As a result of the gradual deceleration of flow farther from pump 61 , and the continued action of gravity on the more dense sand within the water, progressively finer materials will continue to drop from the flow as the flow continues. Adjacent flow 79 , there will be a slight and slow eddy 81 developed, which will tend to drop the most fine sand, and there will also be a return flow 80 which forms a confluence with flow 71 .
In addition to the flow generated by pump 61 , a second flow is produced by the introduction of water through inlets 44 - 46 . This fresh water serves to not only continue to keep rocks within chambers 41 - 43 clean and fresh, but also generates a flow of water which is counter to the direction of movement of aggregate within rotary screen and auger 30 . This counter flow serves to prevent silt from passing into rock chambers 41 - 43 with the aggregate, and additionally moves the lighter materials in the direction of water outlet 25 . The general flow of water from inlets 44 - 46 towards water outlet 25 will also couple with flow 71 , and is encouraged to do the same by turbulence generated by auger 32 . As a result of this turbulence, there is a certain amount of mixing of water circulating through sand classifier 50 and water circulating through rotary screen and auger 30 .
Most preferably, auger 32 will have a variable pitch, which may be varied in discrete steps or may be continuously varied. Most preferably, adjacent finer screen 33 auger 32 will move material more quickly towards outlet 31 . Adjacent each progressively coarser screen 34 - 36 , auger 32 will move material more slowly towards outlet 31 , to where, adjacent outlet 31 and screen 36 , any remaining rock is tumbled more, while traveling the least towards the outlet. One consideration in the design of the variable pitch is the consideration of the amount of active screen. For example, if the initial aggregate is comprised of 80 percent fine sand which passes through screen 33 , than the initial screen 33 will have 80 percent of the received material actively passing through at a given moment. However, as the aggregate progresses towards the outlet, less of the fine sand remains, reducing the amount of active screen surface, and thereby requiring more time for removal. As an adjunct to this principle, it is recognized herein that the screens may be varied in surface area, diameter, and even geometric outline to better optimize performance for a particular source material having particular size range or other characteristic that affects the proportion of processing times needed for a given stage.
FIG. 2 illustrates a second preferred embodiment rotary aggregate washing and classification system 110 . Where possible, like numbers have been used which have the same digits in the tens and ones places as those numbers which correspond to like elements in FIG. 1 . So, for example, aggregate inlet funnel 121 in rotary aggregate washing and classification system 110 performs similar function to aggregate inlet funnel 21 in rotary aggregate washing and classification system 10 . This numbering is preferentially used, and where functions are alike or similar enough, no further discussions are provided herein for brevity.
As may be seen in FIG. 2 , a special baffle 126 is provided within neck region 122 which serves to deflect aggregate away from the entrance to rotary screen and auger 130 , and instead towards water outlet 125 . This deflection enhances the shear and separation of lighter materials. When properly designed, and when accompanied by automated aggregate feeders such as belt feeders that load aggregate into inlet 120 , special baffle 126 will provide sufficient assist to enable the separation of shale and the like within inlet 120 , for discharge directly out of water outlet 125 .
A second difference between rotary aggregate washing and classification system 10 and rotary aggregate washing and classification system 110 is found in the circulation of water therein, and the placement and orientation of baffles therein. As can be seen in FIG. 2 , vertical baffles 162 - 164 (and beyond) are provided. Water flow remains in the direction of rock receiver 140 to outlet 125 , similar to that of FIG. 1 , above vertical baffles 162 - 164 . However, below these baffles, water flow is reversed between the two preferred embodiments. More particularly, in rotary aggregate washing and classification system 110 , water will flow from rock receiver 140 along a flow 171 above vertical baffles 162 - 164 . Below vertical baffles 162 - 164 , water also flows parallel in direction to flow 171 , this time along flow 178 . Vertical baffles 162 - 164 prevent the turbulence created by rotation of auger 132 from interfering with proper vertical dropping of sand and aggregate from rotary screen and auger 130 . In this embodiment, more screen sizes will preferably be provided adjacent inlet 120 , shown as 133 and 133 ′. While only two screens are illustrated, it will be understood herein that only one or more than two may be provided, with no limit on the number other than that which is economically justified and on the desired ultimate length of rotary aggregate washing and classification system 110 . The finest material will still be carried along flow 178 around vertical baffle 162 , and will drop into funnel 151 .
It should now be apparent that while a single funnel 151 is illustrated for collection and recovery of finer sand, rotary aggregate washing and classification system 110 may be extended as desired to permit placement of additional baffles and funnels to the left of funnel 151 shown in the figure. In such case, everything under and including rotary auger 130 would remain as illustrated. However, holding region 123 would be enlarged to the left, along the longitudinal axis of rotary aggregate washing and classification system 110 . Additional funnels similar to funnel 151 would then be provided thereunder, permitting any number of classifications to be made therein, limited only by the ultimate length chosen for rotary aggregate washing and classification system 110 . Since rotary aggregate washing and classification system 110 will most preferably be transportable along a roadway, such length will be determined by the size and weight restrictions placed upon the roadways for a given locale.
Since the flow of water within rotary aggregate washing and classification system 110 is generally opposite the movement of aggregate, and is unidirectional, fresh water must be continually provided at water inlets 144 - 146 , and will continually be taken from water outlet 125 . While it is conceivable in certain environments and climates to draw from a clean fresh water source such as a lake, pond, reservoir, or even flooded quarry, in other instances it will be preferable to provide a separate holding pond or tank exterior to rotary aggregate washing and classification system 110 , into which effluent from flow 182 will pass, and be allowed to settle. In turn, such holding tank or pond will then be drawn from, at different location, to pump back into water inlets 144 - 146 . In yet a third conceived alternative, in some instances it may still be preferred to provide a recirculating pump similar to pump 61 of FIG. 1 . In this instance, the recirculating pump will most preferably draw adjacent to motor 139 , and pump the water back into flow 179 adjacent rock chamber 141 .
A third significant change between the two embodiments is found in rock receiver 140 . As shown in FIG. 2 , rock receiver 140 includes three separate and free-standing rock chambers 141 - 143 , each which are preferably supported upon a scale, thereby keeping the chambers separate from fixed components within rotary aggregate washing and classification system 110 . Consequently, the weight of each may be measured independently, and so the amount of aggregate located therein may be determined. With this configuration, these rock chambers 141 - 143 may be devised to unload from the bottom into and through the underlying funnels. Once again, the amounts present, fill levels, and unloading may all be automatically or numerically controlled.
As discussed herein above, rotary aggregate washing and classification system 10 may be supported upon a wheel set, together with a base which may be used as a stand once rotary aggregate washing and classification system 10 is transported to a point of use. As mentioned herein above, most preferably rotary aggregate washing and classification system 10 is designed to be mobile. Transport will most preferably occur when rotary aggregate washing and classification system 10 is either nearly or completely empty, thereby reducing the weight upon a roadway and hazards associated with a heavy load. With the preferred configurations, each of the rotary aggregate washing and classification systems 10 , 110 may be fully unloaded relatively easily prior to transport, simply by emptying each of the sand and rock funnels.
While the foregoing details what is felt to be the preferred embodiment of the invention, no material limitations to the scope of the claimed invention are intended. Further, features and design alternatives that would be obvious to one of ordinary skill in the art are considered to be incorporated herein. For exemplary purposes only, and specifically not limited solely thereto, rotary auger 130 is illustrated as being tilted slightly with respect to the top of rock receiver 140 and the water level W. However, rotary auger 130 could alternatively be fabricated to be parallel with the top of rock receiver 140 , and the entire rotary aggregate washing and classification system 110 could then be tilted to achieve the same effect. Consequently, the scope of the invention is set forth and particularly described in the claims herein below. | An aggregate washing and classification system incorporates into a water-filled receptacle a sand classifier and one or more rotating augers. The augers are wrapped with screens or perforated walls that are fixed relative to the augers. The size of the perforations may be chosen to selectively sift particular sizes of gravel and rock, and if the perforations increase in size along the length of the augers, either continuously or discontinuously, the material which passes through the perforations will likewise increase in size with greater travel through the auger passageway. Consequently, a set of rock bins may be provided adjacent to the auger outlet, for collecting various sizes of larger aggregate, such as washed rocks. Sand will typically be permitted to pass through the screen perforations near the aggregate inlet. Once outside of the auger and screens, the sand will drop directly into a sand classifier, which is conveniently located directly below the augers and adjacent to the material inlet. Fresh water is pumped into the bottoms of the rock bins, and flows counter to the aggregate passing through the augers. The counter-flow keeps the rock bins clean, and the flow of water adjacent and counter to the material inlet is used to extract and discharge low-density matter from the aggregate inlet. The entire system is desirably incorporated into a single land vehicle for transport to aggregate sources, such as gravel pits and the like, where the finest grades of aggregate may be rapidly prepared. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of PCT international application number PCT/JP2005/007769 filed on Apr. 25, 2005, the subject matter of which is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a network design processing device and method, and program therefor for supporting the network design/construction of computer systems. Particularly, the present invention relates to a technique for automatically detecting a setting error in a network in the network diagram of a designed computer system and for automatically detecting a non-redundant device.
2. Description of the Related Art
Conventionally, when computer systems are designed or constructed, the designers have created a network diagram and performed a network setting for each device using the created network diagram. Specifically, the designers have decided information for setting each device by reviewing the created network diagram based on an empirical approach, written out the information into a data table by hand, and then performed a setting for each device according to the information. The designers have repeated these tasks for each device one by one. This has imposed a great burden on the designers and caused problems with a large number of setting errors.
On the contrary, there are techniques for supporting designers in designing or constructing computer systems. Such techniques include a network configuration and design support system described in Patent Document 1.
This network configuration and design support system of Patent Document 1 is provided a network device graphics information file, in which pictures are stored that indicate the appearance or symbol of network component devices. The designers can create a network configuration diagram by selecting a desired picture from a graphics menu of the pictures on a display screen. This enables the designers to facilitate their tasks, such as the creation of network device configuration diagrams or the selection of hardware or software associated with the network construction.
The network configuration and design support system of Patent Document 1 also has means for validating a combination of attributes that are defined for each device, based on the attribute definition information for each device. The network configuration and design support system further comprises means for validating a connection relationship between devices, a communication relationship between software used by each device, and a reference relationship between data.
(Patent Document 1: Japanese Laid-Open H06-187396)
At the time of network design for the computer system, it is necessary, needless to say, to set correct addresses for all devices, but also to consider other configuration restrictions. This imposes a significant burden on the operators.
Additionally, it is possible to provide communications between devices when the devices are physically connected to each other via a network. However, it is also necessary to consider such restrictions for the device setting when there are some combinations of devices being desired to provide communications and others not, depending on the operational policies.
Further, displaying all communication settings on a single network diagram at a time makes the network diagram significantly complicated. This may result in a problem that a designer forgets to configure a communication setting or configures incorrectly in a communication setting.
On the other hand, as a countermeasure against abnormal conditions during the operation of the computer system, it is desirable to clarify a device at a network design stage, which affects other devices when a failure occurs.
The network configuration and design support system, disclosed in the above-mentioned Patent Document 1, has no function for preventing the oversight of communication settings or incorrect communication settings, or for detecting a critical point (CP) that causes a severe communication failure.
Particularly, in communications between devices, there is service session necessary for actual task execution during the operation of the system and maintenance session necessary for the system maintenance, which is different for respective communication purposes. Therefore, it is desirable to be able to provide setting, displaying, and checking of each session separately. However, the conventional technique could not handle the service session and the maintenance session as distinguished from each other in a network diagram. Thus, it could not also provide a display, which differentiates the two types of communications such that one part displays only the communication of the service session, and another displays only the communication of the maintenance session in the network diagram that is displayed on a display device.
It is an object of the present invention to solve the above problems and prevent the oversight of communication settings or incorrect communication settings at the time of network design for the computer system with greater ease than in the conventional technique.
It is another object of the present invention to differentiate, in a network diagram created with computer, the service session and the maintenance session to enable a separate setting, displaying, and checking of these sessions.
It is still another object of the present invention to provide a technique for detecting a device which may cause a severe communication failure due to the occurrence of failures at the time of network design for the computer system.
SUMMARY OF THE INVENTION
To solve the above problems, the present invention provides a network design processing device for automatically extracting network design information from a network diagram inputted through a computer screen. The network design processing device comprises: a network diagram creation processing unit for inputting service communication setting information for service execution in a network system to be designed and maintenance communication setting information for maintenance management of the network system distinctly and displaying each line connecting a starting point and an ending point of communications on the network diagram in different display modes for the service communications and for the maintenance communications; and a design diagram data storage unit for storing the design diagram data expressing the network diagram, the design diagram data including the service communication setting information and the maintenance communication setting information inputted by the network diagram creation processing unit. The present invention enables the easy and clear communication setting in a network design because the service communications and the maintenance communications are distinctly input and displayed on the network diagram.
Preferably, the present invention may comprise a selective communication display control unit for instructing to display the communication setting information for the communication in which a specific network device, such as a server, designated at the network diagram is the starting point or the ending point. When a selective communication display is instructed for a specific network device, the present invention displays the setting information for the communication having the designated specific network device as the starting point or the ending point is displayed on the network diagram, while the present invention hides the setting information for the other communications. The present invention enables only necessary communications to be displayed on the network diagram, thereby achieving the clearer network design.
Preferably, the present invention may have a unit for instructing to display the setting information for a specific communication designating the types of communication or communication protocol. When a selective communication display is instructed for a specific communication or protocol type, the present invention displays the setting information for the communication for the designated communication or protocol type on the network diagram, while the present invention hides the setting information for the other communications. The present invention enables an easy check of setting information related to the communications depending on the types of communication or communication protocol.
Preferably, the present invention may place the setting information for the input communication on a different layer of a plurality of layers forming the network diagram in accordance with the types of communication, communication protocol of the service communications, the maintenance communications, or the combination of the types of communication and communication protocol, and, for the display of the setting information for communications on the network diagram, select a specific layer or a group of layers to display on the network diagram. The present invention enables a prompt and easy display of setting information for communications on the network diagram.
Preferably, the present invention may store the design diagram data obtained from the network diagram in a design information database, detect a network device is detected that does not correspond to the starting point or the ending point of the communications, and displays such information on the network diagram that indicates the network device. The present invention may eliminate the oversight of communication settings.
Preferably, the present invention may analyze the service communication setting information that is stored in the design information database, search a server communicates which has communication from outside of a network system to be designed, further search another server which is chained and has communications with the server, then detect a remaining-server that deviates from such a communication-chain. Then, the present invention display information is displayed on the network diagram that indicates the server having no interaction with the outside world. Such a server is likely to be incorrect that has only closed communications within the system without any interaction with the outside world. The present invention enables an easy detection of such setting errors in communications.
Preferably, when the server deviating from the communication-chain is a device corresponding to the starting point of the maintenance communications, the present invention does not treat the device as a target for displaying the information that indicates no interaction with the outside world. That is because, for example, a maintenance monitoring server may not have any relationship with communications with the outside world.
Preferably, the present invention may analyze the maintenance communication setting information that is stored in the design diagram database. Then, the present invention may detect communications that have no path between the starting point and the ending point of the maintenance communications, or a device that does not correspond to the starting point or the ending point of the maintenance communications, and display information on the detection result on the network diagram. The present invention enables the designer to ascertain a device to which the maintenance communications may not be provided and eliminate the oversight of setting, thereby improving reliability of the network system.
Preferably, the present invention may cause a pseudo-failure for each device one by one based on the information for each device stored in the design information database, perform a path search to determine whether the service communications are established from the starting point to the ending point based on the service communication setting information with reference to the connection information for said each device, perform a failure simulation that detects the existence of any impossible service communications, and display the device with the pseudo-failure is displayed on the network diagram with a mark of critical point (CP) being added, when the impossible service communications are detected. The present invention enables the system designer to understand which machine could be a critical point and to add redundancy to the machine as needed, thereby improving its fault tolerance. In this case, the analysis for detecting and displaying a critical point with the failure simulation is performed only on the service communications, and not on the maintenance communications. That is because all devices could be a critical point when the maintenance sessions are subject to the failure simulation, since each maintenance session is normally accessed by the redundant devices independently.
According to the present invention, the service session and the maintenance session are described and displayed distinctly on the network diagram. Therefore, any input error in the setting information for their communications would be eliminated and the communication-related network design may be performed in an easier and clearer way.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of an example of a structure of a network design processing device according to an embodiment of the present invention.
FIG. 2 is a diagram of an example focusing on a part of the network design processing device according to an embodiment of the present invention.
FIG. 3 is a diagram illustrating the creation of a network diagram.
FIG. 4 is a diagram illustrating operational procedures for communication setting.
FIG. 5 is a diagram illustrating a property setting.
FIG. 6 is a diagram illustrating an example of the designed network diagram.
FIG. 7 is a diagram illustrating an example of each object ID given to each component.
FIGS. 8A and 8B are diagrams illustrating an exemplary selective communication display.
FIG. 9 is a flowchart of a selective communication display process.
FIG. 10 is a flowchart of a check process on a network diagram.
FIG. 11 is a chart illustrating an example of a device table to be stored in a design information DB.
FIG. 12 is a chart illustrating an example of a connection information table to be stored in the design information DB;
FIG. 13 is a chart illustrating an example of a session table to be stored in the design information DB.
FIG. 14 is a chart illustrating an example of a basic information check result.
FIG. 15 is a chart illustrating an example of a network diagram after address modification.
FIG. 16 is a flowchart of a service communication setting check process.
FIG. 17 is a flowchart of a service communication setting check process.
FIG. 18 is a flowchart of a path search process.
FIG. 19 is an example of service communication setting check result.
FIG. 20 is a flowchart of a maintenance communication setting check process.
FIG. 21 is a chart illustrating an example of maintenance communication setting check result.
FIG. 22 is a chart illustrating an example of the network diagram after Router placement.
FIG. 23 is a chart illustrating an example of state where a device is detected which is isolated from an external communication.
FIG. 24 is a chart illustrating an example of the network diagram to which an external communication is added.
FIG. 25 is a chart illustrating an example of generic filter setting information.
FIG. 26 is a chart illustrating an example of a filter setting file obtained from conversion of the generic filter setting information to an output format for specific filtering program.
FIG. 27 is a flowchart of a failure simulation process.
FIG. 28 is a chart illustrating an example of an operation of the failure simulation.
FIG. 29 is a chart illustrating an example of the network diagram after the completion of the failure simulation.
FIG. 30 is a chart illustrating an example of the network diagram in which CPs are reduced by duplexing of FireWalls and Routers.
FIG. 31 is a chart illustrating an example of redundant configuration data.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the accompanying drawings, embodiments of the present invention is described below.
FIG. 1 is a diagram of an example of a structure of a network design processing device according to an embodiment of the present invention. FIG. 2 is a diagram of an example focusing on a part of the network design processing device according to an embodiment of the present invention.
A network design processing device 1 includes a network diagram creation processing unit 10 , a selective communication display control unit 11 , a design diagram data storage unit 12 , a design diagram data analysis unit 13 , a design information DB 14 , a basic information check unit 15 , a communication setting information check unit 16 , a design information modification unit 17 , a check result output unit 18 , a failure simulation unit 19 , and a CP information output unit 20 . These are realized by a computer system of hardware and software, including a CPU, memory and so on. An input/output device 2 is connected to the network design processing device 1 .
The design diagram data analysis unit 13 includes a basic information extraction unit 21 and a communication setting information extraction unit 22 . The communication setting information check unit 16 comprises a service communication setting check unit 23 , a maintenance communication setting check unit 24 , and a path search unit 25 . The network design processing device 1 also includes a filter setting information creation unit 26 which creates filter setting information for routers and so on with reference to the design information DB 14 .
The network diagram creation processing unit 10 has a processing function of graphics processing software, such as CAD. The network diagram designer creates a network diagram by operating the network diagram creation processing unit 10 via the input/output device 2 .
The selective communication display control unit 11 controls the network diagram creation processing unit 10 in such a way that only the communications instructed by the input/output device 2 would be selected and displayed on the network diagram on the screen of the input/output device 2 .
The design diagram data storage unit 12 stores design diagram data including information of the network diagram that is created by the network diagram creation processing unit 10 . The design diagram data includes graphics information and attributes information for each graphic element (hereafter referred to as an “object”) which comprises the network diagram, and its data format is similar to that of being used in common CAD systems.
The design diagram data analysis unit 13 analyzes the design diagram data of the network diagram stored in the design diagram data storage unit 12 to extract design information. The extracted design information is stored in the design information DB 14 . The basic information extraction unit 21 extracts basic information, such as information for each device described in the network diagram or physical connection information between devices. The communication setting information extraction unit 22 extracts communication setting information for the communications between devices described in the network diagram.
The design information DB 14 stores design information, such as the basic information extracted by the design diagram data analysis unit 13 or the communication setting information.
The basic information check unit 15 checks for any setting error in the basic information stored in the design information DB 14 . As used herein, the term “basic information” refers to the information for each device set in the network diagram or the information for each connection cable which physically connects each device.
The communication setting information check unit 16 checks for any setting error in the communication setting information stored in the design information DB 14 . As used herein, the term “communication setting information” refers to the information which defines communication sessions for the service communication setting or the maintenance communication setting which is set in the network diagram.
The service communication setting check unit 23 extracts the setting information for the service communications from the communication setting information stored in the design information DB 14 and checks for any setting error therein. The maintenance communication setting check unit 24 extracts the setting information for the maintenance communications from the communication setting information stored in the design information DB 14 and checks for any setting error therein. The path search unit 25 performs a path search for the designated communication setting.
The design information modification unit 17 automatically modifies any setting error in the design information DB 14 when that setting error could be automatically modified.
The check result output unit 18 , for example, outputs the check result of the basic information from the basic information check unit 15 or the check result of the communication setting information from the communication setting information check unit 16 .
The failure simulation unit 19 checks if the service communications can be provided which is set with the service communication setting, with a pseudo-failure being caused for each device in the network diagram one by one, and extracts a device which could be of non-redundant configuration (namely, a device which is a critical point (hereafter referred to as a “CP”)). The term “CP” refers to a point where a significant task trouble would occur when the device in question fails.
The CP information output unit 20 writes the information on the device which is a CP extracted by the failure simulation unit 19 to the design information DB 14 and outputs the information to the screen of the input/output device 2 via the network diagram creation processing unit 10 .
The filter setting information creation unit 26 creates filter setting information to be set for each device based on the design information DB 14 .
The embodiment of the present invention will now be described in detail below with reference to FIG. 3 to FIG. 31 .
FIG. 3 is a diagram illustrating the creation of a network diagram. In FIG. 3 , a window 51 of the network diagram is opened on the display screen 50 of the input/output device 2 . The designer creates the network diagram on the window 51 of the network diagram by operating the network diagram creation processing unit 10 via the input/output device 2 . An example will be described below with respect to a mouse which has a left button and a right button, as a pointing device for creating the network diagram. Other pointing devices may be used to achieve the same operation.
The components of each device to be used in the network are listed in a window 52 of the device stencil. The components to be used in setting communications are listed in a window 53 of the communication setting stencil. The designer selects a component of the device to be placed in the network diagram from the window 52 of the device stencil, and places each component of the selected device in the network diagram by drag and drop operation. This network diagram creation method based on the CAD application is as used in the conventional methods.
The present invention can place each device being placed and connected to each other on the network diagram, and also can describe and set the service session and the maintenance session on the network diagram, while differentiating the two types of sessions.
FIG. 4 is a diagram illustrating operational procedures for communication setting. First, the designer selects a communication component which the designer wants to set from the window 53 of the communication setting stencil with a mouse click (operational procedure 1 ). Then, the designer clicks the mouse on a part corresponding to the starting point of the communications in the network diagram (operational procedure 2 ). Lastly, the designer clicks the mouse on a part of corresponding to the ending point of the communications in the network diagram (operational procedure 3 ). Consequently, an arrow is displayed on the network diagram which points from the starting point to the ending point of the communications, and its communication setting information is stored in memory as design diagram data. The above-described operation method is merely an example, and other method may be used, for example, a method may be used where the end point of a communication object, which has been dragged and dropped on the network diagram, may be connected to the starting point/the ending point on the device by drag operation.
FIG. 5 is a diagram illustrating a property setting. The designer clicks the right mouse button (referred to as “right-click”) on a device or communications on the network diagram for which he/she wants to perform the property setting, and then opens a window 54 of the property setting. The designer can set each attribute of the device or communications on the window 54 of the property setting.
The attributes information for each device and communications may be defined in advance for each component of the device stencil and the communication stencil. The defined information may be kept as component attributes information in an attributes file (not shown) which is managed by the network diagram creation processing unit 10 . In the window 54 of the property setting, with respect to an attributes item which has been defined in advance for that attributes file, attributes information which is read from the attributes file is embedded in that attributes item as a default value. Therefore, the designer needs only to input attributes information specific to the individual devices or communications from the window 54 of the property setting, for example, minimal attributes information such as the host name or address information of the server.
FIG. 6 is a diagram illustrating an example of the designed network diagram. For example, the network diagram as illustrated in FIG. 6 is created by the network diagram creation processing unit 10 with input information which is input by the designer of a network system via the input/output device 2 . The design diagram data which defines the created network diagram is stored in the design diagram data storage unit 12 .
In the network diagram illustrated in FIG. 6 , the designed network system is connected to the external Internet 101 through a FireWall 103 having a router function via a connection cable 102 .
A dns server 107 , a web server 111 and a db server 123 are service-type servers for providing a service to an external customer. An admin server 117 is a maintenance-type server for performing the maintenance management such as for checking or making setting changes for each device which constitutes the network system. An admin server 117 needs to be set in a way that, in particular, external ingress communications would not be permitted.
The FireWall 103 , dns server 107 , web server 111 , admin server 117 and db server 123 are each equipped with two network interface cards 104 , 105 , 108 , 109 , 112 , 113 , 118 , 119 , 124 and 125 , respectively. Herein below, the network interface cards are referred to as “NICs”.
The NICs 105 , 109 , 113 and 118 are each connected to a Hub 115 in the Global-net via connection cables 106 , 110 , 114 and 116 , respectively. The NICs 119 and 124 are each connected to a Hub 121 in the Private-net via connection cables 120 and 122 , respectively.
The IP address of the Global-net is “164.77.53.0/27”. The lower five bits in IP addresses of NICs 105 , 109 , 113 and 118 , which are connected to the Global-net, are each “0.1”, “0.15”, “0.15”, “0.5”, respectively.
The IP address of the Private-net is “192.168.100.0/24”. The lower eight bits in IP addresses of NICs 119 and 124 , which are connected to the Private-net, are each “0.5”, “0.10”, respectively. The information for these IP addresses is set in the window 54 of the property setting as described in FIG. 5 .
Further, the designer describes the necessary communication settings for operating the network system by operating the network diagram creation processing unit 10 via the input/output device 2 . The communication setting described in the network diagram is stored in the design diagram data storage unit 12 as the design diagram data. The necessary communication settings for the network system which are described by the designer on the network diagram enables the network design processing device 1 to check for any setting error in the network diagram and to automatically modify setting errors.
In the embodiment of the present invention, the two types of communication settings, namely, the service communication setting and the maintenance communication setting may be described distinctly on the network diagram. In the network diagram of FIG. 6 , an arrow with dotted line represents the service communication setting, and another arrow with dashed-two dotted line represents the maintenance communication setting. In this way, by describing the service communication setting and the maintenance communication setting distinctly on the network diagram, various processing may be facilitated as described below.
In the network diagram of FIG. 6 , a communication setting 126 is described as the service communication setting from the NIC 113 of the web server 111 to the NIC 124 of the db server 123 . For the communication setting 126 , TCP is set as the protocol.
Additionally, also described in the network diagram of FIG. 6 are a communication setting 127 from the NIC 118 of the admin server 117 to the NIC 113 of the web server 111 , a communication setting 128 from the NIC 118 of the admin server 117 to the NIC 109 of the dns server 107 , and a communication setting 129 from the NIC 119 of the admin server 117 to the NIC 124 of the db server 123 as the maintenance communication settings. For the communication settings 127 , 128 and 129 , ICMP and TCP are set as the protocols. The information for these protocols are also input as the attributes information by right-clicking the communication setting indicated by an arrow in the network diagram and opening the window 54 of the property setting.
FIG. 7 is a diagram illustrating an example of each object ID given to each component. Each component of the graphic elements included in the network diagram is automatically given an object ID by the network diagram creation processing unit 10 . The object ID uniquely identifies each component. In FIG. 7 , each numeral in ellipse represents the object ID which is given to the component. The object ID is used in the design data management for the individual components within the network design processing device 1 .
Although only one line of service communication settings and three lines of maintenance communication settings are described in the network diagram illustrated in FIG. 6 , the actually designed network system would include a huge number of lines of communication settings. Therefore, once these communication settings are displayed on the network diagram at a time, congestion of arrows indicating the communication settings would occur, resulting in the indistinguishable communication settings on the screen.
Thus, the network design processing device 1 is provided a function which enables selection with a simple operation and display of only specific communication settings of these communication settings.
FIGS. 8A and 8B are diagrams illustrating an exemplary selective communication display. FIG. 8A illustrates an example of a window 55 of the communication display menu. In the window 55 of the communication display menu, the designer selects which communication setting is to be displayed on the network diagram. The menu item includes “DISPLAY ALL COMMUNICATIONS”, “DISPLAY SERVICE COMMUNICATIONS”, “DISPLAY MAINTENANCE COMMUNICATIONS”, “DISPLAY SERVER DESIGNATION”, “DISPLAY PROTOCOL DESIGNATION” and so on.
The default value is “DISPLAY ALL COMMUNICATIONS”, which displays all of the defined communication settings on the network diagram. When “DISPLAY SERVICE COMMUNICATIONS” is selected, then only the service communication settings are selectively displayed on the screen. When “DISPLAY MAINTENANCE COMMUNICATIONS” is selected, then only the maintenance communication settings are selectively displayed on the screen. When “DISPLAY SERVER DESIGNATION” is selected, then on the screen displayed are only the communication settings which have the server selected as the starting point or the ending point by clicking a left button on a mouse. In “DISPLAY SERVER DESIGNATION”, it is also possible to select only the starting point or the ending point, or both of the starting point and the ending point. When “DISPLAY PROTOCOL DESIGNATION” is selected, then a protocol designation selection screen is displayed and only the communication settings are selectively displayed on the screen which use the protocol selected from that screen. In this case, although a specific server may be designated with “DISPLAY SERVER DESIGNATION”, a specific network device may also be designated instead of servers.
A plurality of these menu items may be selected at a time. When more than one item is selected at a time, the appropriate communication settings would be selected in AND condition and displayed on the screen. For example, when “DISPLAY SERVICE COMMUNICATIONS” and “DISPLAY PROTOCOL DESIGNATION” are selected, and when TCP is selected as the protocol, then only those of the service communication settings, which use TCP protocol, would be selectively displayed on the screen.
In the example in FIG. 8A , “DISPLAY SERVER DESIGNATION” is selected. Then, when the designer selects the web server 111 as the designation server by the designer through mouse click, the selective communication display control unit 11 instructs the network diagram creation processing unit 10 to display only the communication settings in which the web server 111 is set as the starting point or the ending point of the input/output on the network diagram. Consequently, as illustrated in FIG. 8B , the network diagram creation processing unit 10 selects and displays only the communication settings in which the web server 111 is set as the starting point or the ending point of the input/output on the network diagram, while hiding other communication settings.
Since a significant amount of communications are involved in providing actual services, when all of the communication settings are displayed on the network diagram at once, a large number of design mistakes could occur due to the oversight and so on. Therefore, displaying only the communications related to the device selected as stated above, only the incoming communications to the selected device, or only the outgoing communications from the selected device enables clearer sight of the network diagram and reduction of setting errors made by the designer.
In order to achieve such selective display of communication settings in a prompt and simple way, the network diagram creation processing unit 10 includes a layer designation/display function and a function for automatically generating layers and automatically placing objects on the layers.
For a specific description, fixed layers are prepared for each communication protocol and for each communication type as needed, which layers are registered to the appropriate communication protocol and communication type layers when inserting the communication settings into the diagram. Further, one or two dynamic layers are prepared.
Upon receipt of the instruction to display some of the communication settings, the network diagram creation processing unit 10 uses the above-mentioned layers for providing display as follows.
A) When the condition does not include inputting/outputting to a specific server, then the network diagram creation processing unit 10 displays a plurality of fixed layers which meet the instructed condition in “OR” condition.
B) When the condition includes inputting/outputting to a specific server, then, firstly, the network diagram creation processing unit 10 selects a communication setting, which meets the condition, from those having that server as the starting point/the ending point, and registers the communication setting to the non-displayed dynamic layer. Secondly, the network diagram creation processing unit 10 displays the processed dynamic layer with all of the currently displayed layers hidden.
The reason for preparing the fixed layers is that it could lead to the delay of operation to check all of the communication settings in the network diagram at each display time. On the other hand, the reason for preparing the dynamic layers is that it could result in the increase in number of layers used with a large number of servers to display the communication settings focusing on a specific server using the fixed layers. Additionally, provided that a communication setting is displayed focusing on a specific server, the operation delay would not occur even if the appropriate communication settings were checked in each case. Since the number of servers to be focused would be relatively small.
FIG. 9 is a flowchart of a selective communication display process. The communication settings made by the designer is registered in the fixed layer. When a server is designated in the selective communication display, the appropriate communication setting is registered in the dynamic layer.
Part (A) of FIG. 9 is a flowchart of the communication settings register processing to the fixed layer. When the designer performs the communication setting being performed by the designer during the creation of the network diagram, the network diagram creation processing unit 10 registers the input communication settings to the fixed layers of the communication protocol and the communication type corresponding to the set communications in step S 10 , and inserts the communications into the network diagram.
For example, when the communication protocols have three types of TCP, UDP and ICMP, and the communication types have two types of the service communications and the maintenance communications, six fixed layers (2*3=6) are prepared. At this moment, for example, when the communication setting 126 of FIG. 6 is set to the network diagram, the communication setting 126 is registered to the fixed layer with TCP as the communication protocol and the service communications as the communication type.
Part (B) of FIG. 9 is a flowchart of the selective communication display process. When the selective communication display control unit 11 receives a selective communication display instruction by the designer, the network diagram creation processing unit 10 hides all of the communication layers being displayed on the network diagram in step S 11 . A determination is made as to whether the selective communication display request from the designer is “DISPLAY SERVER DESIGNATION” in step S 12 . As a result, when it is determined that the request is not “DISPLAY SERVER DESIGNATION”, then all of the fixed layers are selected which are corresponding to the designation in the request from the designer for the selective communication display and displayed on the network diagram in “OR” in step S 13 , and the process terminates.
In the step S 12 , when the request from the designer for the selective communication display is determined to be “DISPLAY SERVER DESIGNATION”, the designation of the server by the designer is input in step S 14 . The registration for all of the communication settings in the dynamic layer is canceled in step S 15 . The communication settings for the designation server are registered to the dynamic layer in step S 16 . The dynamic layer is displayed on the network diagram in step S 17 , and the process terminates.
For example, as illustrated in FIG. 8B , when the web server 111 is designated as the designation server, the communication settings 126 and 127 , which are the communication settings for the web server 111 , are registered to the dynamic layer and displayed on the network diagram.
FIG. 10 is a flowchart of a check process on the network diagram in accordance with this embodiment. The network diagram, which is created by the network diagram creation processing unit 10 , is processed by the network design processing device 1 as follows.
When the design diagram data analysis unit 13 receives the request for checking the network diagram and extracting the design information from the designer in step S 20 , the design diagram data analysis unit 13 analyzes the design diagram data of the network diagram which is saved in the design diagram data storage unit 12 , and extracts the design information necessary for the network management. The extracted design information is stored in the design information DB 14 in a predetermined format, which manages the information for each network device including the configuration information and the connection information in step S 21 .
The design information check is performed in three steps as described below, namely, the basic information check for the configuration of the individual devices, the service communication setting information check for the service communication settings, and the maintenance communication setting information check for the maintenance communication settings.
The basic information check unit 15 performs the basic information check process on the design information stored in the design information DB 14 in step S 22 , and checks for any setting error in the basic information in step S 23 . The basic information check performed by the basic information check unit 15 is a common technique which has been conventionally employed in the network design support system, for example, for checking the configuration and connection of the devices. In this technique, for example, those situations are detected as “SETTING ERROR EXISTS” where a device exists which is not connected to the network, or the same IP addresses are assigned to a plurality of devices. When a setting error exists in the basic information, it is determined whether the setting error can be modified automatically in step S 24 . When the setting error can be modified automatically, the design information modification unit 17 performs the automatic modification process on the setting error in step S 25 , and the process returns to the basic information check process of the step S 22 . The automatic modification is performed in such a way that when the same IP addresses are assigned to a plurality of devices, one of the IP addresses is automatically changed to a non-assigned IP address. The result of the automatic modification is acknowledged by the designer and then written to the design information DB 14 . When the automatic modification is impossible, then the error information output processing is performed in step S 26 , and the process terminates.
In step S 23 , when no setting error exists in the basic information, the communication setting information check unit 16 performs the service communication setting information check process on the design information which is stored in the design information DB 14 in step S 27 , and checks for any setting error in the service communication setting information in step S 28 . When a setting error exists in the service communication setting information, the error information indicating the setting error is stored in step S 29 .
The communication setting information check unit 16 further performs the maintenance communication setting information check process on the design information which is stored in the design information DB 14 in step S 30 , and checks for any setting error in the maintenance communication setting information in step S 31 . When a setting error exists in the maintenance communication setting information, the error information indicating the setting error is stored in step S 32 .
The communication setting information check unit 16 determines whether the error information exists which indicates the setting error in the service communication setting information or the maintenance communication setting information in step S 33 . When the error information exists, the communication setting information check unit 16 performs the error information output process in step S 26 , and the process terminates.
When no setting error exists in all of the basic information, the service communication setting information, and the maintenance communication setting information, then the failure simulation unit 19 performs the CP extraction process based on the failure simulation for extracting a critical point in step S 34 . The CP information output unit 20 performs the CP information output process for outputting the critical point information which is obtained from the CP extraction process in step S 35 , and the process terminates.
FIG. 11 illustrates an example of a device table to be stored in the design information DB 14 . FIG. 12 illustrates an example of a connection information table to be stored in the design information DB 14 . FIG. 13 illustrates an example of a session table to be stored in the design information DB 14 .
In step S 21 described above, the device table 56 of FIG. 11 and the communication information table 57 of FIG. 12 are created by the basic information extraction unit 21 illustrated in FIG. 2 from the design diagram data of the network diagram which is stored in the design diagram data storage unit 12 , and then stored in the design information DB 14 . Additionally, the session table 58 of FIG. 13 is created by the communication setting information extraction unit 22 illustrated in FIG. 2 , and then stored in the design information DB 14 .
The object IDs in the device table 56 , the communication information table 57 , and the session table 58 represent identifiers for uniquely identifying each device or communications placed in the network diagram. These object IDs in each table correspond to the object IDs illustrated in FIG. 7 , which were automatically given by the network diagram creation processing unit 10 .
Each name in the device table 56 represents a name which is given to that device. Any name may be set as long as the name can be recognized by the designer or operator of the network system. Each type represents information for the type of that device. Each address represents an IP address which is set for that device.
Each child object ID and each parent object ID represent each object ID for a device which has a parent-child relationship with the device in question. For example, a dns server 107 with an object ID “ 7 ” contains a NIC 108 with an object ID “ 8 ” and a NIC 109 with an object ID “ 9 ”. Therefore, “ 8 ” and “ 9 ” are set as the child object ID of the dns server 107 with the object ID “ 7 ”. On the other hand, “ 7 ” is set as the parent object ID of the NIC 108 with the object ID “ 8 ” and the NIC 109 with the object ID “ 9 ”.
These kinds of information are mainly extracted from the attributes information which is set as a property for each device, or obtained by analyzing the hierarchical structure of a group (for example, grouped objects as server itself+NIC+NIC) of components (for example, a server itself, a NIC and so on) which represent each device.
When an error exists for the device setting, such error information is inserted in the status information. Additionally, the status information is used in the CP extraction process by the failure simulation unit 19 . When a pseudo-failure is caused for a device, the failure simulation unit 19 sets the pseudo-failure status for the status information of the device.
The object IDs in the communication information table 57 of FIG. 12 represent identifiers for uniquely identifying each connection cable placed in the network diagram. The object Ids correspond to the object IDs illustrated in FIG. 7 as described above. Each type represents information for the type of the cable. Each end-point object ID represents an object ID for each device that corresponds to the opposite ends of the connection cable.
When an error exists for the connection cable setting, such error information is inserted in the status information. Additionally, the status information is used in the CP extraction process by the failure simulation unit 19 . When a pseudo-failure is caused for a connection cable, the failure simulation unit 19 sets the pseudo-failure status for the status information of the connection cable.
The object IDs in the session table 58 of FIG. 13 represent identifiers for uniquely identifying the set communications, which correspond to the object IDs illustrated in FIG. 7 as described above. Each type represents the information which indicates whether the communications are the service communications or the maintenance communications.
Each protocol represent a protocol which is used in the communications. When a plurality of protocols is set for a single communication, a plurality of record is generated on the session table 58 . For example, since the two types of protocols, namely, TCP and ICMP are set in the communication setting 127 , the communication setting 128 and the communication setting 129 , with respect to each communication setting with the object IDs “ 27 ”, “ 28 ” and “ 29 ”, two records of each setting are generated in the session table 58 of FIG. 13 .
The starting point ID and the ending point ID represent the object IDs for the devices which are corresponding to the starting points or the ending points of their communications. For example, since the communication setting 126 with an object ID “ 26 ” corresponds to the NIC 113 which has the web server 111 as the starting point and to the NIC 124 which has the db server 123 as the ending point, an object ID “ 13 ” of the NIC 113 is set as the starting point ID, and an object ID “ 24 ” of the NIC 124 is set as the ending point ID.
Other information includes, for example, more specific settings for the protocol used in the communications. For example, when the protocol is TCP, then, the source port number and the destination port number and so on will be set. When an error exists for the communication setting, such error information is inserted in the status information.
FIG. 14 illustrates an exemplary basic information check result. When the basic information check unit 15 finds a setting error in the basic information of the design information DB 14 , then the check result output unit 18 outputs the error information on the network diagram.
As can be seen from the device table 56 of FIG. 11 , in the network diagram of FIG. 6 , the addresses for the dns server 107 and the web server 111 are set in an overlapping fashion. Consequently, a setting error is detected at the basic information check process. At this moment, as illustrated in FIG. 14 , an error object is inserted on the network diagram, indicating that the addresses for the dns server 107 and the web server 111 are overlapping. In the example illustrated in FIG. 14 , the error object is displayed in the form of a dotted frame and error massages indicating the appropriate portions.
FIG. 15 illustrates an exemplary network diagram after address modification. In this case, the lower five bits of the address for the NIC 113 on the web server 111 are modified from “0.15” to “0.8”. This eliminates all setting errors due to the address overlapping.
This address modification may be performed by the designer through the property setting of the NIC 113 from the network diagram. If possible, setting errors may be automatically modified by the design information modification unit 17 . For example, since the range of IP addresses which can be easily set may be known from the network address of the network to which the device is connected, for example, the setting error due to the address overlapping as described above may also be automatically modified by the design information modification unit 17 . When the automatic modification is possible, the process may proceed to the next process without prompting the designer a setting error modification. This enables reduction of person-hours for the design by the designer.
FIGS. 16 and 17 are flowcharts of a service communication setting check process according to the embodiment of the present invention. The service communication setting check unit 23 checks whether or not the service communications are possible for the service communication settings in the session table 58 with reference to the device table 56 and the communication information table 57 . Additionally, for example, the service communication setting check unit 23 performs detection for a server which has no communications with the outside world (the Internet 101 ) or the other internal servers.
First, the service communication setting check unit 23 stores service communications in which an external device is the starting point of the service, in a matrix “EXTERNAL” in step S 40 . The service communication setting check unit 23 determines whether the matrix “EXTERNAL” is empty in step S 41 . When the matrix “EXTERNAL” is empty, an error object of “NO EXTERNAL COMMUNICATION” is inserted into all servers in step S 42 .
Then, the service communication setting check unit 23 selects one server from the device table 56 in step S 43 , and determines whether the selected server has the starting point or the ending point of the service communications in step S 44 . When the selected server has the starting point or the ending point of the service communications, the communications in which the selected server is set as the starting point is stored in a matrix “INTERNAL” in step S 45 .
When the server selected in step S 44 does not have the starting point or the ending point of the service communications, then the service communication setting check unit 23 determines whether the selected server has the starting point of the maintenance communications in step S 46 . When the selected server does not have the starting point of the maintenance communications, an error object of “NO COMMUNICATION” is inserted into the selected server in step S 47 .
The service communication setting check unit 23 determines whether a non-selected server exists in the device table 56 in step S 48 . When a non-selected server exists, the process returns to the process of step S 43 . Thereafter, the processes of steps S 43 through S 48 are repeated until there does not exist a non-selected server in the device table 56 .
When there does not exist a non-selected server in the device table 56 , the service communication setting check unit 23 selects one communication from the matrix “EXTERNAL” in step S 49 . The path search unit 25 performs a path search process with respect to the selected communications in step S 50 , and the service communication setting check unit 23 determines whether a path is detected in step S 51 . The path search unit 25 is to perform a process to detect the presence of a communication route capable of the selected communication, and the detail of the process will be described below.
When a path is detected, the communications in which a server at the ending point of the selected communication is set as the starting point is moved from the matrix “INTERNAL” to the matrix “EXTERNAL” in step S 52 . When the pass is not detected, an error object of “COMMUNICATION IMPOSSIBLE” is inserted into the selected communication in step S 53 .
A determination is made as to whether the matrix “EXTERNAL” is empty in step S 54 . When the matrix “EXTERNAL” is not empty, the process returns to the process of the step S 49 . Thereafter, the processes of steps S 49 through S 54 are repeated until the matrix “EXTERNAL” becomes empty.
When the matrix “EXTERNAL” becomes empty, then the service communication setting check unit 23 determines whether the matrix “INTERNAL” is empty in step S 55 . When the matrix “INTERNAL” is not empty, the service communication setting check unit 23 selects one communication from the matrix “INTERNAL” in step S 56 . An error object of “NO EXTERNAL COMMUNICATION” is inserted into the servers which are corresponding to the starting point and the ending point of the selected communication, respectively in step S 57 .
Additionally, the path search unit 25 performs the path search process with respect to the selected communication in step S 58 , and the service communication setting check unit 23 determines whether a path is detected in step S 59 . When a path is not detected, the service communication setting check unit 23 inserts an error object of “COMMUNICATION IMPOSSIBLE” into the selected communication in step S 60 .
The process of steps S 55 through S 60 are repeated until the matrix “INTERNAL” becomes empty, and the process terminates when the matrix becomes empty.
FIG. 18 is a flowchart of a path search process according to the embodiment of the present invention. The path search process by the path search unit 25 takes the starting point ID and the ending point ID of the communication setting as input, and the presence or absence of paths (communication routes) as output.
The path search unit 25 retrieves an end-point object ID in the communication information table 57 by the starting point ID of the designated communications in step S 70 , and obtains the end-point object ID of a connection target. All of the end-point object IDs of the connection target, which are obtained from the retrieval, are stored in a matrix “SEARCH”, while giving a “stored” mark to the status information section of the appropriate object in the device table 56 in step S 71 . For example, since the communication setting 126 with an object ID “ 26 ” in the session table 58 of FIG. 13 has the starting point ID “ 13 ”, when an end-point object ID is retrieved in the communication information table 57 by the starting point ID, there will be obtained “ 15 ” as the end-point object ID of the connection target.
A determination is made as to whether the matrix “SEARCH” is empty in step S 72 . When the matrix “SEARCH” is empty, a return code of “PATH NOT FOUND” is returned to the source node from which the search request was sent, and the process terminates.
When the matrix “SEARCH” is not empty in step S 72 , one ID is selected from the matrix “SEARCH” in step S 73 . A determination is made as to whether the selected ID is the ending point ID in step S 74 . When the selected ID is the ending point ID, a return code of “PATH FOUND” is returned to the source node from which the search request was sent, and the process terminates.
When the selected ID is not the ending point ID in step S 74 , a determination is made as to whether the ID is a Hub ID in the device table 56 in step S 75 . When the selected ID is the Hub ID, a determination is made as to whether the object has a “stored” mark in the device table 56 in step S 76 . When the object has a “stored” mark, the process returns to the process of step S 72 . When the object does not have a “stored” mark, an end-point object ID of the communication information table 57 is retrieved by the ID in step S 77 , and the end-point object ID of the connection target is obtained. All of the end-point object IDs of the connection target, which are obtained from the retrieval, are stored in the matrix “SEARCH” in step S 78 , and the process returns to the process of the step S 72 .
When the selected ID is not the Hub ID in the step S 75 , a determination is made as to whether a device corresponding to a parent of another device which has the Hub ID as its object ID is a Router in the device table 56 in step S 79 . When a device corresponding to a parent of another device which has the Hub ID as its object ID is a Router, all of the other child object IDs of the Router, which have not yet been given a “stored” mark, are obtained from the device table 56 , and these IDs are stored in the matrix “SEARCH” in step S 80 . Then the process returns to the process of the step S 72 .
FIG. 19 illustrates an example of a service communication setting check result. When the service communication setting check unit 23 found a setting error in the service communication setting in the design information DB 14 , then the check result output unit 18 outputs such error information on the network diagram.
As illustrated in the network diagram of FIG. 19 , since there is no device for Routing between the Global-net and the Private-net, the communications between the web server 111 and the db server 123 is impossible. In this respect, the admin server 117 is a maintenance server, which has no routing function for the service communications. Therefore, a setting error is detected at the service communication setting check process, and an error object is inserted on the network diagram indicating that the communications is impossible between the web server 111 and the db server 123 .
Additionally, as illustrated in the network diagram of FIG. 19 , there is no service communications set for the dns server 107 . Therefore, a setting error is detected at the service communication setting check process, and the error object is inserted on the network diagram indicating the absence of the service communication setting for the dns server 107 .
Although there is no service communication set for the admin server 117 , a setting error would not be detected at the service communication setting check process which indicates the absence of the service communication setting, since the admin server 117 would be determined to be a device for maintenance as the admin server 117 corresponds to the starting point of the maintenance communication setting. Such an effect is obtained by managing the service communication setting and the maintenance communication setting in a distinct manner.
FIG. 20 is a flowchart of a maintenance communication setting check process according to the embodiment of the present invention. The maintenance communication setting check unit 24 selects one device such as a server or a Router from the device table 56 in step S 90 , and determines whether the selected device has the starting point or the ending point of the maintenance communications in step S 91 . When the selected device does not have the starting point or the ending point of the maintenance communications, then an error object of “NO MAINTENANCE COMMUNICATION” is inserted into the selected device in step S 92 .
When the device selected at the step S 91 has the starting point or the ending point of the maintenance communications, then one maintenance communication in which the selected device selected as the starting point is selected in step S 93 . The path search unit 25 performs the path search process with respect to the selected communication in step S 94 , and the maintenance communication setting check unit 24 determines whether a path is detected in step S 95 . When the path is not detected, an error object of “COMMUNICATION IMPOSSIBLE” is inserted into the selected device in step S 96 .
A determination is made as to whether there exists any non-selected maintenance communication in which the selected device is set as the starting point in step S 97 . When any non-selected maintenance communication exists, the process returns to the process of the step S 93 . Thereafter, the processes of steps S 93 through S 97 are repeated until there does not exist a non-selected maintenance communication which has the selected device as the starting point.
When there does not exist non-selected maintenance communication in which the selected device is set as the starting point, a determination is made as to whether there exists a non-selected device in the device table 56 in step S 98 . When there is a non-selected device, the process returns to the process of the step S 90 . Thereafter, the processes of steps S 90 through S 98 are repeated until not being a non-selected device in the device table 56 , and the process terminates when there is not a non-selected device in the device table 56 .
FIG. 21 illustrates an example of maintenance communication setting check result. When the maintenance communication setting check unit 24 finds a setting error in the maintenance communication setting of the design information DB 14 , then the check result output unit 18 outputs error information on the network diagram.
As illustrated in the network diagram of FIG. 21 , there is no maintenance communication set for the NICs 104 and 105 on the FireWall 103 . Therefore, a setting error is detected at the maintenance communication setting check process, and an error object is inserted on the network diagram indicating the absence of the maintenance communication setting for the FireWall 103 .
The operational monitoring for a computer system is fundamentally performed on all NICs for all devices which can be monitored. Therefore, when there is a device which provides no communications for the operational monitoring, then a setting error is detected at the maintenance communication setting check process.
FIG. 22 illustrates an exemplary network diagram after Router placement. This network diagram is created by the designer modifying the setting errors indicated in FIGS. 19 and 20 via the input from the input/output device 2 .
First, in order to deal with the setting errors indicating that the communication is impossible between the web server 111 and the db server 123 , a Router 131 is provided between the Global-net and the Private-net. A NIC 132 and a Hub 115 on the side of the Global-net are connected via a connection cable 130 , while a NIC 133 and a Hub 121 on the side of the Private-net are connected via a connection cable 134 . The lower five bits of the address for the NIC 132 on the side of the Global-net are set to “0.2”, while the lower eight bits of the address for the NIC 133 on the side of the Private-net are set to “0.2”. Due to the presence of the Router 131 , the communications would be possible between a device on the side of the Global-net and another device on the side of the Private-net.
Then, in order to deal with the setting errors indicating the absence of the service communication setting for the dns server 107 , a service communication setting 135 from the external Internet 101 to the dns server 107 is set on the network diagram.
Additionally, in order to deal with the setting errors indicating the absence of the maintenance communication setting for the FireWall 103 , a maintenance communication setting 136 connected from the NIC 118 on the admin server 117 to the NIC 104 on the FireWall 103 , and a maintenance communication setting 137 connected from the NIC 118 on the admin server 117 to the NIC 105 on the FireWall 103 , are set on the network diagram.
Further, in association with the placement of the Router 131 , a maintenance communication setting 138 connected from the NIC 118 on the admin server 117 to the NIC 132 on the Router 131 and a maintenance communication setting 139 connected from the NIC 119 on the admin server 117 to the NIC 133 on the Router 131 , are also set on the network diagram.
FIG. 23 illustrates an example of state where a device is detected which is isolated from an external communication. As illustrated in FIG. 23 , there exists other error information indicating that an external communication has not arrived by the service communication setting check process, in addition to the error information illustrated in FIGS. 19 and 21 .
As illustrated in the network diagram of FIG. 23 , although the service communication setting 135 is made from the external Internet 101 to the dns server 107 , there is no service communication setting from the outside world for the web server 111 . Therefore, a setting error is detected at the service communication setting check process, and an error object, which indicates the absence of the service communication setting for the web server 111 from the outside world, is inserted on the network diagram.
Similarly, since there is no service communication setting for the db server 123 from the outside world, an error object, which indicates the absence of the service communication setting for the db server 123 from the outside world, is inserted on the network diagram. The service communications from the web server 111 is set for the db server 123 . However, since there is no service communication setting for the web server 111 from the outside world, there is even no indirect service communication setting.
Generally, the service task is achieved by performing some process in response to the request from the outside world. In the embodiment of the present invention, the outside world in this service task refers to the Internet 101 . Since any device at which no communications arrives from the outside world is considered to provide no contribution to the service task, a setting error will likely exist in the device. Therefore, by checking the connectivity of each device with the external communication at the time of the service communication setting check, an indication is made for the server to which the external communication has not arrived, which is then alerted to the designer. This enables the designer to find a setting error indicating the presence of devices which provides no contribution to the service task.
FIG. 24 illustrates an example of the network diagram to which an external communication is added. With respect to the NIC 113 on the web server 111 , for which the non-arrival of the external communication is indicated as shown in FIG. 23 , the network diagram is modified by the designer, and the service communication setting 140 from the Internet 101 is set. Since the external communication is set for the web server 111 , it is also set for the db server 123 indirectly, for which the service the communication setting 126 from the web server 111 is set.
As described above, the detection of setting errors by checking the basic information check, the service communication setting check, and the maintenance communication setting check enables the modification of the network diagram as initially designed in FIG. 6 , which includes a mass of setting errors to the network diagram as designed in FIG. 24 , which includes no setting error.
FIG. 25 illustrates an example of generic filter setting information. For security setting, a restriction needs to be provided for each device regarding which packet can be passed or transmitted or received. The filter setting information 59 of FIG. 25 is an example of definition for the filter setting for each device. The filter setting information creation unit 26 illustrated in FIG. 2 creates the filter information for performing the filtering setting for each device from each design information stored in the design information DB 14 . At this moment, since the filtering program is different for different venders of the devices, the filter setting information creation unit 26 creates generic filter setting information 59 with information independent from the device type as the example illustrated in FIG. 25 .
The filter setting information 59 of FIG. 25 is an example of the setting information as filters automatically generated from the design information DB 14 , each of which are created as a generic file in text respectively, namely, Router_generalFilters.txt, which is a file for filter setting with respect to the Router 131 , web_generalFilters.txt, which is a file for filter setting for the web server 111 , and db_generalFilters.txt, which is a file for filter setting for the db server 123 .
By converting the format of the generic filter setting information 59 which is created by the filter setting information creation unit 26 using conversion program depending on the vendors of the devices, a filter setting file can be obtained which is corresponding to the filtering program for the appropriate devices.
FIG. 26 illustrates an example of a generic filter setting file obtained from conversion of the generic filter setting information to an output format for specific filtering program. For example, db_generalFilters.txt, which is a file for filter setting to the db server 123 in the generic filter setting information 59 of FIG. 25 , is rewritten by an output filter for the filtering program of the db server 123 to db_filters.txt, which is a filter setting file 60 in a format for the filtering program of the db server 123 as illustrated in FIG. 26 .
When the db server 123 is constructed or set according to the network diagram actually created, the filter setting of the db server 123 is completed by only positioning a filter setting file 60 as illustrated in FIG. 26 in a predetermined place. This would significantly reduce the load on the operators.
FIG. 27 is a flowchart of a failure simulation process according to the embodiment of the present invention. The failure simulation unit 19 performs the service communication setting check process with the status of each device virtually in fault successively to extract a device which could be a critical point (CP) with less redundancy.
The failure simulation unit 19 selects one device from the device table 56 in step S 100 . In order to virtually make the selected device in a fault state, the status information of the selected device is set to “FAILED” in the device table 56 in step S 101 .
In this state, the path search process is performed for each service communication setting in step S 102 , and a determination is made as to whether there exists a service communication setting of “PATH NOT FOUND” in step S 103 . Although the path search process is performed in the operational logic as described in FIG. 18 , when the status information of the device is “FAILED” in search for each device, the device would be processed as if it were not exist. When there exists a service communication setting of “PATH NOT FOUND”, the CP information output unit 20 gives a “CP” mark to the selected device on the network diagram in step S 104 .
A determination is made as to whether there exists a non-selected device in the device table 56 in step S 105 . When there exists a non-selected device, the process returns to the process of step S 100 . Thereafter, the processes of steps S 100 through S 105 are repeated until there does not exist a non-selected device in the device table 56 .
FIG. 28 illustrates an example of an operation of the failure simulation. In the example of FIG. 28 , the Router 131 is virtually made to a fault state. In this state, a path search is performed for each service communication setting. At this moment, since the communication setting 126 turns to “PATH NOT FOUND” due to the fault state of the Router 131 , the Router 131 would be determined to be a device corresponding to the critical point. In this respect, it is not necessary to display the information indicating, namely, “FAILED” or “PATH NOT FOUND” on the window 51 of the network diagram during the fault simulation.
FIG. 29 illustrates an example of the network diagram after the completion of the failure simulation. Any device, which is determined to be a critical point by the failure simulation process, is given a “CP” mark. In the network diagram of FIG. 29 , the “CP” mark is given to the FireWall 103 , the dns server 107 , the web server 111 , the db server 123 and the Router 131 . When the device with the “CP” mark fails when the network system is constructed according to the network diagram as illustrated in FIG. 29 , severe effects would be imposed on the service task.
Additionally, the maintenance communications generally needs to be set for each device independently, regardless of the redundant configuration. Therefore, it is not necessary to detect a critical point for the maintenance communications and the maintenance communications are ignored at the time of fault simulation.
FIG. 30 illustrates an example of the network diagram in which CPs are reduced by duplexing of FireWalls and Routers. In the network diagram of FIG. 30 , a FireWall 142 and a Router 147 are newly placed on the network diagram as compared to that of FIG. 29 . Upon the fault simulation performed again in this state, the “CP” marks are erased for the Router 131 and the FireWall 103 .
The dns server 107 , the web server 111 and the db server 123 still remain in the CP state, since they are not in the redundant configuration. However, since it is clearly illustrated on the network diagram that these devices could be “the device imposing significant effects due to their faults”, the network diagram as illustrated in FIG. 30 is expected to provide useful information for the subsequent design/construction operations or operational plan decision, even if the operation is continued for some reason with these devices left in the CP state.
Since the Routers 131 and 147 are both in the redundant configuration, a virtual address (VirtualAddress) is set for these Routers for recognizing two Routers as a whole, in addition to the actual addresses held by their NICs. In the example of FIG. 30 , the virtual address on the side of the Hub 115 is set to “164.77.53.4”, while the virtual address on the side of the Hub 121 is set to “192.168.100.4”. The virtual addresses are similarly set for the redundant configuration of the FireWalls 103 and 142 .
For the Routing setting for the web server 111 under these conditions, the address of the Router is automatically recognized as the virtual address of “164.77.53.4”, and a routing or filtering rule with such a setting is output as a network setting file. This is also the case with the network setting files of the db server 123 .
FIG. 31 illustrates an example of redundant configuration data. For the redundant configuration management, redundant configuration data 61 as in FIG. 31 is used which is an object for storing the parent-child relationships on the network. In the redundant configuration data 61 of FIG. 31 , the parent-child relationship between the virtual addresses (VirtualAddresses) and the NICs is set for the Routers and the FireWalls which are made in redundant configuration at FIG. 30 . For example, the suitable information may be obtained by using information for the parent of the redundant configuration data 61 at the time of filter setting information creation, or by traversing relationships from a parent to its child of the redundant configuration data 61 at the time of path search.
The network design processing device 1 illustrated in FIG. 1 may be realized by, for example, a server device and a client terminal. For example, by placing the input/output device 2 , the network diagram creation processing unit 10 , and the selective communication display control unit 11 illustrated in FIG. 1 in a plurality of client terminals, and the remaining parts on the server device, the design diagram data held by the server device in the design diagram data storage unit 12 may be shared by each client terminal, and the network design may be jointly performed by a plurality of designers who use each client terminal.
The above-mentioned processes at each step may be realized by a computer and software program, and such program may be stored in computer readable recording medium or provided through the network.
According to the present invention, in the network design, in particular, a support device for constructing a high-quality network system which eliminates setting errors or the setting oversight for the service communications and the maintenance communications and so on is realized. | In a network design processing device, a network drawing creation processing unit inputs the service communication setting information for business execution in a network system to be designed and the maintenance communication setting information for maintenance management of the network system, while differentiating two types of information on a network diagram, and displays the line joining the starting point and the ending point of communications in the network diagram in display modes different for the service communications and for the maintenance communications. The design diagram data expressing the network diagram inputted by the network diagram creation processing unit is stored in a design diagram data storage unit. Based on this, a design diagram analysis unit creates a design information DB. With reference to this design information database, a communication setting information check unit detects a setting error concerning the communication. | 6 |
BACKGROUND
[0001] The present disclosure generally relates to wind turbines, and more particularly, to a monitor for measuring stress in a wind turbine blade during operation of the wind turbine as well as to processes for monitoring stress in a wind turbine blade.
[0002] Wind turbines generally convert the mechanical energy captured by the rotating wind turbine blades into electrical energy using a generator. A wind turbine, like some other structures such as aircraft propellers, fans, and the like, includes blades configured for rotating about an axis. Typically, two or more blades are provided each coupled to a rotatable hub. Most turbines have either two or three blades. Wind blowing over the blades causes the blades to lift and rotate. During this conversion, the wind turbine blades can be exposed to relatively large and variable loads during their operation. Because wind is a natural force and cannot be controlled, the wind turbine must withstand exposure to varying wind conditions from no wind at all to winds in excess of 100 miles per hour.
[0003] Cyclic stresses can fatigue the blade, axle and bearing materials, and have been a cause of turbine failure for many years. Components that are subject to repeated bending, such as rotor blades, may eventually develop cracks that ultimately may make the component break. Current monitoring processes for measuring the stress applied to the wind turbine blades employ the use of strain gages. The strain gauges are typically flat electrical resistors that are glued onto the surface of the rotor blades being tested and are used to measure very accurately the bending and stretching behavior of the rotor blades. The measurement that results from the strain gauges can be continuously monitored on computers. Nonlinear variations in the pattern of bending may reveal damage to the rotor blade structure.
[0004] Other methods for monitoring blade fatigue include infrared analysis (also referred to as thermography). In these methods, infrared cameras are typically used to reveal local build-up of heat in the blade. The heat build-up may either indicate an area with structural dampening, i.e. an area where the blade designer has deliberately laid out fibers which convert the bending energy into heat in order to stabilize the blade, or it may indicate an area of delamination or an area which is moving toward the breaking point for the fibers. In this manner, catastrophic failure can be prevented.
[0005] Rotor blades are also tested for strength (and thus their ability to withstand extreme loads) by being bent once with a very large force. This test is made after the blades has been subject to fatigue testing, in order to verify the strength for a blade which has been in operation for a substantial amount of time.
[0006] Although the above noted monitoring processes are suitable for their intended use, they are generally complex in nature or cannot be implemented during actual operation of the wind turbine. Accordingly, it is desirable to have a relatively simple method for monitoring stress in the wind turbine blade so as to prevent the occurrence of catastrophic failures.
BRIEF SUMMARY
[0007] Disclosed herein are monitoring systems, wind turbine systems and processes for monitoring stress in a wind turbine blade. In one embodiment, the monitoring system for a wind turbine blade comprises a glass optical fiber embedded and/or on a surface of the wind turbine blade, the wind turbine blade comprising a composite material; an optical receiver in optical communication with an end of the optical glass fiber; and a transmitter in optical communication with an other end of the optical glass fiber.
[0008] The wind turbine system comprises a nacelle seated on a tower; a rotor rotatably coupled to the nacelle, the rotor comprising a central hub and at least one wind turbine blade attached thereto, wherein the at least one wind turbine blade is formed of a composite material and has a glass optical fiber embedded and/or on a surface of the wind turbine blade; an optical receiver in optical communication with an end of the optical glass fiber; and a transmitter in optical communication with an other end of the optical glass fiber.
[0009] A process for monitoring stress in a wind turbine blade of a wind turbine system comprises embedding and/or disposing an optical glass fiber on a surface of the wind turbine blade, wherein one end of the optical glass fiber is in optical communication with a light transmitter and an other end of the optical glass fiber is in optical communication with an optical receiver; transmitting light from the light transmitter through the optical glass fiber to the optical receiver; and monitoring a reduction or a loss in light transmission through the optical glass fiber.
[0010] The disclosure may be understood more readily by reference to the following detailed description of the various features of the disclosure and the examples included therein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Referring now to the figures wherein the like elements are numbered alike:
[0012] FIG. 1 schematically illustrates a sectional view of a turbine blade including an array of optical fibers coupled to a monitor;
[0013] FIG. 2 illustrates a sectional view of a rotor including a wind turbine blade having a plurality of optical fibers therein or thereon for monitoring the stress applied to the wind turbine blade during operation; and
[0014] FIG. 3 graphically illustrates tensile strength as a function of glass fiber diameter.
DETAILED DESCRIPTION
[0015] FIG. 1 illustrates an exemplary wind turbine generally designated by reference numeral 10 with which the present disclosure may be practiced. It is to be understood that the wind turbine has been simplified to illustrate only those components that are relevant to an understanding of the present disclosure. Those of ordinary skill in the art will recognize that other components may be required to produce an operational wind turbine 10 . However, because such components are well known in the art, and because they do not further aid in the understanding of the present disclosure, a detailed discussion of such components is not provided. It should also be understood that the wind turbine monitor and processes for monitoring stress in a wind turbine blade are nor intended to be limited to the particular wind turbine shown. The monitor and processes herein are generally applicable to monitoring turbine blades used in horizontal axis wind turbines, vertical axis turbines (also referred to as a Darrieus machine), and the like.
[0016] The wind turbine generally includes a tower 12 . The tower 12 is typically made from tubular steel as shown or is formed of a steel lattice network. Because wind speed increases with height, taller towers enable turbines to capture more energy and generate more electricity. A rotor 14 attaches to a nacelle 16 , which sits atop the tower 12 and generally includes a gearbox or a direct drive mechanism, low- and high-speed shafts, a generator, a controller, and a brake. A cover 18 protects the components inside the nacelle 16 .
[0017] The gearbox generally contains gears that connect the low-speed shaft to the high-speed shaft and increase the rotational speeds from about 30 to about 60 rotations per minute (rpm) to about 1,200 to about 1,500 rpm, which is the rotational speed required by most generators to produce electricity, although lower or higher speeds can be used. During operation, the high-speed shaft drives the generator whereas the low-speed shaft rotates as a function of rotor rotation. The controller generally starts up the machine at wind speeds of about 8 to 16 miles per hour (mph) and shuts off the machine at a higher speed to prevent overheating of the generator. The brake, which can be applied mechanically, electrically, or hydraulically to stop the rotor in emergencies, can be of a disc or drum brake design, an electromagnetic design, or the like.
[0018] For horizontal axis wind turbines, the nacelle 16 may further include a yaw drive that orients the nacelle so that the blades are substantially perpendicular to the prevailing wind. A wind direction sensor, e.g., a wind vane, may be included in and/or attached to the nacelle 16 to detect the wind direction. The wind sensor communicates with the yaw drive to orient the turbine properly with respect to the wind. Vertical axis turbine machines will not include a yaw drive.
[0019] FIG. 2 illustrates a partial sectional view of the rotor 14 and nacelle 16 . The rotor includes a hub 20 and one or more blades 22 extending from the hub 20 . The point of attachment of the blade 22 to the hub is generally referred to as the root 21 . The one or more of the wind turbine blades 22 include one or more glass optical fibers 24 disposed on or within the wind turbine blade 22 . The glass optical fiber 24 spans across a portion of the blade 22 that is to be monitored. An optical receiver 26 is in optical communication with one end 28 of the fiber and a light source 30 is in optical communication with other end 32 . In this manner, the integrity of the optical fiber can be monitored during operation of the wind turbine. In one embodiment, the ends 28 , 30 terminate at about the root 21 of the wind turbine blade. In still other embodiments, the ends terminate with the nacelle 16 . In still other embodiments the ends terminate at a location external to the blade and nacelle.
[0020] Light transmission through the optical fiber can be monitored to detect any changes thereto. Any changes in light transmission can be indicative of a break in the optical fiber. By varying the diameter for different glass optical fibers, an end user can estimate the maximum tensile load that can be applied to the blade. For example, if the glass optical fiber breaks during operation of the wind turbine, the breakage is an indication that the stress applied by the wind force exceeded the strength of the fiber. Since fibers of different diameters have breaking stresses that are a function of fiber diameter, these fibers can be used as indictors of blade overload.
[0021] The wind turbine blades 22 are usually made using a matrix of glass fiber mats, which are impregnated with a material such as polyester. The polyester is hardened after it has impregnated the glass fiber. Epoxy may be used instead of polyester. Likewise the basic matrix may be made wholly or partially from carbon fiber, which is a lighter, but costlier material with high strength. Wood-epoxy laminates are also being used for large rotor blades. The glass optical fibers 24 can be embedded within the matrix or may be applied to a blade surface after the wind turbine blade has been formed.
[0022] FIG. 3 graphically illustrates tensile strength of glass optical fibers a function of fiber diameter. It is observed and is widely known by those in the art that tensile strength rapidly increases as fiber diameter decreases. It can be expected that a similar relationship will be observed when the optical fiber is placed in the environment provided in the present disclosure, i.e., optical fibers embedded in and/or on the surface of the wind turbine blade. More importantly, because of this relationship, a range of fiber diameters can be embedded in and/or on the surface of the wind turbine blade to provide a tensile strength range to be monitored and correlated to the tensile strength of the wind turbine blade itself.
[0023] Several configurations of turbine wind blades including the glass optical fibers are contemplated herein. In one embodiment, at least a portion of the glass optical fibers spanning the wind turbine blade is formed of fibers having different diameters. In another embodiment, a single or multiple fibers of the same diameter are embedded and/or on a surface of the blade. In still another embodiment, an optical fiber having a variable diameter. For example, the diameter can increase or decrease from one end to the other end. In this embodiment, pulse propagation methods can be used with the monitoring system to determine the location of the break and correlate he location to the tensile strength associated with the fiber diameter at the break location. Of course, it should be noted that pulse propagation techniques could be used for any of the embodiments described here in to locate the position of the break. In this manner, the break location could be used the design of the wind turbine blade such that the optical fiber break location would be fortified in the design of the blade so as to increase the tensile strength.
[0024] The range of fiber diameters are not intended to be limited and will generally depend on the desired range of tensile strength to be measured. For the glass optical fibers, the diameter of the core can generally range between about 10 to about 600 microns, the cladding thickness can be between about 125 to about 630 microns, and that of the jacket, if present, varies between about 250 to about 1040 microns.
[0025] Each one of the optical glass fibers is in optical communication with the optical receiver on one end and a transmitter (light source) on the other end. In this manner, the loss or reduction of transmitted light in a fiber can be used to indicate breakage along the length of the optical fiber spanning a portion of the wind turbine blade. The loss or reduction of transmitted light infers the fiber's maximum tensile strength at the point of breakage was exceeded. Optionally, a bundle of several fibers can be used to bracket the value of the applied tensile strengths. The data thus generated can be combined with an understanding of the fracture energy and the details of the fiberglass reinforced composite fracture mechanism. Although this may lead to some correction of the data that was used to provide the graph in FIG. 3 , it will still be understood by those in the art that the basic approach to determining tensile strength at various points of the turbine blade will not change.
[0026] The optical receiver and/or light transmitter may be integrated into the nacelle 16 and/or may be located externally within or about the tower 12 . Data generated from the optical receiver can be processed using algorithm programmed by a computer (not shown), or the like. The optical receiver can be any available photodetector sensitive to the light transmitted from the light transmitter. For example, the optical receiver can be a photodiode responsive to radiation emitted from the light transmitter. A wind turbine system utilizing the monitoring system may further include a feedback loop with a controller for regulating operation of the wind turbine system.
[0027] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. | Wind turbine systems, monitoring systems, and processes for measuring stress in a wind turbine blade generally includes embedding and or disposing optical glass fibers on a surface of the wind turbine blade and monitoring light transmission through the optical glass fiber. A reduction or loss of transmission indicates that the tensile strength of the optical glass fiber has been exceeded, which directly correlates to the level of stress exposed to the wind turbine blade. | 5 |
[0001] This is a divisional application of U.S. non-provisional patent application Ser. No. 13/464,725 filed on May 4, 2012 the contents of which are hereby incorporated by reference, and for which the benefit of priority is claimed under 35 U.S.C. §§120 & 121. This application also claims the benefit of priority under 35 U.S.C. §120 to U.S. Provisional Patent Application No. 61/628,930, filed Nov. 8, 2011 the contents of which are hereby incorporated by reference, and to U.S. Provisional Patent Application No. 61/518,454, filed May 4, 2011 the contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to the art of brain mapping, and more specifically to a device and method for simulating the stimulation of brain areas and neural pathways in a user.
[0003] Knowledge of the human brain has increased substantially in recent years. Among the areas of greatest interest to scientists are brain mapping and connectomics. Brain mapping relates the physical structure of the brain to functional properties. This localization of function provides researchers with invaluable information about changes in the brain over time, such as changes due to disease, aging, or physical damage. Brain mapping allows correlation between physical changes and function, opening the door to new possibilities in understanding how disease, aging, injury, and other factors affect the brain physically and, thus, how they impact a person's functional qualities.
[0004] Broad functional localizations are well understood by science. For example, it is known that the frontal lobe encompasses thinking, planning, and central executive functions, as well as motor execution. The occipital lobe deals with visual perception and processing, among other things. The temporal lobe handles language functions, auditory perception, emotions, long-term memory, and so on. Although these broad functional categories are of use, scientists are increasingly looking at smaller areas of the brain to determine more specifically the functions that correspond to various physical structures. These endeavors allow scientists to answer increasingly specific questions about how stimuli, physical damage, and the like, to a given area of the brain may impact function.
[0005] Connectomics is the study of the specific connections between neurons in an intact brain. The goal is to produce a “wiring diagram” of the brain itself, allowing study of the multitude of individual pathways and connections therein. Complete wiring diagrams have been developed for relatively simple organisms, such as C. elegans. Increasingly, scientists are developing wiring diagrams for areas of the human brain.
[0006] Brain mapping and the study of the wiring of the brain provide a number of advantages. A more complete picture of the physical structure of the brain allows for greater and more detailed study of the organ. This may allow scientists to understand how humans and other organisms learn and adapt to the environment. Further, greater physical knowledge of the brain can lead to increased safety of neurosurgical procedures, with surgeons having a greater understanding of the effects of the surgery, as well as which portion of tissue to excise and which to leave intact. Further, many disease states have a structural basis in the brain and a greater understanding of brain structure and function can lead to new treatments of these disease states, as well as to methods of observing the efficacy of treatments.
[0007] An increased understanding of the structure and function of the brain is also useful to individuals in daily life. For example, the brain undertakes a complex series of behaviors in the formation of habits. First, a trigger event is identified by the brain and interpreted as a signal to enter an “automatic” mode, allowing a specific behavior state to unfold. The brain engages the routine that corresponds to the behavior and, finally, ascertains whether the behavior is rewarded, and therefore whether it is worthwhile as a habit. Habit-forming activities in the brain are based, at least in part, in the basal ganglia, which deal with emotion, memory, and pattern recognition. Decisions that transition from requiring active thought, which takes place in the prefrontal cortex, to habit, in the basal ganglia, free up processing power for other decision-making. The ability to recognize cues and triggers, the corresponding habit behaviors, and the rewards, are of great value in breaking habits. The conscious recognition of what occurs in the brain can lead to increased awareness of a habit, and thereby increase the likelihood that an individual will be able to successfully break the habit.
[0008] Brain mapping and awareness of structure and function in the brain may also allow individuals to affect the physical properties of the brain. Neuroscientists have observed, for example, that habitual meditation can strengthen circuits in the brain relating to maintaining concentration or generating empathy. Certain less desirable habits are effectively replaced with new, desirable habits. Awareness of the brain and its functions can provide a benefit to individuals, even if the benefit stems only from the perceived connection to the structure in the brain, and that perception subsequently influences individual behavior.
[0009] Finally, brain structure and function is of interest to many in the general public because of a fascination with how the brain works. Such individuals enjoy learning about the various connections and structures in the brain, and how these connections and structures impact their lives.
BRIEF SUMMARY OF THE INVENTION
[0010] One aspect of the present invention provides a method of simulating brain activity and neural pathways in a user. The method includes the step of providing a networked server for access by a user of the invention, using a general purpose computer. A database is provided in communication with the networked server. The general purpose computer carries out a step of detecting a movement of the user, the movement then being communicated to the networked server, which associates that movement with a certain set of data in the database relating to predetermined simulated neural activity. The simulated neural activity associated with the user's movement is communicated to the user.
[0011] In another aspect of the invention, at least one interface attachment is provided to be worn by the user. The interface attachment is in communication with the general purpose computer, and the simulated neural activity is communicated to the user via the interface attachment.
[0012] In another aspect of the invention, the simulated neural activity is communicated to the user by displaying the simulated neural activity on the screen of a general purpose computer. The simulated neural activity is associated with at least a portion of the user's body.
[0013] In another aspect of the invention, input is received from the user relating to the simulated neural activity. The user can cause the display of new simulated neural pathways, or the blocking of existing simulated neural pathways, based on the user's input to the system.
[0014] In another aspect of the invention, a photograph of the user is received via the general purpose computer and transmitted to the networked server. The simulation of neural activity is displayed to the user as associated with at least a portion of the user's body derived from the photograph.
[0015] In another aspect of the invention, the interface attachment is a sleeve, a head piece, or a combination of these.
[0016] In another aspect of the invention, a device is provided, the device including an interface attachment sized and shaped to be worn by the user, a stimulator attached to the interface attachment for providing a stimulus to the user, and a data link attached to the interface attachment for transmitting signals to, and receiving signals from, the general purpose computer.
[0017] In another aspect of the invention, the stimulator is a light, a speaker, a device for imparting an electric shock to a user, or a combination of these.
[0018] In another aspect of the invention, the data link is a USB cable, an Ethernet cable, a wireless communications device, or a combination of these.
[0019] In another aspect of the invention, the device includes a plurality of stimulators including a plurality of lights along an exterior surface of the interface attachment. The stimulators are adapted to display patterns of stimulation according to signals receive by the interface attachment via the data link
[0020] In another aspect of the invention, a method of simulating brain and neurological activity includes providing a networked server for access with a general purpose computer, providing a database in communication with the networked server, accepting a variable from a user, correlating the variable with at least one datum in the database, displaying a simulated image of a portion of the human nervous system on the general purpose computer, determining the portion of the human nervous system impacted by the variable, and animating the portion of the human nervous system determined to be impacted by the variable.
[0021] In another aspect of the invention, the variable accepted from the user may be a movement, the name or chemical structure or formula of a drug, or information relating to thoughts, emotions, habits, and the like.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0022] FIG. 1 is a schematic illustration of a system according to the present invention.
[0023] FIG. 2 illustrates one exemplary embodiment of an interface attachment according to the teachings of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] It should be noted that some embodiments of the present invention relate to a computing environment, including, but not limited to a web or internet based computing environment. In such embodiments, computing systems for use with the present invention may include any type of computer system, including a general purpose computer, based on a microprocessor, a mainframe computer, a digital signal processor, a portable computing device, a personal organizer, a device controller, or a computational engine within another device. Suitable computer systems include, but are not limited to, personal computers, laptops, tablets, and hand-held phones. For purposes of this writing, the word “general purpose computer” will be used to refer to each of the aforementioned type of device.
[0025] As used herein, the word “network” can refer to any type of wired or wireless communication channel capable of coupling two or more computing nodes. Examples include, but are not limited to, local area networks, wide area networks, or a combination of the two. Exemplary networks include the Internet and the Word Wide Web.
[0026] In some embodiments of the present invention, a web server may be utilized. Web servers may include any computational node including a mechanism for servicing requests from a client for computational and/or data storage resources. A web server can generally include any system that can host web pages, web sites, web-based applications, or server-side portions of client-server applications.
[0027] Embodiments of the present invention may also incorporate a browser. As used herein, the word “browser” includes any application that can display web pages, such as, for example, a web browser. Furthermore, the word “browser” can generally include any system that can interact with web pages be provided using any suitable programming language. Examples of programming languages suitable for use in providing server-side functionality includes, but it not limited to, ASP, Java, Perl, PHP, Python, Ruby, .NET, and combinations of these, web sites, web-based applications, or client-server applications. Embodiments of the present invention wherein aspects of the invention run in a web browser may be developed using any suitable programming language. Examples of such languages include, but are not limited to, Asynchronous JavaScript (Ajax), Flash, JavaScript, Microsoft Silverlight, HTML, HTMLS, CSS3, and combinations of these.
[0028] Data relating to the present invention may be stored on any non-volatile storage system, including, but not limited to, Magnetic, optical, and magneto-optical storage devices, as well as storage devices based on flash memory and/or battery backed up memory. Data so stored in a database may be distributed across any network used in conjunction with the present invention. Any suitable programming language may be used for managing data in databases associated with the present invention. Examples of such languages include, but are not limited to, Microsoft SQL Server, MySQL, Apache Derby, Oracle, and combinations of these.
[0029] Embodiments of the present invention using web-based functionality are preferably secure in order to protect the data of a user of the present system. Security may be provided by, for example, using the Secure Socket Layer (SSL) protocol, which provides for encryption of data transmitted across a network. Web connections for exchange of data preferably employ HTIP Secure (HTIPS), which adds a layer of encryption to communication via the HTIP protocol.
[0030] Although as noted above, embodiments of the present invention may be designed to be provided to a user via a web browser, it is contemplated that the functionality of the present invention may be instead provided by a program that is downloaded or otherwise loaded onto a computer system and installed thereon. Such programs may be written in any suitable language, and may be provided for any computer platform, including Windows, Mac OS, iOS, Android, Linux, BSD, Unix, WebOS, and other platforms. Such programs may utilize the internet to communicate with one or more databases used in association with the present invention, or may communicate with databases via a secure link provided solely for that purpose. In addition, it is contemplated that the present invention may be implemented with some combination of web-based service and functionality provided by a computer program installed onto a user's local device.
[0031] One aspect of the present invention provides a simulated neural pathway allowing a user to correlate actions and behaviors to the simulated pathway. The simulated neural pathway may be provided via a general purpose computer, being displayed on a screen or monitor associated therewith, and may be provided via a network such as the Internet, or via data contained on a local storage medium. The user of the present invention preferably utilizes an interface device associated with the general purpose computer via any suitable connection, including via a USB connection, Bluetooth, or over a wired or wireless network. Regardless of the type of structure used for communication, this aspect of the present invention may be referred to generally by use of the term “data link.” The interface device may indicate activity in a given area of the body, or may provide a stimulus to a given area of the body, or both.
[0032] Data for the simulated neural pathway may be stored on any suitable storage medium and is preferably displayed graphically in a manner readily understood by a user of the present device. For example, the computer display utilized may display the image of a human brain, areas of which may be highlighted using color or other suitable indicia to indicate that a given area of the brain is engaged by the user. For example, when a user raises an arm, the portion of the brain that controls the motor function related to raising that arm may be highlighted on the screen. This provides the user with a visual perception of brain function corresponding to the action taken, and allows the brain to make a correlation between the two. The computer display of the brain, with color or other indicia mapped to an area of the brain corresponding to a given action, can assist the user in repeatedly engaging the same part of the brain. It should be understood that this is true even if the area of the brain displayed on the computer display is not the precise portion of the brain actually involved in the action.
[0033] Turning to FIG. 1 , the interrelations between various components of one embodiment of the present invention is provided. User 12 utilizes a general purpose computer 14 (or, in other embodiments, a mobile device, tablet, or other suitable computing device) programmed to provide the functionality of the present invention, or to access a web server for providing the functionality of the present invention. Information flows both from user 12 to general purpose computer 14 , and from general purpose computer 14 to user 12 . General purpose computer 14 provides images, text, and other information to user 12 as a result of commands or requests entered by user 12 . User 12 may then respond to the information provided by issuing additional commands or requests, initiating new tasks, closing the web browser or other program, or the like. As will be discussed below, in embodiments of the present invention wherein user 12 wears an interface device associated with the present invention, general purpose computer 14 also directs information, such as commands, to the interface device, causing a predetermined response by the interface device.
[0034] The interface device of the present invention preferably includes a component worn on a portion of the body of the user of the present invention. This component is able to sense a movement or action on the part of the user and provide a signal to the computer, which in turn provides a corresponding indication on the computer screen to indicate the area of the brain involved in the action. In some embodiments of the invention, the interface device may include a simple sleeve or other structure that slips over a portion of the body, the sleeve or other structure including sensors that are able to register the presence, speed, and directional movement of a user's action. It should be understood, however, that an interface device worn on the body is not required in all embodiments of the present invention. In some embodiments, the interface device may be physically separate from the user, such as when a camera or other device is used. The camera may be used by the present system to identify body movements using technology known in the art, and those body movements may cause a corresponding highlighting of a specific area of the simulated brain shown on the computer monitor.
[0035] FIG. 2 provides one embodiment of an interface device of the present invention in the form of sleeve 20 . Sleeve 20 slides over an arm of user 12 , preferably engaging the arm snugly so that sensors within sleeve 20 can better detect movement of the arm by user 12 , as well as to better distinguish various types of movement of the arm by user 12 . Sleeve 20 preferably includes a plurality of light-emitting diodes (LEDs) that light up in response to movements by user 12 . The LEDs may be arrayed in set paths, such that a single line of LEDs light up in response to a given movement of the arm, thus allowing user 12 to associate in her mind a certain pattern of LEDs with a particular movement. Optionally, the LEDs may also light of flash in various patterns, each pattern corresponding to a given movement of the arm of user 12 . These patterns may also be associated in the mind of user 12 with a given arm movement. Further, in some embodiments of the invention, speakers associated with general purpose computer 14 may emit distinctive sounds corresponding to a given movement of the arm of user 12 , as well as a pattern of LEDs, thereby engaging additional areas of the brain of user 12 in an attempt to associate the various stimuli with the movement. As also shown in FIG. 2 , it is preferred that sleeve 20 include a cord 22 for connecting to a USB port 24 of a computing device. It is contemplated, however, that any suitable method of communication between sleeve 20 and the computing device may be used, including wireless methods of communication.
[0036] In addition to the sleeve 20 described above, and other embodiments of an interface attachment described herein, it is contemplated that one embodiment of an interface attachment can extend from a finger of the use to the head of the user, creating an simulated neurological pathways extending over that same area. The interface attachment may include a portion extending over a finger of the user, the portion secured with a Velcro strap or other suitable fastener. Similar straps of fasteners may be used to secure portions of the interface attachment to the forearm and upper arm of the user. The interface attachment may then secure at or near the neck or upper body of the user, and may again extend onto or around the head, where it is also fastened in place. Stimulators may be provided at various points along the length of the interface attachment in order to allow a simulated transmission of stimuli that are meant to simulate a neurological pathway, the path of a drug or medicament, and the like.
[0037] As described above, the interface device of the present invention communicates with the computer system in a unidirectional manner. When the interface device senses movement, for example, a signal is sent to the computer implementing the present invention, and the computer system highlights a portion of the simulated brain onscreen corresponding to the signal received from the interface device. It is contemplated, however, that the interface device may work bi-directionally, receiving signals from the computer system as well as transmitting signals to the computer system. When receiving a signal from the computer system, the interface device may respond by performing some function. For example, one embodiment of the interface device may be provided with LEDs or other visual stimuli, as described with respect to sleeve 20 , above. Signals received from the computer system of the present invention may direct the interface device to light certain LEDs, such as LEDs 26 , or to engage other visual or auditory stimuli. For example, when the user of the present invention lifts an arm, the interface device may send a signal to the computer system indicating that an arm has been lifted. The computer system may then signal the device to light LEDs along the arm of the user. The user now has multiple stimuli to associate with the arm movement, and the brain can correlate those stimuli with that specific movement of the arm. It is contemplated that in some embodiments of the invention, the interface device may produce the visual or other stimuli on its own, without waiting to receive a signal from the computer system. Components of the present invention that provide stimuli to a user, whether visual, auditory, electric, or otherwise, may be referred to generally herein by the term “stimulator.”
[0038] The interface device may provide other stimuli in addition to, or in place of, visual stimuli. For example, the interface device may provide a vibration at a specific location on the user's body, or may provide a mild electric shock to a specific location on the user's body. In this way, the user involves additional senses in utilizing the present invention to simulate the functional localization of an act to a specific portion of the brain. In addition to visual stimuli from the brain map depicted on the computer display, the user's tactile senses may be engaged by vibration or electric shock to the appropriate area of the body. This use of additional senses can allow the brain to more quickly come to associate a movement or action with a specific region of the simulated brain. It should be noted, of course, that the interface device may employ any combination of visual, auditory, tactile, or other stimuli in order to aid the user in the creation of an association between a single action and engagement of specific loci of the functional brain.
[0039] In addition to singular stimuli, or combinations of localized stimuli, the present invention may provide a cycle of stimuli to impact many senses of the user and to create patterns that come to be recognized by the brain. For example, the interface device may include speakers or earphones, either as an integrated part of the interface device or as a separate component of the present invention. When an action is undertaken by a user, the present device may produce a sound played through the speaker or earphone of the device, and may also display a sequence of LEDs and/or produce localized vibrations or vibratory patterns along the body of the user. These patterns of visual, auditory, and tactile sensations may cycle, producing a reoccurrence of the stimuli as often as necessary or desired by the user. The brain of the user can begin to recognize complex patterns of stimuli and associate them with specific actions.
[0040] In addition to the interface device described above, the interface device of the present invention may include a series of ribbons or other flexible members extending from a device of the present invention to the body of a user thereof. The flexible members may be attached to the body of the user by use of adhesives or other suitable mechanism. The flexible members may also include a series of lights or other indicia that can be selectively engaged by the computer system of the present invention. The flexible members may be used to simulate a neural pathway, such as by placing the flexible member along an arm or other body part of the user. The flexible member can light up, or engage other selectively engageable indicia, along the body part of the user when that body part is actuated in some manner by the user. The flexible members may also impart vibration or mild electric shock along the path simulated by the flexible member, simulating the transmission of a signal along the simulated neural pathway.
[0041] In some embodiments of the present invention, the computer display may also provide an image of the user of the present invention, the image including a mirror image of the flexible members attached to the user's body, the flexible members in the computer-simulated image lighting or engaging other indicia corresponding to the lighting or indicia engaged in the flexible members located on the user's body. Thus, the user is provided with a holistic impression of the various stimuli associated with a given action, experiencing visual, tactile, and/or auditory feedback, or any combination of these, along with the ability to see an overall representation of the visual indicia along the flexible members located on the body. The computer display may also provide a detailed view of the internal neural pathways and wiring of the brain associated with a given action. Again, this imaging on the computer screen is simulated and intended to provide a point of reference to the user. This information mayor may not be representative of specific, actual physiological pathways in use, depending on whether the database used in conjunction with the present invention includes such information.
[0042] It is contemplated that one embodiment of the present invention is implemented via a web-based service accessible to users via the internet. In such embodiments of the invention a web site is provided where a user can order components of the present invention and/or create an account for use with the present invention. In some embodiments of the invention, the user may create a user account on the web site, creating a password for securely logging into a protected account. The user may select the actions and corresponding areas of the brain desired to be tracked, and may upload to the web serve a photo desired to be used in the display of simulated neural pathways superimposed on the image of the user. In other embodiments of the invention, the web site may simply provide a portal through which a user can order the components of the present invention for use on a local machine. A photograph or other representation of the user can be transmitted via mail, such as on a CD or other storage medium, and the resulting image with superimposed neural pathways can be provided to the user in the same manner, or can be made available via the web site. In other embodiments of the present invention, a web cam may be used to take a photograph of the user while using the present invention, the photograph then being uploaded directly to a web server utilized by a provider of the present invention.
[0043] The user, via the interface device and the computer display having the image of the user thereon, along with a simulated brain and/or neural pathways, can now suspend disbelief and allow himself to accept that he is connected to various areas of his own brain as simulated by the interface device and the onscreen image. The user can then undertake actions, such as movement, and allow his brain to absorb the pattern of interactions created and correlate the patterns with the action taken.
[0044] In addition to actions such as movement of a body part, a user of the present invention may associate certain thoughts, moods, and emotions with simulated neural pathways and with certain areas of the brain. For example, the user may choose to bind certain keys or key combinations to specific simulated pathways and structural areas of the simulated brain. These keys or key combinations may also be associated with given thoughts, moods, emotions, and the like. When the user experiences the thoughts, moods, or emotions desired to be tracked, the user can use the key or key combination to engage a series of auditory, visual, tactile, or other stimuli. The brain can then begin to associate the pattern of stimuli with the mood, thought, or emotion. A user can then reinforce positive mental images, feelings, and the like, particularly through the use of pleasant stimuli. In the same manner, negative thoughts, feelings, images, and the like can be disfavored, particularly through the use of negative stimuli. Even where the stimuli themselves are not positive or negative, the awareness created by the brain's association of the thoughts, moods, or emotions with certain simulated neural pathways or portions of the brain may be of value to the user.
[0045] In still other embodiments of the present invention, the invention is used to create a game for a user. In some of these embodiments of the invention, the computer display may provide an extremely close view of the simulated neural pathway at issue, allowing the user a visual representation as though the user is actually traveling along those pathways. The user may be given the option to create new pathways that were not previously in existence or to travel to areas of the brain locked by the initial programming of the system, representing areas of the brain previously inaccessible to the user. Thus, the user is able to symbolically forge new pathways in the brain, or to access those areas of the brain that were previously inaccessible. This symbolic achievement may aid the user in achieving certain goals with respect to the mind, such as enhanced awareness, or fighting undesirable habits or unwanted thoughts in the mind. The game provided by the present invention has no direct affect on the brain of the user, but can instead provide psychological motivation and positive reinforcement to the user. These can be useful in altering existing thought patterns, moods, emotions, and the like. Further, the present invention may allow the user to achieve a feeling or impression of external control of the brain, despite being aware of the simulated nature of the invention. This feeling of control can be empowering and can aid the user in addressing the unwanted actions, thoughts, moods, emotions, and the like being addressed with the present invention.
[0046] In some embodiments of the invention, it is contemplated that a web site provided by a provider of the present invention includes information relating to the functioning of the brain, brain activity, the effects of drugs and other medicaments on the brain and central nervous system, and the like. The information can be displayed to the user to provide education about various aspects of brain structure and function, as well as about neurological function in general. In embodiments of the present invention, an image of a brain may be superimposed over the image of the user, and as the user accesses information regarding the structure and function of the brain, locations on the superimposed image of the brain may be highlighted to indicate structural and functional aspects and relationships of the brain that correlate with the information the user is accessing.
[0047] The database associated with the web site of a provider of the present invention may also include detailed information on various psychoactive drugs and other medicaments. This information may also be utilized to provide textual and graphical information to a user of the present invention. When a given drug is selected by the user, the image of the superimposed, simulated brain may be highlighted to show the area of the brain impacted by use of the chosen drug. If more than one drug is chosen, different colored highlights may be used to distinguish the pathways and areas of activity of each drug. These pathways may be animated as well, showing a simulated depiction of the action of the drug in the body and it travels through areas of the brain, or as it leaves the brain and moves into other areas of the body. In embodiments of the invention wherein a picture of the user's body is also represented in the image provided onscreen, areas of the user's body may also be highlighted to show the simulated travel of a drug through the body, or the action of a drug at a particular region of the body.
[0048] In other embodiments of the invention, the user can, in a simulated fashion, trace the flow of neurological activity, or the activity of a drug, along the user's own body. The image onscreen may illustrate this through animation and highlighting, and the interface attachment worn by the user may engage a stimulator (as described above; for example, an LED, a device to generate a mild electric shock, and the like). The movement of the stimulus along the interface device can coincide with the animation of the path of a drug or neurological activity shown on the computer screen. The user can associate this simulated path of activity with a given thought or action which the user wishes to identify with a given pathway.
EXAMPLE
[0049] The following is an example of one game embodiment of the present invention. It should be noted that the following example is intended to be illustrative of the present invention and is not intended to be limiting.
[0050] In this game embodiment of the invention, the user wears an arm piece that is, in essence, a tubular sleeve that extends from the user's fingers to the base of the neck. The sleeve may also be attached to a ring, collar, or other structure that extends around a user's head. The sleeve and the structure extending around the user's head have electrical conductive properties, allowing varying levels of electrical stimulation to be imparted to the skin of the user. The sleeve and apparatus extending around the head may also include a vibration effect, allowing the user to experience localized vibrations from the device. A lighting system on the components of the invention correlates with the electrical shock and/or vibrational pathways of the device, allowing the user to visualize as well as feel stimuli from the components.
[0051] The user provides a photo of himself, either by upload via the internet or by sending an image, digital or otherwise, to a provider of the present system. The photo is used to produce a silhouette or largely transparent image of the user, onto which an image of the human brain and/or neural pathways is superimposed. The image so provided can be enlarged or animated to show all of the features selected by the user utilizing the present invention, and also to indicate the various neural pathways and regions of the brain, as well as the underlying functions of each.
[0052] Using the game aspect of the present invention, the user simulates a stimulus to an area of the brain, thereby creating an impression of use or engagement of that area of the brain. A mild electrical shock is provided along the sleeve and the structure extending around the head, creating a simulated nerve transmission that the user can feel. According to the visualization on the computer screen, the user can see the impulse traveling to the same area of the brain desired to be engaged. This can be seen on the computer screen as well as on the other components of the device actually worn by the user. Animations may be used to show stimulation to the area at issue, and to see the stimulation of positive responses in the brain.
[0053] The game aspect of the present invention may be incorporated into any game on the market in order to show positive responses to the brain when desired effects are achieved within the context of the game.
[0054] Another aspect of the invention makes available an external interactive brain system. In this embodiment of the invention, a robot or automaton is provided wearing an interface device on its body corresponding to an interface device worn by the user of the present invention. The interface device provided on the automaton can reproduce all of the properties seen by the user when using the present invention, as well as those images seen by the user when watching the computer screen. The robotic implementation of the present invention can be used to further enhance the perception that a certain region of the brain is being stimulated.
[0055] While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that based upon the teachings herein, that changes and modifications may be made without departing from this invention and its broader aspects. Therefore, the appended claims are to encompass within their scope all such changes and modifications as are within the true spirit and scope of the invention. | A method of simulating the activity of the human nervous system includes providing a networked server for access by a user of a general purpose computer, with a database having predetermined data on human nervous system activity being in communication with the networked server. User information is input into the general purpose computer which is correlated with data in the networked database to determine what part of the human nervous system is impacted by the user information input. The general purpose computer displays a simulated image of a portion of the human nervous system and animates the impacted part of the human nervous system determined in the correlation. | 6 |
RELATED APPLICATIONS
This application claims priority to Taiwan Application Serial Number 103110904, filed on Mar. 24, 2014, which is herein incorporated by reference.
BACKGROUND
1. Field of Invention
The present invention relates to a blue photosensitive resin composition for a color filter and a color filter formed by the blue photosensitive resin composition of liquid crystal display (LCD) device thereof. More particularly, the present invention relates a blue photosensitive resin composition for a color filter having excellent voltage holding ratio and contrast ratio.
2. Description of Related Art
With the upgrading technology and wider application of the liquid crystal display (LCD), the large LCD (for example, LC television) is under progressively developing. Typically, the National Television System Committee (NTSC) ratio of the color reproducibility of the desktop LCD is approximately 50% to 60%, while the NTSC ratio of the LC television is approximately 60% to 75%. Thus, when the components of the desktop LCD, for example, the LCD components and the backlight components (e.g., cold cathode fluorescent lamp; CCFL) being applied in the LC television, such LC television cannot meet the requirements on the color reproducibility of the LC television.
To make the LC television with a desired specification of the color reproducibility, when the backlight component of the desktop LCD is used, the film thickness or the pigment concentration of the blue filter portion of the color filter in the LC television must be increased. However, such practices will drastically eliminate the transmittance of the blue filter portion.
The Japanese patent publication No. H09-95638 discloses a blue photosensitive resin composition for a color filter, and the composition includes an alpha-copper phthalocyanine blue pigment, an epsilon-copper phthalocyanine, a photosensitive resin, a photo-initiator and a solvent. Besides, the Japanese patent publication No. H09-197663 also discloses a blue photosensitive resin composition for a color filter, and the composition includes a copper phthalocyanine blue pigment, an indanthrone blue pigment, a photosensitive resin, a photo-initiator and a solvent.
In the aforementioned two patents, the transmittance of the blue photosensitive resin composition is improved by using different kinds of blue pigments. However, due to the light scattering generated by the pigment particles having certain diameters, if the concentration of the pigment of the blue photosensitive resin is increased, the color filter having such blue photosensitive resin composition will result in decreased contrast ratio. Thus, the Japanese patent publication No. 2006-079012 discloses the combination of a light-absorbing pyrazole squarylium and a blue pigment (Pigment Blue; P.B.) 15:6, so as to enhance the contrast ratio of the color filter. However, the method easily causes less voltage holding ratio of the photosensitive resin composition, resulting in the defect of the retained image on the LCD screen.
Thus, the research of the invention in the technical field is aimed to enhance the voltage holding ratio and the contrast ratio of the LCD device for meeting the current requirements of the industry field.
SUMMARY
Therefore, an aspect of the present invention provides a blue photosensitive resin composition for a color filter. The blue photosensitive resin composition can enhance the voltage holding ratio and the contrast ratio of the color filter.
Another aspect of the present invention provides a method of producing a color filter, in which the aforementioned blue photosensitive resin composition for the color filter is employed to form a pixel layer.
A further aspect of the present invention provides a color filter produced by the aforementioned method.
A further aspect of the present invention provides a LCD device, which includes the aforementioned color filter.
According to the aforementioned aspects of the invention, a blue photosensitive resin composition for a color filter is provided, which comprises an organic pigment (A), a dye (B), an alkali-soluble resin (C), a compound having an ethylenically unsaturated group (D), a photo-initiator (E) and a solvent (F), all of which are described in detail as follows.
Blue Photosensitive Resin Composition
Organic Pigment (A)
The organic pigment (A) of the invention is a blue pigment. Preferably, the organic pigment (A) comprises a blue organic pigment mainly having a structure of copper phthalocyanine (A-1).
Blue Organic Pigment Mainly Having Structure of Copper Phthalocyanine (A-1)
The blue organic pigment mainly having the structure of copper phthalocyanine (A-1) includes but is not limited to C.I. Pigment blue 15:1 (C.I. PB15:1), C.I. Pigment blue 15:2 (C.I. PB15:2), C.I. Pigment blue 15:3 (C.I. PB15:3), C.I. Pigment blue 15:4 (C.I. PB15:4), C.I. Pigment blue 15:5 (C.I. PB15:5) or C.I. Pigment blue 15:6 (C.I. PB15:6). The blue organic pigment mainly having the structure of copper phthalocyanine (A-1) can be used alone or in a combination thereof.
Based on a total amount of the following alkali-soluble resin (C) as 100 parts by weight, an amount of the blue organic pigment mainly having the structure of copper phthalocyanine (A-1) is 20 parts by weight to 200 parts by weight, preferably 30 parts by weight to 180 parts by weight, and more preferably 40 parts by weight to 160 parts by weight.
When the organic pigment of the present invention (A) comprises the blue organic pigment mainly having the structure of copper phthalocyanine (A-1), the produced blue photosensitive resin composition can enhance the contrast ratio of the color filter.
Purple Organic Pigment (A-2)
In addition to the aforementioned blue organic pigment mainly having the structure of copper phthalocyanine (A-1), the organic pigment (A) can optionally include a purple organic pigment (A-2).
The purple organic pigment (A-2) can include but be not limited to C.I. Pigment purple 14 (C.I. PV14), C.I. Pigment purple 19 (C.I. PV19), C.I. Pigment purple 23 (C.I. PV23), C.I. Pigment purple 29 (C.I. PV29), C.I. Pigment purple 32 (C.I. PV32), C.I. Pigment purple 33 (C.I. PV33), C.I. Pigment purple 36 (C.I. PV36), C.I. Pigment purple 37 (C.I. PV37), C.I. Pigment purple 38 (C.I. PV38), C.I. Pigment purple 40 (C.I. PV40) or C.I. Pigment purple 50 (C.I. PV50). The aforementioned purple organic pigment (A-2) can be used alone or in a combination of two or more.
Based on the total amount of the alkali-soluble resin (C) as 100 parts by weight, an amount of the purple organic pigment (A-2) is 10 parts by weight to 100 parts by weight, preferably 15 parts by weight to 90 parts by weight, and more preferably 20 parts by weight to 80 parts by weight.
When the organic pigment (A) of the invention comprises the purple organic pigment (A-2), the produced blue photosensitive resin composition can further enhance the contrast ratio of the color filter.
Blue Pigment (A-3) Except from Blue Organic Pigment Mainly Having Structure of Copper Phthalocyanine (A-1)
The organic pigment (A) can optionally include the blue pigment (A-3) except from the blue organic pigment mainly having the structure of copper phthalocyanine (A-1). The blue pigment (A-3) can include but be not limited to C.I. Pigment blue 1, C.I. Pigment blue 21, C.I. Pigment blue 22, C.I. Pigment blue 60, C.I. Pigment blue 61 or C.I. Pigment blue 64. The aforementioned blue pigment (A-3) can be used alone or in a combination of two or more.
Green Pigment (A-4) Mainly Having Structure of Halogenated Phthalocyanine
For adjusting the chromaticity of the blue photosensitive resin composition, the organic pigment (A) can optionally include a green pigment mainly having a structure of halogenated phthalocyanine (A-4).
The green pigment mainly having the structure of halogenated phthalocyanine (A-4) can include but be not limited to C.I. Pigment green 07, C.I. Pigment green 36, C.I. Pigment green 37, C.I. Pigment green 42 or C.I. Pigment green 58. More preferably, the green pigment mainly having the structure of halogenated phthalocyanine (A-4) is C.I. Pigment green 07, C.I. Pigment green 36, C.I. Pigment green 37, C.I. Pigment green 42, C.I. Pigment green 58 or the combination thereof. The aforementioned green pigment mainly having the structure of halogenated phthalocyanine (A-4) can be used alone or in a combination of two or more.
Dye (B)
The dye (B) of the present invention is a red dye having a structure as the formula (I):
in the formula (I), the R 1 to the R 4 individually and independently represents a hydrogen atom, —R 6 , an aromatic hydroxyl group having 6 to 10 carbon atoms or the aromatic hydroxyl group having 6 to 10 carbon atoms substituted by a halogen atom, —R 6 , —OH, —OR 6 , —SO 3 − , —SO 3 H, —SO 3 M, —COOH, —COOR 6 , —SO 3 R 6 , —SO 2 NHR 8 or —SO 2 NR 8 R 9 ; the R 5 represents —SO 3 − , —SO 3 H, —SO 3 M, —COOH, —COOR 6 , —SO 3 R 6 , —SO 2 NHR 8 or —SO 2 NR 8 R 9 ; the X represents a halogen atom; and the a represents 0 or 1 and the b represents an integer of 0 to 5. When the b is 2 to 5, a plurality of the R 5 is the same or different from each other. The aforementioned R 6 , R 8 , R 9 and M are described as follows.
The aforementioned R 6 represents an alkyl group of 1 to 10 carbon atoms or the alkyl group of 1 to 10 carbon atoms substituted by a halogen atom, in which the —CH 2 — in the alkyl group of 1 to 10 carbon atoms or the alkyl group of 1 to 10 carbon atoms substituted by the halogen atom is unsubstituted or can be substituted by —O—, carbonyl group or —NR 7 —. The R 7 represents an alkyl group of 1 to 10 carbon atoms or the alkyl group of 1 to 10 carbon atoms substituted by a halogen atom.
The aforementioned R 8 and the R 9 independently and individually represents a linear or a branched alkyl group of 1 to 10 carbon atoms, a cycloalkyl group of 3 to 30 carbon atoms, or -Q. The Q represents an aromatic hydroxyl group of 6 to 10 carbon atoms, a heterocyclic aromatic group of 5 to 10 carbon atoms. Furthermore, the Q can also represent the aromatic hydroxyl group of 6 to 10 carbon atoms substituted by a halogen atom, —R 6 , —OH, —OR 6 , —NO 2 , —CH═CH 2 or —CH═CH—R 6 , or a heterocyclic aromatic group of 5 to 10 carbon atoms substituted by a halogen atom, —R 6 , —OH, —OR 6 , —NO 2 , —CH═CH 2 or —CH═CH—R 6 , in which the R 6 is defined as above.
When the R 8 and the R 9 independently and individually represents a linear or a branched alkyl group of 1 to 10 carbon atoms, or a cycloalkyl group of 3 to 30 carbon atoms, the hydrogen atom of the linear alkyl, branched alkyl or cycloalkyl group is unsubstituted or can be substituted by a substituent, in which the substituent is selected from the group consisting of a hydroxyl group, a halogen atom, -Q, —CH═CH 2 and —CH═CH—R 6 , and the Q and the R 6 are defined as above.
When the R 8 and the R 9 independently and individually represents a linear or a branched alkyl groups of 1 to 10 carbon atoms, or a cycloalkyl group of 3 to 30 carbon atoms, the —CH 2 — group in the linear alkyl, branched alkyl or cycloalkyl group is unsubstituted or can be substituted by —O—, carboxyl group or —NR 7 —. The R 7 is defined as above-mentioned.
The aforementioned R 6 and the R 9 can bound to form a heterocyclic group of 1 to 10 carbon atoms, in which a hydrogen atom in the heterocyclic group of 1 to 10 carbon atoms is unsubstituted or can be substituted by —R 6 , —OH or -Q, and the Q and the R 6 are defined as the above-mentioned description.
The aforementioned M represents potassium or sodium.
Preferably, the aforementioned R 6 can be methyl, ethyl, propyl, isopropyl, butyl, isobutyl, pentyl, isopentyl, neopentyl, cyclopentyl, hexyl, cyclohexyl, heptyl, cycloheptyl, octyl, cyclooctyl, 2-ethylhexyl, nonyl, decyl, tricyclo(5.3.0.0 3,10 ) decyl, methoxy propyl, hexyloxy propyl, 2-ethyl hexyloxy propyl, methoxy hexyl or epoxy propyl group.
Among the aforementioned R 1 to R 4 , the aromatic hydroxyl group of 6 to 10 carbon atoms can preferably be a benzene group or a naphthalene group.
Among the aforementioned R 1 to R 5 , the —SO 3 R 6 can be methylsulfonyl, ethylsulfonyl, hexylsulfonyl or decylsulfonyl group.
Among the aforementioned R 1 to R 5 , the —COOR 6 can be methoxycarbonyl, ethoxycarbonyl, propoxycarbonyl, isopropoxycarbonyl, butoxycarbonyl, isobutoxycarbonyl, pentyloxycarbonyl, isopentyloxycarbonyl, neopentyloxycarbonyl, cyclopentyloxycarbonyl, hexyloxycarbonyl, cyclohexyloxycarbonyl, heptyloxycarbonyl, cycloheptyloxycarbonyl, octyloxycarbonyl, cyclooctyloxycarbonyl, 2-ethylhexyloxycarbonyl, nonyloxycarbonyl, decyloxycarbonyl, tricyclo[5.3.0.0 3,10 ]decylcarbonyl, methoxypropoxycarbonyl, hexyloxypropoxycarbonyl, 2-ethylhexyloxypropoxycarbonyl or methoxyhexyloxycarbonyl group.
Among the aforementioned R 1 to R 5 , the —SO 2 NHR 8 can be sulfamoyl, methylsulfamoyl, ethylsulfamoyl, propylsulfamoyl, isopropylsulfamoyl, butylsulfamoyl, isobutylsulfamoyl, pentylsulfamoyl, isopentylsulfamoyl, neopentylsulfamoyl, cyclopentylsulfamoyl, hexylsulfamoyl, cyclohexylsulfamoyl, heptylsulfamoyl, cycloheptylsulfamoyl, octylsulfamoyl, cyclooctylsulfamoyl, 2-ethylhexylsulfamoyl, nonylsulfamoyl, decylsulfamoyl, tricyco[5.3.0.0 3,10 ]decylsulfamoyl, methoxypropylsulfamoyl, hexyloxypropylsulfamoyl, 2-ethylhexyloxypropylsulfamoyl, methoxyhexylsulfamoyl, epoxypropylsulfamoyl, 1,5-dimethylhexylsulfamoyl, propoxypropylsulfamoyl, isopropoxypropylsulfamoyl, 3-phenyl-1-methylpropylsulfamoyl,
The aforementioned R a represents an alkyl group of 1 to 3 carbon atoms, an alkoxy group of 1 to 3 carbon atoms, the alkyl group of 1 to 3 carbon atoms substituted by a halogen atom, or the alkoxy group of 1 to 3 carbon atoms substituted by a halogen atom.
The aforementioned —SO 2 NR 8 R 9 can preferably be
The R a is defined as above rather than being mentioned repetitively.
The dye (B) is preferably a red dye having a structure as the formula (I-1):
in the formula (I-1), the R 11 to the R 14 individually and independently represents a hydrogen atom, —R 6 , an aromatic hydroxyl group having 6 to 10 carbon atoms or the aromatic hydroxyl group having 6 to 10 carbon atoms substituted by a halogen atom, —R 6 , —OH, —OR 6 , —SO 3 − , —SO 3 H, —SO 3 Na, —COOH, —COOR 6 , —SO 3 R 6 , —SO 2 NHR 8 or —SO 2 NR 8 R 9 , in which the R 6 is defined as the aforementioned description; the R 15 represents a hydrogen atom, —SO 3 − , —SO 3 H, —SO 2 NHR 8 or —SO 2 NR 8 R 9 , and the R 16 represents —SO 3 − , —SO 3 H, —SO 2 NHR 8 or —SO 2 NR 8 R 9 , in which the R 8 and the R 9 are defined as the above-mentioned description; the X 1 represents a halogen atom; and the a 1 represents 0 or 1.
The dye (B) is preferably a red dye having a structure as the formula (I-2):
in the formula (I-2), the R 21 to the R 24 individually and independently represents a hydrogen atom, an aromatic hydroxyl group having 6 to 10 carbon atoms or the aromatic hydroxyl group having 6 to 10 carbon atoms substituted by a halogen atom, —R 26 , —OH, —OR 26 , —SO 3 − , —SO 3 H, —SO 3 Na, —COOH, —COOR 26 , —SO 3 R 26 or —SO 2 NHR 28 ; the R 25 represents —SO 3 − , —SO 3 Na, —COOH, —COOR 26 , —SO 3 H or —SO 2 NHR 28 ; the b 1 represents an integer of 0 to 5, and when the b 1 is 2 to 5, a plurality of the R 25 is the same or different from each other; the X 2 represents a halogen atom; and the a 2 represents 0 or 1.
The aforementioned R 26 represents the alkyl group of 1 to 10 carbon atoms, or the alkyl group of 1 to 10 carbon atoms substituted by the halogen atom or —OR 27 , in which the R 27 represents the alkyl group of 1 to 10 carbon atoms.
The aforementioned R 28 represents a hydrogen atom, —R 26 , —COOR 26 , an aromatic hydrocarbon group of 6 to 10 carbon atoms, or the aromatic hydrocarbon group of 6 to 10 carbon atoms substituted by —R 26 or —OR 26 .
The dye (B) is preferably a red dye having a structure as the formula (I-3):
in the formula (I-3), the R 31 and the R 32 individually and independently represents a phenyl group or the phenyl group substituted by a halogen atom, —R 26 , —OR 26 , —COOR 26 , —SO 3 R 26 or —SO 2 NHR 28 ; the R 33 represents —SO 3 − or —SO 2 NHR 26 ; the R 34 represents a hydrogen atom, —SO 3 − or —SO 2 NHR 28 ; the X 3 represents a halogen atom; and the a 3 represents 0 or 1.
The aforementioned R 26 represents the alkyl group of 1 to 10 carbon atoms, or the alkyl group of 1 to 10 carbon atoms substituted by a halogen atom or —OR 27 , in which the R 27 represents the alkyl group of 1 to 10 carbon atoms.
The aforementioned R 28 represents a hydrogen atom, —R 26 , —COOR 26 , an aromatic hydrocarbon group of 6 to 10 carbon atoms or an aromatic hydrocarbon group of 6 to 10 carbon atoms substituted by —R 26 or —OR 26 , in which R 26 is defined as the above-mentioned description rather than being mentioned repetitively.
The dye (B) is preferably a red dye having a structure as the formula (I-4):
in the formula (I-4), the R 41 and the R 42 individually and independently represents a phenyl group or the phenyl group substituted by —R 26 or —SO 2 NHR 28 ; the R 43 represents —SO 3 − or —SO 2 NHR 28 ; the X 4 represents a halogen atom; the a 4 represents 0 or 1; and the R 26 and the R 28 are defined as the above-mentioned description rather than being mentioned repetitively.
The example of dye (B) can include but be not limited to the formula (I-5) to the formula (I-35) as follows:
in the formula (I-5), the R b and the R c individually and independently represents a hydrogen atom, —SO 3 − , COOH or —SO 2 NHR 81 , in which the R 81 represents 2-ethylhexyl; and the X and the a are defined as above rather than being mentioned repetitively.
in the formula (I-6), the R d represents a hydrogen atom, —SO 3 − , COOH or —SO 2 NHR 81 , in which the R 81 represents 2-ethylhexyl; and the X and the a are defined as above rather than being mentioned repetitively.
in the formula (I-7), the R d represents a hydrogen atom, —SO 3 − , COOH or —SO 2 NHR 81 , in which the R 81 represents 2-ethylhexyl; and the X and the a are defined as the above-mentioned description rather than being mentioned repetitively.
in the formula (I-8), the R e , R f and R g individually and independently represents —SO 3 − , —SO 3 Na or —SO 2 NHR 81 , in which the R 81 represents 2-ethylhexyl group.
in the formula (I-9), the R e , R f , and R g individually and independently represents —SO 3 − , —SO 3 Na or —SO 2 NHR 81 , in which the R 81 represents 2-ethylhexyl group.
in the formula (I-10), the R h , R i , and R j individually and independently represents —SO 3 − , —SO 3 H or —SO 2 NHR 81 , in which the R 81 represents 2-ethylhexyl group.
in the formula (I-11), the R h , R i , and R j individually and independently represents —SO 3 − , —SO 3 H or —SO 2 NHR 81 , in which the R 81 represents 2-ethylhexyl group.
in the formula (I-12), the R k , R m and R n individually and independently represents —SO 3 − , —SO 3 Na or —SO 2 NHR 81 , in which the R 81 represents 2-ethylhexyl group.
in the formula (I-13), the R k , R m , and R n individually and independently represents —SO 3 − , —SO 3 Na or —SO 2 NHR 81 , in which the R 81 represents 2-ethylhexyl group.
in the formula (I-14), the R p , R q , and R r individually and independently represents —SO 3 − , —SO 3 H or —SO 2 NHR 81 , in which the R 81 represents 2-ethylhexyl group.
in the formula (I-15), the R p , R q , and R r individually and independently represents —SO 3 − , —SO 3 H or —SO 2 NHR 81 , in which the R 81 represents 2-ethylhexyl group.
The dye (B) can preferably be the compound having the structure as the formula (I-5) (in which the R b and the R c are respectively —SO 3 − , and the a is 0; C.I. acidic red dye 52), the compound having the structure as the formula (I-26) (C.I. acidic red dye 289), the compound having the structure as the formula (I-32) or the formula (I-35), or any combination thereof.
Based on the total amount of the alkali-soluble resin (C) as 100 parts by weight, the amount of the dye (B) is 5 parts by weight to 50 parts by weight, preferably 6 parts by weight to 45 parts by weight, and more preferably 7 parts by weight to 40 parts by weight.
If the blue photosensitive resin composition of the present invention has no dye (B), the resulted color filter will have a poor contrast ratio.
Alkali-Soluble Resin (C)
The alkali-soluble resin (C) can comprise a first alkali-soluble resin (C-1) having a hindered-amine structure.
First Alkali-Soluble Resin (C-1)
The first alkali-soluble resin (C-1) is copolymerized by an ethylenically monomer having a hindered-amine structure (c1), an ethylenically unsaturated monomer having one or more carboxyl groups (c2) and an other copolymerizable ethylenically unsaturated monomer (c3) except from the ethylenically monomer having the hindered-amine structure (c1) and the ethylenically unsaturated monomer having one or more carboxyl groups (c2).
Ethylenically Monomer Having Hindered-Amine Structure (c1)
The ethylenically monomer having the hindered-amine structure (c1) can be the one as the formula (II):
in the formula (II), the Y 1 represents a hydrogen atom, a linear-, branched- or cyclo-alkyl group of 1 to 18 carbon atoms, an aromatic group of 6 to 20 carbon atoms, an aromatic alkyl group, an acyl group, an oxygen free radical or —OY 4 of 7 to 12 carbon atoms; the Y 4 represents a hydrogen atom, a linear-, branched- or cyclo-alkyl group of 1 to 18 carbon atoms, an aromatic group of 6 to 20 carbon atoms, or an aromatic alkyl group of 7 to 12 carbon atoms; the Y 2 and the Y 3 individually and independently represents methyl, ethyl, phenyl or aliphatic ring bound by 4 to 12 carbon atoms; and the symbol*represents a covalent bond.
When the Y 1 and the Y 4 represents the linear-, branched- or cyclo-alkyl group of 1 to 18 carbon atoms, the Y 1 and the Y 4 can be a linear or a branched alkyl group of 1 to 18 carbon atoms or cycloalkyl group of 3 to 8 carbon atoms, for example: methyl, ethyl, n-propyl, isopropyl, n-butyl, t-butyl, n-hexyl, cyclohexyl, n-octyl, or, cetyl and the like. When the Y 1 represents an aromatic group of 6 to 20 carbon atoms, the Examples can be phenyl group, α-naphthyl or β-naphthyl. When the Y 1 and the Y 4 represents the aromatic alkyl group of 7 to 12 carbon atoms, the Y 1 and the Y 4 can be the aromatic group bound with the alkyl group of 1 to 8 carbon atoms, and carbon atoms of the aromatic group is 6 to 10, the Examples can be benzyl group, ethylbenzene group, α-methyl benzyl group, or 2-phenyl propane-2-yl. When the Y 1 and the Y 4 represents the acyl group, the alkyl acyl group or the aromatic acyl group of 2 to 8 carbon atoms, the examples of the Y 1 and the Y 4 can be an acetyl or a benzoyl group.
The Y 1 of the present invention can preferably be a hydrogen atom, an alkyl group of 1 to 5 carbon atoms or an oxygen free radical, in which the hydrogen atom, oxygen free radical and methyl group is more preferable.
Moreover, the Y 2 and the Y 3 in the formula (II) can bind to form a structure of aliphatic ring, the Examples can be cyclopentane or cyclohexane and the like. The Y 2 and the Y 3 can preferably be a methyl group.
The ethylenically monomer having the hindered-amine structure as the formula (II) can be a compound of the structure in the formula (II-1) and the formula (II-2):
in the formula (II-1) and (II-2), the Y 5 and the Y 7 independently and individually represents a hydrogen atom or a methyl group; the Y 6 represents a methylene or alkylmethylene of 2 to 5 carbon atoms; the Y 8 represents the structure as the formula (II); the Y 9 represents —CONH—*, —SO 2 —, —SO 2 NH—*, in which the*represents a covalent bond bound with the Y 8 ; the Y 6 is preferably ethylene or propylene, and more preferably ethylene; and the s is an integer of 0 to 8, and more preferably 0 to 6.
The Examples of the ethylenically monomer having the hindered-amine structure (c1) as the formula (II-1) can be the structures in the following formula (II-1-1) to (II-1-7):
in the formulas (II-1-1) to (II-1-7), the Y 5 is defined as the above-mentioned description rather than being mentioned repetitively.
The Examples of the ethylenically monomer having the hindered-amine structure as the formula (II-2) can be the structures in the following formulas (II-2-1) to (II-2-4):
in the formulas (II-2-1) to (II-2-4), the Y 7 is defined as above rather than being mentioned repetitively.
The ethylenically monomer having the hindered-amine structure (c1) of the present invention can be 4-methacrylamido-2,2,6,6-tetramethylpiperidine or the products made by Hitachi Co. Ltd. such as the trade name of FA-712HM [2,2,6,6-tetramethylpiperidine methacrylate as the formula (II-1-1), and the Y 5 represents a methyl group] or the trade name of FA-711MM [1,2,2,6,6-pentamethylpiperidyl methacrylate as the formula (II-1-2), and the Y 5 represents a methyl group].
The above-mentioned ethylenically Monomer (c1) having the hindered-amine structure can be used alone or in a combination of two or more.
Based on the total amount of the above-mentioned ethylenically monomer having the hindered-amine structure (c1), a following ethylenically unsaturated monomer having one or more carboxyl groups (c2) and an other copolymerizable ethylenically unsaturated monomer (c3) as 100 parts by weight, an amount of the ethylenically monomer having the hindered-amine structure (c1) is 3 parts by weight to 45 parts by weight, preferably 4 parts by weight to 40 parts by weight, and more preferably 5 parts by weight to 35 parts by weight.
Ethylenically Unsaturated Monomer Having One or More Carboxyl Groups (c2)
The ethylenically unsaturated monomer having one or more carboxyl groups (c2) can include but be not limited to a unsaturated monocarboxylic compound such as acrylic acid, methacrylic acid, butenic acid, α-chloro acrylic acid, ethyl acrylic acid, benzalacetic acid, 2-acryloyloxyethylsuccinate monoester, 2-methacryloyloxyethyl succinate monoester or the like; a unsaturated dicarboxylic acid (anhydride) compound such as maleic acid, maleic anhydride, fumaric acid, itaconic acid, itaconic anhydride, citraconic acid, citraconic anhydride and the like; and a unsaturated polycarboxylic acid (anhydride) compound having more than three carboxyl groups. The above-mentioned ethylenically unsaturated monomer having one or more carboxyl groups (c2) can be used alone or in a combination of two or more.
Preferably, the ethylenically unsaturated monomer having one or more carboxyl groups (c2) is selected from the group consisting of acrylic acid, methacrylic acid, 2-acryloyloxyethyl succinate monoester or 2-methacryloyloxyethyl succinate monoester, in which the 2-acryloyloxyethyl succinate monoester or the 2-methacryloyloxyethyl succinate monoester is more preferable.
Based on the total amount of the above-mentioned ethylenically monomer having the hindered-amine structure (c1), the ethylenically unsaturated monomer having one or more carboxyl groups (c2) and the following copolymerizable ethylenically unsaturated monomer (c3) as 100 parts by weight, an amount of the ethylenically monomer having one or more carboxyl groups (c2) is 15 parts by weight to 55 parts by weight, preferably 20 parts by weight to 50 parts by weight, and more preferably 25 parts by weight to 45 parts by weight.
Other Copolymerizable Ethylenically Unsaturated Monomer (c3)
The other copolymerizable ethylenically unsaturated monomer (c3) except from the ethylenically monomer having the hindered-amine structure (c1) and the ethylenically monomer having one or more carboxyl groups (c2) can include but be not limited to aromatic ethylenically compounds such as styrene (SM), α-methylstyrene, vinyl toluene, p-chlorostyrene, methoxystyrene and the like; maleimide compounds such as N-phenylmaleimide (PMI), N-o-hydroxyphenylmaleimide, N-m-hydroxyphenylmaleimide, N-p-hydroxyphenylmaleimide, N-o-methylphenylmaleimide, N-m-methylphenylmaleimide, N-p-methylphenylmaleimide, N-o-methoxyphenylmaleimide, N-m-methoxyphenylmaleimide, N-p-methoxyphenylmaleimide, N-cyclohexylmaleimide and the like; unsaturated carboxylic acid ester compounds such as methyl acrylate (MA), methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-propyl acrylate, n-propyl methacrylate, isopropyl acrylate, isopropyl methacrylate, n-butyl acrylate, n-butyl methacrylate, isobutyl acrylate, isobutyl methacrylate, sec-butyl acrylate, sec-butyl methacrylate, tert-butyl acrylate, tert-butyl methacrylate, 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl acrylate, 2-hydroxypropyl methacrylate, 3-hydroxypropyl acrylate, 3-hydroxypropyl methacrylate, 2-hydroxybutyl acrylate, 2-hydroxybutyl methacrylate, 3-hydroxybutyl acrylate, 3-hydroxybutyl methacrylate, 4-hydroxybutyl acrylate, 4-hydroxybutyl methacrylate, propylene acrylate, propylene methacrylate, benzyl acrylate, benzyl methacrylate (BzMA), phenyl acrylate, phenyl methacrylate, methoxy triethylene glycol acrylate, methoxy triethylene glycol methacrylate, dodecyl methacrylate, tetradecyl methacrylate, hexadecyl methacrylate, octadecyl methacrylate, eicosyl methacrylate, docosanyl methacrylate, dicyclopentenyloxyethyl acrylate (DCPOA) and the like; N,N-dimethyl amino ethyl acrylate, N,N-dimethyl amino ethyl methacrylate, N,N-diethyl amino propyl acrylate, N,N-dimethyl amino propyl methacrylate, N,N-dibutyl amino propyl acrylate and N-isobutyl amino ethyl methacrylate; unsaturated carboxylic epoxypropyl ester compounds such as epoxypropyl acrylate, epoxypropyl methacrylate and the like; vinyl carboxylate compounds such as vinyl acetate, vinyl pivalate, vinyl butanoate and the like; unsaturated ether compounds such as methoxyethene, ethoxyethene, allyl epoxypropyl ether, methallyl epoxypropyl ether and the like; vinyl nitrile compounds such as acrylonitrile, methacrylonitrile, α-chloro acrylonitrile, vinylidene cyanide and the like; unsaturated amide compounds such as acrylamide, methacrylamide, α-chloro acrylamide, N-hydroxyethyl acrylamide, N-hydroxyethyl methacrylamide and the like; and aliphatic conjugated diene compounds such as 1,3-butadiene, isoprene, chlorinated butadiene and the like. The aforementioned other copolymerizable ethylenically unsaturated monomer (c3) can be used alone or in a combination of two or more.
Preferably, the other copolymerizable ethylenically unsaturated monomer is selected from styrene, N-phenylmaleimide, methacrylate, methyl methacrylate, 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, benzyl acrylate, benzyl methacrylate, dicyclopentenyloxyethyl acrylate or in any combination thereof.
Based on the total amount of the above-mentioned ethylenically monomer having the hindered-amine structure (c1), the ethylenically unsaturated monomer having one or more carboxyl groups (c2) and the other copolymerizable ethylenically unsaturated monomer (c3) as 100 parts by weight, an amount of the other copolymerizable ethylenically unsaturated monomer (c3) is 0 part by weight to 82 parts by weight, preferably 10 parts by weight to 70 parts by weight, and more preferably 20 parts by weight to 60 parts by weight.
If the blue photosensitive resin of the present invention has no the first alkali-soluble resin (C-1), the produced color filter will have an issue of very low voltage holding ratio.
Based on the total amount of the alkali-soluble resin (C) as 100 parts by weight, an amount of the first alkali-soluble resin (C-1) is 30 parts by weight to 100 parts by weight, preferably 40 parts by weight to 90 parts by weight, and more preferably 50 parts by weight to 80 parts by weight.
Second Alkali-Soluble Resin (C-2)
The alkali-soluble resin (C) of the present invention can optionally include the second alkali-soluble resin (C-2).
The second alkali-soluble resin (C-2) is copolymerized via the aforementioned ethylenically unsaturated monomer having one or more carboxylic acid groups (c2) and the other copolymerizable ethylenically unsaturated monomer (c3) except from the ethylenically monomer having the hindered-amine structure (c1) and the ethylenically unsaturated monomer having one or more carboxylic acid groups (c2), in which the ethylenically unsaturated monomer having one or more carboxylic acid groups (c2) and the other copolymerizable ethylenically unsaturated monomer (c3) are described as aforementioned rather than being mentioned repetitively.
Based on the total amount of the alkali-soluble resin (C) as 100 parts by weight, an amount of the second alkali-soluble resin (C-2) is 0 part by weight to 70 parts by weight, preferably 10 parts by weight to 60 parts by weight, and more preferably 20 parts by weight to 50 parts by weight.
Compound Having Ethylenically Unsaturated Group (D)
The compound having the ethylenically unsaturated group (D) denotes a unsaturated compound having at least one ethylenically unsaturated group or the unsaturated compound having two or more ethylenically unsaturated groups.
The unsaturated compound having at least one ethylenically unsaturated group can include but be not limited to acrylamide, acryloyl morpholine, methacryloyl morpholine, 7-amino-3,7-dimethyloctyl acrylate, 7-amino-3,7-dimethyloctyl methacrylate, isobutoxy methyl acrylamide, isobutoxy methyl methacrylamide, isobornyl ethoxy acrylate, isobornyl ethoxy methacrylate, isobornyl acrylate, isobornyl methacrylate, 2-ethylhexyl acrylate, 2-ethylhexyl methacrylate, ethyl diethylene glycol acrylate, ethyl diethylene glycol methacrylate, tert-octyl acrylamide, tert-octyl methacrylamide, diacetone acrylamide, diacetone methacrylamide, dimethylamino acrylate, dimethylamino methacrylate, dodecyl acrylate, dodecyl methacrylate, dicyclopentenyl ethoxy acrylate, dicyclopentenyl ethoxy methacrylate, dicyclopentenyl acrylate, dicyclopentenyl methacrylate, N,N-dimethyl acrylamide, N,N-dimethyl methacrylamide, tetrachlorophenyl acrylate, tetrachlorophenyl methacrylate, 2-tetrachlorophenoxy ethyl acrylate, 2-tetrachlorophenoxy ethyl methacrylate, tetrahydrofurfuryl acrylate, tetrahydrofurfuryl methacrylate, tetrabromophenyl acrylate, tetrabromophenyl methacrylate, 2-tetrabromophenoxyethyl acrylate, 2-tetrabromophenoxyethyl methacrylate, 2-trichlorophenoxyethyl acrylate, 2-trichlorophenoxyethyl methacrylate, tribromophenyl acrylate, tribromophenyl methacrylate, 2-tribromophenoxyethyl acrylate, 2-tribromophenoxyethyl methacrylate, 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl acrylate, 2-hydroxypropyl methacrylate, vinyl caprolactam, N-vinyl pyrrolidone, ethyl phenoxy acrylate, ethyl phenoxy methacrylate, pentachlorophenyl acrylate, pentachlorophenyl methacrylate, pentabromophenyl acrylate, pentabromophenyl methacrylate, polyethylene glycol monoacrylate, polyethylene glycol monomethacrylate, polypropylene glycol monoacrylate, polypropylene glycol monomethacrylate, bornyl acrylate or bornyl methacrylate and the like.
The aforementioned unsaturated compound having at least one ethylenically unsaturated group can be used alone or in a combination of two or more.
The unsaturated compound having two or more ethylenically unsaturated groups includes but is not limited to ethylene glycol diacrylate, ethylene glycol dimethacrylate, dicyclopentyl diacrylate, dicyclopentyl dimethacrylate, triethylene glycol diacrylate, tetraethylene glycol diacrylate, tetraethylene glycol dimethacrylate, tri(2-hydroxyethyl)isocyanate diacrylate, tri(2-hydroxyethyl)isocyanate dimethacrylate, tri(2-hydroxyethyl)isocyanate triacrylate, tri(2-hydroxyethyl)isocyanate trimethacrylate, caprolactone-modified tri(2-hydroxyethyl)isocyanate triacrylate, caprolactone-modified tri(2-hydroxyethyl)isocyanate trimethacrylate, trihydroxymethylpropyl triacrylate, trihydroxymethylpropyl trimethacrylate, ethylene oxide (hereinafter as EO)-modified trihydroxymethylpropyl triacrylate, EO-modified trihydroxymethylpropyl trimethacrylate, propylene oxide (hereinafter as PO)-modified trihydroxymethylpropyl triacrylate, PO-modified trihydroxymethylpropyl trimethacrylate, triethylene glycol dimethacrylate, neopentylene glycol diacrylate, neopentylene glycol dimethacrylate, 1,4-butylene glycol diacrylate, 1,4-butylene glycol dimethacrylate, 1,6-hexylene glycol diacrylate, 1,6-hexylene glycol dimethacrylate, pentaerythritol triacrylate, pentaerythritol trimethacrylate, pentaerythritol tetraacrylate, pentaerythritol tetramethacrylate, polyester diacrylate, polyester dimethacrylate, polyethylene glycol diacrylate, polyethylene glycol dimethacrylate, dipentaerythritol hexaacrylate (DPHA), dipentaerythritol hexamethacrylate, dipentaerythritol pentaacrylate, dipentaerythritol pentamethacrylate, dipentaerythritol tetraacrylate, dipentaerythritol tetramethacrylate, caprolactone-modified dipentaerythritol hexaacrylate, caprolactone-modified dipentaerythritol hexamethacrylate, caprolactone-modified dipentaerythritol pentaacrylate, caprolactone-modified dipentaerythritol pentamethacrylate, ditrihydroxymethylpropyl tetraacrylate, ditrihydroxymethylpropyl tetramethacrylate, EO-modified bisphenol A diacrylate, EO-modified bisphenol A dimethacrylate, PO-modified bisphenol A diacrylate, PO-modified bisphenol A dimethacrylate, EO-modified hydrobisphenol A diacrylate, EO-modified hydrobisphenol A dimethacrylate, PO-modified hydrobisphenol A diacrylate, PO-modified hydrobisphenol A dimethacrylate, PO-modified tripropionin, EO-modified bisphenol F diacrylate, EO-modified bisphenol F dimethacrylate, novolac polyglycidyl ether acrylate, novolac polyglycidyl ether methacrylate, or the products such as the trade name of TO-1382 made by TOAGOSEI Co. Ltd. in Japan and the like.
Preferably, the compound having the ethylenically unsaturated group (D) is selected from the group consisting of trihydroxymethylpropyl triacrylate, EO-modified trihydroxymethylpropyl triacrylate, PO-modified trihydroxymethylpropyl triacrylate, pentaerythritol triacrylate, pentaerythritol tetraacrylate, dipentaerythritol hexaacrylate, dipentaerythritol pentaacrylate, dipentaerythritol tetraacrylate, caprolactone-modified dipentaerythritol hexaacrylate, ditrihydroxymethylpropyl tetraacrylate, PO-modified tripropionin or any combination thereof.
Based on the total amount of the aforementioned alkali-soluble resin (C) as 100 parts by weight, an amount of the compound having the ethylenically unsaturated group (D) is 60 parts by weight to 600 parts by weight, preferably 80 parts by weight to 500 parts by weight, and more preferably 100 parts by weight to 400 parts by weight.
Photo-Initiator (E)
The photo-initiator (E) can be O-acyl oxime compound, triazine compound, acetonephenone compound, biimidazole compound, benzophenone compound or the like. The aforementioned photo-initiator (E) can be used alone or in a combination of two or more.
The O-acyl oxime compound includes but is not limited to 1-[4-(phenylthio)phenyl]-heptane-1,2-dione-2-(O-benzoyl oxime), 1-[4-(phenylthio)phenyl]-octane-1,2-dione-2-(O-benzoyl oxime), 1-[4-(benzoyl)phenyl]-heptane-1,2-dione-2-(O-benzoyl oxime), 1-[9-ethyl-6-(2-methylbenzoyl)-9H-carbazol-3-yl]-ethanone-1-(O-acetyl oxime), 1-[9-ethyl-6-(3-methylbenzoyl)-9H-carbazol-3-yl]-ethanone-1-(O-acetyl oxime), 1-[9-ethyl-6-benzoyl-9H-carbazol-3-yl]-ethanone-1-(O-acetyl oxime), ethanone-1-[9-ethyl-6-(2-methyl-4-tetrahydrofuranyl benzoyl)-9H-carbazol-3-yl]-1-(O-acetyl oxime), ethanone-1-[9-ethyl-6-(2-methyl-5-tetrahydropyranyl benzoyl)-9H-carbazol-3-yl]-1-(O-acetyl oxime), ethanone-1-[9-ethyl-6-(2-methyl-4-tetrahydrofuranyl methoxybenzoyl)-9H-carbazol-3-yl]-1-(O-acetyl oxime), ethanone-1-[9-ethyl-6-(2-methyl-5-tetrahydrofuranyl methoxybenzoyl)-9H-carbazole-3-yl]-1-(O-acetyl oxime), ethanone-1-{9-ethyl-6-[2-methyl-4-(2,2-dimethyl-1,3-dioxolanyl)benzoyl]-9H-carbazol-3-yl}-1-(O-acetyl oxime), ethanone-1-{9-ethyl-6-[2-methyl-4-(2,2-dimethyl-1,3-dioxolanyl)methoxybenzoyl]-9H-carbazol-3-yl}-1-(O-acetyl oxime) or the like. The aforementioned O-acyl oxime compound can be used alone or in a combination of two or more.
The triazine compound includes but is not limited to 2,4-bis(trichloromethyl)-6-(p-methoxy)styryl-s-triazine, 2,4-bis(trichloromethyl)-6-(1-p-dimethylaminophenyl-1,3-butadienyl)-s-triazine, or 2-trichloromethyl-4-amino-6-(p-methoxy)styryl-s-triazine and the like. The aforementioned triazine compound can be used alone or in a combination of two or more.
The acetophenone compound includes but is not limited to p-dimethylamino acetophenone, α,α′-dimethoxyazoxy acetophenone, 2,2′-dimethyl-2-phenyl acetophenone, p-methoxy acetophenone, 2-methyl-1-(4-methylthio phenyl)-2-morpholino-1-acetone, 2-benzyl-2-N,N-dimethylamino-1-(4-morpholino phenyl)-1-butanone or the like. The aforementioned acetophenone compound can be used alone or in a combination of two or more.
The biimidazole compound includes but is not limited to 2,2′-bis(o-chlorophenyl)-4,4′,5,5′-tetraphenyl biimidazole, 2,2′-bis(o-fluorophenyl)-4,4′,5,5′-tetraphenyl biimidazole, 2,2′-bis(o-methylphenyl)-4,4′,5,5′-tetraphenyl biimidazole, 2,2′-bis(o-methoxyphenyl)-4,4′,5,5′-tetraphenyl biimidazole, 2,2′-bis(o-ethylphenyl)-4,4′,5,5′-tetraphenyl biimidazole, 2,2′-bis(p-methoxyphenyl)-4,4′,5,5′-tetraphenyl biimidazole, 2,2′-bis(2,2′,4,4′-tetramethoxyphenyl)-4,4′,5,5′-tetraphenyl biimidazole, 2,2′-bis(2-chlorophenyl)-4,4′,5,5′-tetraphenyl biimidazole, 2,2′-bis(2,4-dichlorophenyl)-4,4′,5,5′-tetraphenyl biimidazole or the like. The aforementioned biimidazole compound can be used alone or in a combination of two or more.
The benzophenone compound includes but is not limited to thiaxanthone, 2,4-diethyl thiaxanthone, thiaxanthone-4-sulfone, benzophenone, 4,4′-bis(dimethylamino)benzophenone, 4,4′-bis(diethylamino)benzophenone or the like. The benzophenone compound can be used alone or in a combination of two or more.
Preferably, the photo-initiator (E) can be 1-[4-(phenylthio)phenyl]-octane-1,2-dione-2-(O-benzoyl oxime), 1-[9-ethyl-6-(2-methylbenzoyl)-9H-carbazol-3-yl]-ethanone-1-(O-acetyl oxime), ethanone-1-[9-ethyl-6-(2-methyl-4-tetrahydrofuranyl methoxybenzoyl)-9H-carbazol-3-yl]-1-(O-acetyl oxime), ethanone-1-{9-ethyl-6-[2-methyl-4-(2,2-dimethyl-1,3-dioxolanyl)methoxybenzoyl]-9H-carbazol-3-yl}-1-(O-acetyl oxime), 2,4-bis(trichloromethyl)-6-(p-methoxy)styryl-s-triazine, 2-benzyl-2-N,N-dimethylamino-1-(4-morpholino phenyl)-1-butanone, 2,2′-bis(2,4-dichlorophenyl)-4,4′,5,5′-tetraphenyl-1,2′-biimidazole, 4,4′-bis(diethylamino)benzophenone or any combination thereof.
Without adversely affecting the physical properties of the blue photosensitive resin composition, the blue photosensitive resin composition of the present invention can further be added with an initiator except from the photo-initiator (E). Examples of the initiator can be, for example, α-diketone compound, acyloin compound, acyloin ether compound, acylphosphine oxide compound, quinone compound, halogen-containing compound, peroxide compound or the like.
The α-diketone compound includes but is not limited to benzil compound, acetyl compound or the like. The aforementioned α-diketone compound can be used alone or in a combination of two or more.
The acyloin compound includes but is not limited to benzoin and the like. The aforementioned acyloin compound can be used alone or in a combination of two or more.
The acyloin ether compound includes but is not limited to benzoin methylether, benzoin ethylether, benzoin isopropyl ether or the like. The aforementioned acyloin ether compound can be used alone or in a combination of two or more.
The acylphosphineoxide compound includes but is not limited to 2,4,6-trimethyl-benzoyl diphenylphosphineoxide, bis-(2,6-dimethoxy-benzoyl)-2,4,4-trimethylphenyl phosphine oxide or the like. The aforementioned acylphosphineoxide compound can be used alone or in a combination of two or more.
The quinone compound includes but is not limited to anthraquinone, 1,4-naphthoquinone and the like. The aforementioned quinone compound can be used alone or in a combination of two or more.
The halogen-containing compound includes but is not limited to phenacyl chloride, tribromomethyl phenylsulfone, tris(trichloromethyl)-s-triazine or the like. The aforementioned compounds having a halogen atom can be used alone or in a combination of two or more.
The peroxide compound includes but is not limited to di-tertbutylperoxide and the like. The aforementioned peroxide compound can be used alone or in a combination of two or more.
Based on the total amount of the aforementioned alkali-soluble resin (C) as 100 parts by weight, an amount of the photo-initiator (E) is 10 parts by weight to 100 parts by weight, preferably 15 parts by weight to 90 parts by weight, and more preferably 20 parts by weight to 80 parts by weight.
Organic Solvent (F)
The organic solvent of the present invention includes but is not limited to a (poly)alkylene glycol monoalkyl ether solvent, such as ethylene glycol methyl ether, ethylene glycol ethyl ether, diethylene glycol methyl ether, diethylene glycol ethyl ether, diethylene glycol n-propyl ether, diethylene glycol n-butyl ether, triethylene glycol methyl ether, triethylene glycol ethyl ether, propylene glycol methyl ether, propylene glycol ethyl ether, dipropylene glycol monomethyl ether, dipropylene glycol monoethyl ether, dipropylene glycol n-propyl ether, dipropylene glycol n-butyl ether, tripropylene glycol methyl ether, tripropylene glycol ethyl ether or the like; (poly)alkylene glycol monoalkyl ether acetate solvent, such as ethylene glycol methyl ether acetate, ethylene glycol ethyl ether acetate, propylene glycol methyl ether acetate (PGMEA), propylene glycol ethyl ether acetate or the like; an other ether solvent such as diethylene glycol dimethyl ether, diethylene glycol ethyl methyl ether, diethylene glycol diethyl ether, tetrahydrofuran or the like; a ketone solvent, such as ethyl methylketone, cyclohexanone, 2-heptanone, 3-heptanone or the like; an alkyl lactate solvent such as methyl 2-hydroxypropanoate, ethyl 2-hydroxypropanoate or the like; an other ester solvent such as methyl 2-hydroxy-2-methylpropionate, ethyl 2-hydroxy-2-methylpropionate, methyl 3-methoxypropionate, ethyl 3-methoxypropionate, methyl 3-ethoxypropionate, ethyl 3-ethoxypropionate (EEP), ethyl ethoxyacetate, ethyl hydroxyacetate, methyl 2-hydroxy-3-methyl butyrate, 3-methyl-3-methoxybutyl acetate, 3-methyl-3-methoxybutyl propionate, ethyl acetate, n-propyl acetate, isopropyl acetate, n-butyl acetate, isobutyl acetate, n-pentyl acetate, isopentyl acetate, n-butyl propionate, ethyl butyrate, n-propyl butyrate, isopropyl butyrate, n-butyl butyrate, methyl pyruvate, ethyl pyruvate, n-propyl pyruvate, methyl acetoacetate, ethyl acetoacetate, ethyl 2-methoxybutyrate or the like; an aromatic hydrocarbon compound solvent such as toluene, xylene or the like; and an amide solvent such as N-methylpyrrolidone, N,N-dimethylformamide, N,N-dimethyl acetamide or the like.
Preferably, the organic solvent (F) can be propylene glycol monomethyl ether acetate or ethyl 3-ethoxypropionate.
Based on the total amount of the aforementioned alkali-soluble resin (C) as 100 parts by weight, an amount of the organic solvent (F) is 500 parts by weight to 5,000 parts by weight, preferably 800 parts by weight to 4,500 parts by weight, and more preferably 1,000 parts by weight to 4,000 parts by weight.
Additive (G)
For satisfying the requirements on the physical-chemical properties of the color filter portion, the blue photosensitive resin composition in the present invention can optionally include an additive (G) such as a filling agent, a polymer compound except from the aforementioned alkali-soluble resin (C), an adhesion promoter, an antioxidant, an ultraviolet absorber, an anti-agglutinant or the like.
The additive (G) includes but is not limited to the filler agent of glass, aluminum or the like; the polymer compound except from the alkali-soluble resin (C) such as polyvinyl alcohol, polyethylene glycol monoalkyl ether, polyfluoroalkyl acrylate or the like; the adhesion promoter such as vinyl trimethoxysilane, vinyl triethoxysilane, vinyl tris(2-methoxyethoxy)silane, N-(2-aminoethyl)-3-aminopropylmethyl dimethoxysilane, N-(2-aminoethyl)-3-aminopropyl trimethoxysilane, 3-aminopropyl triethoxysilane, 3-glycidoxypropyl trimethoxysilane, 3-glycidoxymethyl propyldimethoxysilane, 2-(3,4-epoxycyclohexyl)ethyl trimethoxysilane, 3-chloromethylpropyl dimethoxysilane, 3-chloropropyl trimethoxysilane, 3-methylallyloxypropyl trimethoxysilane, 3-mercaptopropyl trimethoxysilane or the like; the antioxidant such as 2,2-thiobis(4-methyl-6-tertbutylphenol), 2,6-di-tertbutylphenol or the like; the ultraviolet absorber such as 2-(3-tertbutyl-5-methyl-2-hydroxyphenyl)-5-chlorophenylazide, alkoxyphenyl ketone or the like; and the anti-agglutinant such as sodium polyacrylate and so on.
Preparation of Photosensitive Resin Composition
The blue photosensitive resin composition for the color filter of the present invention is prepared by mixing the above-mentioned organic pigment (A), the dye (B), the alkali-soluble resin (C), the compound having the ethylenically unsaturated group (D), the photo-initiator (E) and the organic solvent (F) in a mixer uniformly until all components are formed into a solution state, optionally adding the additive (G) such as the filler agent, the polymer compound except from the alkali-soluble resin (C), the adhesion promoter, the antioxidant, the ultraviolet absorber, the anti-agglutinant or the like thereto if necessary.
Based on the total amount of the alkali-soluble resin (C) as 100 parts by weight, an amount of the organic pigment (A) is 30 parts by weight to 300 parts by weight, an amount of the dye (B) is 5 parts by weight to 50 parts by weight, an amount of the compound having the ethylenically unsaturated group (D) is 60 parts by weight to 600 parts by weight, the amount of the photo-initiator (E) is 10 parts by weight to 100 parts by weight, and the amount of the organic solvent (F) is 500 parts by weight to 5,000 parts by weight.
Preparation of Color Filter
In the preparation of the color filter for the present invention, a pixel layer is formed by using the aforementioned blue photosensitive resin of the color filter, and then the color filter is formed by the following method.
During the preparation of the color filter for the present invention, the solution state of the aforementioned blue photosensitive resin composition of the color filter is coated on a substrate mainly by a coating method such as spin coating, curtain coating, ink-jet printing, roll coating or the like. After being coated, the solvent is mostly removed by the reduced-pressure dehydration, and the residual solvent is removed by a prebake step to form a prebaked coating film. The conditions of the reduced-pressure dehydration and the prebake step can vary depending on the kinds and ratios of the ingredients. The reduced-pressure dehydration is typically performed under a pressure of 0 mmHg to 200 mmHg for 1 second to 60 seconds, and the prebake step is performed at a temperature of 70° C. to 110° C. for 1 minute to 15 minutes. Afterwards, the prebaked coating film is exposed under a given mask, in which the light used in the exposing step preferably is ultraviolet light such as g-line, h-line, i-line and the like. A (super) high-pressure mercury lamp or a metal halide lamp can be used as the ultraviolet light device. And then, the substrate is immersed in a developing solution at 23±2° C. for 15 seconds to 5 minutes, for removing the undesirable parts to form a pattern, so as to form a substrate with a photo-curing coating layer.
Examples of the aforementioned substrate can be an alkali-free glass, a Na—Ca glass, a hard glass (Pyrex glass) or a quartz glass used in the LCD device, those having an electrically conductive transparent film disposed thereon, or a substrate of the photoelectric conversion substrate (such as silica substrate) used in a solid-camera device and the like. These substrates typically have the pre-formed black matrix for isolating various pixel color layers.
Furthermore, Examples of the developing solution can be an alkaline solution containing alkali compounds such as sodium hydroxide, potassium hydroxide, sodium carbonate, sodium hydrocarbonate, potassium carbonate, potassium hydrocarbonate, sodium silicate, sodium methyl silicate, ammonium solution, ethylamine, diethylamine, dimethyl ethanolamine, tetramethyl ammonium hydroxide, tetraethyl ammonium hydroxide, choline, pyrrole, piperidine, 1,8-diazabicyclo(5,4,0)-7-undecene or the like. A concentration of the developing solution is typically 0.001 wt % to 10 wt %, preferably 0.005 wt % to 5 wt %, and more preferably 0.01 wt % to 1 wt %.
When the aforementioned alkaline water solution is utilized for the developing solution, the pattern is typically cleaned by water after being developed and air-dried by compressed air or compressed nitrogen gas.
After air-drying the substrate having the photo-curing coating layer, the substrate is heated by a heating device such as a hot plate or an oven at 100° C. to 280° C. for 1 minute to 15 minutes, so as to remove the volatile ingredients in the coating layer and to make the unreacted ethylenically unsaturated double bonds in the coating layer to perform a thermal curing reaction. The photosensitive resin compositions of various colors (mainly including three colors of red, green and blue) are applied on the given pixel and practiced repetitively by using the same procedure in three times, so as to obtain the photocured pixel color layer of red, green and blue colors.
Furthermore, an ITO (Indium Tin Oxide) evaporated film is formed on the aforementioned pixel color layer at 220° C. to 250° C. in vacuum. If necessarily, the ITO evaporated film is etched, wired and coated with the polyimide of the LC alignment film, followed by a calcination step, so as to obtain the color filter for the LCD device.
Preparation of LCD Device
The LCD device of the present invention includes the aforementioned color filter.
The LCD device of the present invention includes the aforementioned color filter substrate and a driving substrate having thin film transistor (TFT) disposed thereon. The two substrates are opposite to each other while leaving a cell gap interposed therebetween, and a sealing agent is adhered the surrounding of the two substrates. Next, the LC is injected and filled into the cell gap defined by the surfaces of the two substrates and the sealing agent, followed by sealing a gap-hole and forming an LC cell. And then, the polarized plates are respectively adhered on the external surfaces and sides of the two substrates of the LC cell, so as to obtain the LCD element.
Several embodiments are described below to illustrate the application of the present invention. However, these embodiments are not used for limiting the present invention. For those skilled in the art of the present invention, various variations and modifications can be made without departing from the spirit and the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be more fully understood by reading the following detailed description of the embodiment, with reference made to the accompanying drawings as follows:
FIG. 1 is a stereo diagram of a device of detecting contrast ratio according to an evaluated method of the present invention.
FIG. 2 is a stereo diagram of an another device of detecting contrast ratio according to the evaluated method of the present invention.
DETAILED DESCRIPTION
Preparation of Alkali-Soluble Resin (C)
Hereinafter, the alkali-soluble resins of synthesis examples C-1-1 to C-1-8 and C-2-1 to C-2-4 were prepared according to Table 1.
Preparation of First Alkali-Soluble Resin (C-1)
Synthesis Example C-1-1
3 parts by weight of 1,2,2,6,6-pentamethylpiperidyl methacrylate (hereinafter as FA-711MM), 45 parts by weight of 2-methacryloylethoxy succinate (hereinafter as HOMS), 12 parts by weight of dicyclopentenyl acrylate (hereinafter as FA-511A), 20 parts by weight of styrene (hereinafter as SM), 5 parts by weight of benzyl methacrylate (hereinafter as BzMA), 15 parts by weight of methyl methacrylate (hereinafter as MMA), 4 parts by weight of 2,2′-azo-bis-2-methylbutyronitrile (hereinafter as AMBN) and 200 parts by weight of ethyl 3-ethoxypropionate (hereinafter as EEP) were added to a 500 ml four-necked flask continuously, the feeding speed was controlled at 25 parts by weight per minute and the temperature was maintained at 100° C. After reacting for 6 hours, the first alkali-soluble resin (C-1-1) was obtained.
Synthesis Examples C-1-2 to C-1-8
Synthesis Examples C-1-2 to C-1-8 were practiced with the same method as Synthesis Example C-1-1 by using various kinds and amounts of the components of the first alkali-soluble resin and various polymerization conditions. The formulations and polymerization conditions thereof were listed in Table 1 rather than focusing or mentioning them in details.
Preparation of Second Alkali-Soluble Resin (C-2)
Synthesis Example C-2-1
A 1,000 ml four-necked conical flask equipped with a nitrogen inlet, a stirrer, a heater, a condenser and a thermometer was purged with nitrogen gas. In an environment with the nitrogen gas, 45 parts by weight of 2-methacryloylethoxy succinate (hereinafter as HOMS), 15 parts by weight of dicyclopentenyl acrylate (hereinafter as FA-511A), 20 parts by weight of styrene (hereinafter as SM), 5 parts by weight of benzyl methacrylate (hereinafter as BzMA), 15 parts by weight of methyl methacrylate (hereinafter as MMA), and 200 parts by weight of ethyl 3-ethoxypropionate (hereinafter as EEP) were added into the four-necked conical flask continuously and mixed uniformly. Then a temperature of an oil bath was increased to 100° C., and 4 parts by weight of 2,2′-azo-bis-2-methylbutyronitrile (hereinafter as AMBN) was dissolved in EEP, and the solution was divided into five equal parts in weight and the five parts were added into the four-necked conical flask in 1 hour. The reacting temperature of the polymerization process was maintained at 100° C. and reacted for 6 hours. Afterwards, a polymer product was separated from the four-necked conical flask and the solvent was removed, so as to obtain the second alkali-soluble resin (C-2-1).
Synthesis Examples C-2-2 to C-2-4
Synthesis Examples C-2-2 to C-2-4 were prepared with the same method as Synthesis Example C-2-1 by using various kinds and amounts of the components of the second alkali-soluble resin and various polymerization conditions. The formulations and polymerization conditions thereof were listed in Table 1 rather than mentioning them in details.
Preparation of Blue Photosensitive Resin Composition
Hereinafter, the blue photosensitive resin compositions of Examples 1 to 8 and Comparative Examples 1 to 7 were prepared according to Table 2 and Table 3.
Example 1
20 parts by weight of the C.I. Pigment blue 15:4 (hereinafter as A-1-1), 5 parts by weight of the aforementioned dye as the formula (I-5) (hereinafter as B-1), 100 parts by weight of the alkali-soluble resin obtained from the aforementioned Synthesis Example C-1-1 (hereinafter as C-1-1), 60 parts by weight of dipentaerythritol hexaacrylate (made by TOAGOSEI Co. Ltd., hereinafter as D-1), 3 parts by weight of 2-methyl-1-(4-methylthio phenyl)-2-morpholino-1-acetone (hereinafter as E-1), 3 parts by weight of 2,2′-bis(2,4-dichlorophenyl)-4,4′,5,5′-tetraphenyl biimidazole (hereinafter as E-2), and 4 parts by weight of 4,4′-bis(diethylamino)benzophenone were added into 500 parts by weight of ethyl 3-ethoxypropionate (hereinafter as F-1), being uniformly mixed and dissolved by an mixer, so as to obtain the blue photosensitive resin composition for the color filter of Example 1. The obtained blue photosensitive resin composition for the color filter was evaluated according to the following various evaluation methods, and the results were shown in Table 2, in which the method of detecting the contrast ratio and the voltage holding ratio were described as follows.
Examples 2 to 8 and Comparative Examples 1 to 7
Examples 2 to 8 and Comparative Examples 1 to 7 were prepared with the same method as in Example 1 by using various kinds and amounts of the components of the blue photosensitive resin compositions. The formulations and the evaluation results were shown in Tables 2 and 3 rather than mentioning them in details.
Evaluation Methods
1. Contrast Ratio
Each blue photosensitive resin composition of the aforementioned Examples and Comparative Examples was coated on a glass substrate with a size of 100 mm in width and 100 mm in length. Next, the glass substrate was subjected to a reduced-pressure dehydration for 30 seconds under a pressure of 100 mmHg. Then, the aforementioned glass substrate was prebaked for 3 minutes at 80° C. to form a prebaked coating film with 2.5 μm in thickness. Next, the aforementioned prebaked coating film was exposed under 300 mJ/cm 2 of ultraviolet light by an exposure machine (the trade name of PLA-501F was made by Canon Co. Ltd.). After being exposed under the ultraviolet light, the prebaked coating film was immersed in a developing solution at 23° C. After 2 minutes, the prebaked coating film was cleaned by pure water, followed by being postbaked at 200° C. for 80 minutes, so as to form a blue photosensitive resin layer with 2.0 μm in thickness on the glass substrate.
A detecting device as illustrated in FIGS. 1 and 2 was used to measure the luminance of the blue photosensitive resin layer with 2.0 μm in thickness and compute a ratio thereof. In the detecting device 100 of FIG. 1 , the aforementioned produced blue photosensitive resin layer 110 was interposed between the two polarized plates 120 and 130 , and the light emitted from the light source 140 passed through the polarized plate 120 , the blue photosensitive resin layer 110 and the polarized plate 130 in sequence. Then, the luminance (cd/cm 2 ) of the light passing through the polarized plate 130 was measured by a luminance meter 150 (the trade name of BM-5A was made by Topcon Co. Ltd.).
Among the aforementioned description, a polarized light direction 120 a of the polarized plate 120 was parallel to a polarized light direction 130 a of the polarized plate 130 , and the luminance measured by the detecting device 100 of FIG. 1 was A. The detecting device 200 illustrated in FIG. 2 was approximately the same as the detecting device 100 illustrated in FIG. 1 , but the two detecting devices had some differences. A polarized light direction 220 a of a polarized plate 220 was perpendicular to a polarized light direction 230 a of a polarized plate 230 in the detecting device 200 , and the luminance measured by the device 200 was B.
Then, the contrast ratio of the blue photosensitive resin composition was defined as the following formula (III) and evaluated according to the following criterion:
Contrast
ratio
=
Luminance
A
Luminance
B
(
III
)
⊚: 1500≦contrast ratio
◯: 1200≦contrast ratio<1500
Δ: 900≦contrast ratio<1200
X: contrast ratio<900
2. Voltage Holding Ratio
Firstly, a SiO 2 film was formed on a Na—Ca glass substrate for preventing sodium ions from being dissolved out, and then an ITO (Indium Tin Oxide) electrode with a given pattern was further evaporated on the Na—Ca glass substrate. And then, the resulted blue photosensitive resin compositions of the aforementioned Examples 1 to 8 and Comparative Examples 1 to 7 were spin-coated on the above-mentioned glass substrate. Next, the substrate was prebaked for 1 minute at 100° C. to form a prebaked coating film with a thickness of 2 μm. Then, the aforementioned prebaked coating film was irradiated under the light of 700 J/m 2 without covering the mask. The post-exposure coating film was immersed in a potassium hydroxide developing solution with the concentration of 0.04 wt %. After 1 minute, the substrate was cleaned by ultrapure water and air-dried. Afterwards, the post-exposure coating film was post-baked for 30 minutes at 230° C., thereby forming a cured coating film.
Next, a sealing agent was used to adhere the pixel substrate formed by the aforementioned curing coating film and the ITO electrode with the given evaporated pattern, and the glass beads with a diameter of 1.8 mm were placed in between thereof. The LC material (the trade name of MLC6608 was made by Merck Co. Ltd.) was injected into the cell gap defined by the aforementioned sealing agent, the pixel substrate and the driving substrate, so as to form an LC cell.
Afterwards, the produced LC cell was placed into a thermostat at 60° C., and the voltage holding ratio (VHR) of the produced LC cell was measured at a square wave of 5.5 V and a frequency of 60 Hz by a VHR measuring instrument (Model No. VHR-1A was made by Toyo Co.).
The aforementioned VHR denotes a value, which represents a potential difference of the LC cell after 16.7 milli-seconds divided by the voltage imposed to the LC cell at 0 milli-second. When the VHR of the LC cell is less than 90%, the produced LC cell is unable to maintain a stable voltage within 16.7 milli-seconds, and the situation easily causes the defect of retained image generated by the LC cell molecules. The measured VHR of the aforementioned Examples 1 to 8 and Comparative Examples 1 to 7 is evaluated by the following criteria:
⊚: 95%<VHR≦100%
◯: 90%<VHR≦95%
Δ: 80%<VHR≦90%
X: VHR≦900
Inferred from the results of Table 2 and Table 3, when the organic pigment of the blue photosensitive resin composition of the present invention (A) includes the blue organic pigment mainly having the structure of copper phthalocyanine (A-1), the resulted photosensitive resin composition will reveal preferable contrast ratio. Moreover, when the aforementioned organic pigment further containing the purple organic pigment (A-2) (A), the resulted photosensitive resin composition will reveal more preferable contrast ratio.
Furthermore, when the alkali-soluble resin of the blue photosensitive resin composition of the present invention (C) has no the first alkali-soluble resin (C-1), then the VHR of the resulted photosensitive resin composition will be poor.
It should be supplemented that, although specific compounds, components, specific reaction conditions, specific processes, specific evaluation methods or specific instruments are employed as exemplary embodiments of the present invention, for illustrating the blue photosensitive resin composition and the application of the same of the present invention. However, as is understood by a person skilled in the art instead of limiting to the aforementioned examples, the blue photosensitive resin composition and the application of the same of the present invention also can be manufactured by using other compounds, components, reaction conditions, processes, evaluation methods and instruments without departing from the spirit and the scope of the present invention.
As is understood by a person skilled in the art, the foregoing preferred embodiments of the present invention are illustrated of the present invention rather than limiting of the present invention. In view of the foregoing, it is intended to cover various modifications and similar arrangements included within the spirit and the scope of the appended claims. Therefore, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structures.
TABLE 1
Composition (parts by weight)
Copolymerizabale Monomers
Synthesis
c1
c2
c3
Examples
FA-711MM
FA-712HM
MATP
HOMS
MAA
AA
FA-511A
FA-512A
SM
BzMA
MMA
C-1-1
3
45
12
20
5
15
C-1-2
5
20
35
40
C-1-3
15
20
20
25
20
C-1-4
20
55
10
15
C-1-5
25
15
30
10
20
C-1-6
30
50
10
10
C-1-7
20
20
35
5
10
10
C-1-8
15
30
30
15
10
C-2-1
45
15
20
5
15
C-2-2
35
35
30
C-2-3
20
20
30
30
C-2-4
30
35
35
Composition (parts by weight)
Polymerization Conditions
Synthesis
Photo Initiator
Solvent
Method of Adding
Reaction
Polymerization
Examples
AMBN
ADVN
EEP
Monomer
Temperature (° C.)
Time (hr)
C-1-1
4
200
Continuously added
100
6
C-1-2
4.5
200
Simultaneously added
105
6
C-1-3
4
200
Continuously added
100
5.5
C-1-4
4
200
Simultaneously added
105
6
C-1-5
4
200
Continuously added
100
6
C-1-6
4.5
200
Simultaneously added
105
6
C-1-7
4
200
Continuously added
100
5.5
C-1-8
4
200
Simultaneously added
105
6
C-2-1
4
200
Continuously added
100
6
C-2-2
4.5
200
Simultaneously added
105
6
C-2-3
4
200
Continuously added
100
5.5
C-2-4
4
200
Simultaneously added
105
6
FA-711MM 1,2,2,6,6-pentamethyl-piperidyl methacrylate
FA-712HM 2,2,6,6-tetramethyl-piperidyl methacrylate
MATP 4-methacrylamido-2,2,6,6-tetramethylpiperidine
HOMS 2-methacryloyloxyethyl succinate monoester
MAA methacrylic acid
AA acrylic add
FA-511A dicyclopenteny acrylate
FA-512A dicyclopentenyloxyethyl acrylate
SM styrene monomer
BzMA benzyl methacrylate
MMA methyl methacrylate
AMBN 2,2′-azobis-2-methyl butyronitrile
ADVN 2,2′-azobis(2,4-dimethylvaleronitrile)
EEP ethyl 3-ethoxypropionate
TABLE 2
Examples
Components
1
2
3
4
5
6
7
8
Organic Pigment
A-1
A-1-1
20
100
20
(A)
A-1-2
50
150
200
(parts by weight)
A-1-3
80
200
A-2
A-2-1
30
10
A-2-2
20
100
Dye (B)
B-1
formula (I-5)
5
20
(parts by weight)
B-2
formula (I-26)
10
30
30
B-3
formula (I-32)
20
40
B-4
formula (I-35)
30
50
Alkali-soluble
C-1
C-1-1
100
Resin (C)
C-1-2
100
(parts by weight)
C-1-3
70
C-1-4
50
C-1-5
20
C-1-6
30
C-1-7
30
50
C-1-8
50
70
C-2
C-2-1
80
C-2-2
70
C-2-3
50
C-2-4
30
Compound having
D-1
60
300
80
unsaturated
D-2
100
200
600
ethylenically group
D-3
150
100
450
(D)
(parts by weight)
Photo-initiator (E)
E-1
3
10
20
30
15
50
(parts by weight)
E-2
3
20
30
20
30
20
30
E-3
4
25
25
E-4
10
10
30
25
Organic Solvent
F-1
500
1000
2000
2500
3000
4000
2000
(F)
F-2
2500
3000
(parts by weight)
Additive (G)
G-1
1
(parts by weight)
G-2
5
Evaluation
Contrast Ratio
◯
◯
◯
⊚
◯
◯
⊚
⊚
VHR
⊚
⊚
⊚
⊚
◯
⊚
⊚
⊚
TABLE 3
Comparative Examples
Components
1
2
3
4
5
6
7
Organic Pigment
A-1
A-1-1
100
150
(A)
A-1-2
100
(parts by weight)
A-1-3
120
A-2
A-2-1
10
20
A-2-2
10
30
Dye (B)
B-1
formula (I-5)
50
(parts by weight)
B-2
formula (I-26)
50
B-3
formula (I-32)
20
B-4
formula (I-35)
50
Alkali-soluble
C-1
C-1-1
100
Resin (C)
C-1-2
50
(parts by weight)
C-1-3
100
C-1-4
50
C-1-5
C-1-6
C-1-7
C-1-8
C-2
C-2-1
50
C-2-2
100
C-2-3
100
C-2-4
50
100
Compound having
D-1
80
150
300
unsaturated
D-2
80
200
ethylenically group
D-3
150
80
(D)
(parts by weight)
Photo-initiator (E)
E-1
10
10
20
20
10
30
(parts by weight)
E-2
20
20
20
20
10
20
E-3
20
10
E-4
10
10
30
10
Organic Solvent
F-1
1000
1000
2500
3000
3000
(F)
F-2
2500
1000
(parts by weight)
Additive (G)
G-1
(parts by weight)
G-2
Evaluation
Contrast Ratio
X
X
X
X
◯
X
X
VHR
◯
◯
◯
◯
X
X
X
A-1-1 C.I. Pigment Blue 15:4
A-1-2 C.I. Pigment Blue 15:6
A-1-3 C.I. Pigment Blue 60
A-2-1 C.I. Pigment Purple 19
A-2-2 C.I. Pigment Purple 23
B-1 Dye as shown in formula (I-5)
B-2 Dye as shown in formula (I-26)
B-3 Dye as shown in formula (I-32)
B-4 Dye as shown in formula (I-35)
D-1 Dipentaerythritol hexaacrylate (made by Toagosei Co. Ltd)
D-2 Trihydromethylpropyl triacrylate
D-3 TO-1382 (made by Toagosei Co. Ltd)
E-1 2-Methyl-1-(4-methyl thiol benzyl)-2-morpholines-1-acetone
E-2 2,2′-Bis(2-dichlorophenyl)-4,4′5,5′-tetraphenyl-1,2′-biimidazole
E-3 4,4′-Bis(diethylamine)benzophenone
E-4 1-(4-Phenyl-thio-phenyl)-octane-1.2-dion 2-oxime-O-benzoate
F-1 Ethyl 3-ethoxypropionate
F-2 Propylene Glycol Mono-methyl Ether Acetate
G-1 3-Sulfanol propyl trimethoxylsilane
G-2 2,2-Thio bis(4-methyl-6-tertbutylphenol) | The present invention relates to a blue photosensitive resin composition for a color filter and an application thereof. The blue photosensitive resin composition includes an organic pigment (A), a dye (B), an alkali-soluble resin (C), a compound having an ethylenically unsaturated group (D), a photo-initiator (E) and a solvent (F). The alkali-soluble resin (C) includes a first alkali-soluble resin (C-1) having a hindered amine structure. The blue photosensitive resin composition of the present invention can improve a voltage holding ratio and a contrast ratio of the color filter. | 6 |
BACKGROUND OF THE INVENTION
This invention pertains to data processing systems employing virtual memory organizations, and more specifically to the organization and operation of cache tables in such systems.
The cost of memory hardware practically limits the amount of semiconductor memory that can be used in a processor system. However, users are demanding broader capabilities from their systems than can be practically and economically supported by a reasonable amount of semiconductor memory. In order to expand its memory capability, a system can be provided with a virtual memory using secondary storage devices, such as electromagnetic disks or tapes, as an adjunct to the semiconductor memory.
The requirement for efficient utilization of a virtual memory system has led to the development of virtual addressing in which a virtual address defining the map of the entire memory system is subject to address translation that converts the virtual address into a physical address corresponding to a location in the main memory.
As is known, a virtual memory organization is transparent to the system user who writes programs for a processing system as though all sectors of the virtual memory space are equally accessible. However, the operating program of a virtual memory processing system manipulates the virtual address supplied by the user to shift data between the main semiconductor memory and the secondary memory so that currently-accessed memory segments are stored into the main memory when needed, and returned to the secondary memory when not needed. Conventionally, this process involves translation of the virtual address to the physical address, with the physical address identifying main memory storage space wherein the currently-used memory segments are stored.
In order to increase the speed with which address translation takes place, a memory address cache is often used. The cache can comprise a table associating the most recently accessed virtual addresses and their translated physical addresses. Thus, when a virtual address is produced by the central processing unit (CPU) of the processing system, a memory management unit (MMU) will first attempt to match the virtual address with an entry in the cache table. If the produced virtual address is contained in the cache table, the address translation is complete and the main memory location can be immediately accessed.
The cache table is normally constructed as a lookup table whose contents are the most recently-used physical addresses, each of which is stored together with a plurality of status or control bits. As is known, the status or control bits can be used to monitor, among other things, the frequency with which a physical address is referenced and whether or not data at the referenced main memory location indicated by the physical address has been modified.
A cache memory can take any one of several well-known general forms such as directly-, associatively-, set associatively-, or sector-mapped. See Computer Architecture and Parallel Processing, K. Hwang Et Al, McGraw-Hill, 1984. These representative cache memory organizations all require a two-level cache structure: the first level contains the virtual-to-physical memory address translation, while the second confirms that the desired memory sector indicated by the physical memory is actually in the main memory storage. This requires two lookup table operations and two levels of circuitry to implement them.
A simplified cache address table would reduce the total number of lookup table operations and the amount of circuitry.
It is therefore the principal object of the present invention to provide a cache address table affording a simplified lookup operation.
It is a further object of the present invention to reduce the hardware requirements for such a cache address table.
SUMMARY OF THE INVENTION
The present invention simplifies the cache address table lookup operation by implementing a lookup table associating the most recently accessed virtual memory addresses with their corresponding physical memory addresses in a single lookup table implemented by three random access memory devices (RAM's).
The invention concerns a cache memory address apparatus for use in a processing system producing virtual memory addresses, cache memory addresses corresponding to respective virtual memory addresses, and physical memory addresses translated from corresponding virtual memory addresses.
The apparatus of the invention includes a cache address storage unit having plural addressable locations, each for storing the upper most significant bit (MSB) portion of a cache memory address at a storage location that is addressed by the upper MSB portion of a virtual memory address to which the cache memory address corresponds and for storing the lower MSB portion of the cache memory address at another storage location that is addressed by the lower MSB portion of the correspondent virtual memory address.
An enabling gate responsive to data stored in the cache address storage unit provides a miss signal when one storage location of the cache address storage unit addressed by a portion of a virtual memory address does not contain a corresponding cache memory address portion. The gate further provides an enabling signal when each cache address storage unit location addressed by a virtual memory address contains a corresponding stored cache memory portion.
Finally, the cache memory address apparatus includes a physical address RAM having plural addressable storage locations for storing physical memory addresses at locations addressed by cache memory addresses when the enabling gate provides the enabling signal.
Other objects, features and advantages of the present invention will become apparent and be appreciated by reference to the detailed description of the invention provided below considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating a portion of a processing system, including a cache memory table.
FIG. 2 is a block diagram illustrating how virtual memory addresses produced by a processing system are converted to physical addresses by an address translator.
FIG. 3 is a block diagram illustrating a cache memory address apparatus in accordance with the present invention and schematic figures of address signals that illustrate the operation of the apparatus.
FIGS. 4A and 4B are schematic diagrams illustrating how flag data entered into the apparatus of the invention enable the apparatus to access a stored physical address.
FIG. 5 is a flow diagram illustrating how the memory management unit of FIG. 1 controls the operation of the apparatus of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A conventional processing system can embrace a number of basic equipments including a programmable central processing unit (CPU), a main semiconductor memory, a memory management unit (MMU) and programmable capability in the MMU for performing address translation on virtual memory addresses provided by the CPU. Such components are known in the art. For example, a microprocessor, including a high performance CPU and a memory management unit, are available from National Semiconductor Corporation under the product designations NS32032 and NS16082, respectively. Devices suitable for assembling a main semiconductor memory are generally available in the form of random access memories (RAM's) of varying storage capacity.
The general interconnection of such units is illustrated in FIGS. 1 and 2 where a CPU 10 is connected to a memory 12 by way of an MMU 14 containing a cache table 16. During its operation, the CPU 10 will provide virtual memory addresses to the MMU 14 which translates them, by well-known methods, into other addresses. One result of address translation is a physical memory address which accesses storage space in the memory 12.
The process of address translation is speeded up by the provision of a cache table in the MMU. As is known, the cache table 16 can be used to hold a predetermined number of virtual memory addresses which have been most recently provided to the MMU 14. Associated with the virtual addresses are their translated physical addresses. Thus, when the CPU 10 provides a virtual address to the MMU 14, the MMU 14 first attempts to match the virtual address entry in the cache table 16 associated with a previously-translated physical address.
If the current virtual address does not have an associated physical address contained in the cache table 16, the MMU 14 obtains a physical address by the address translation operation represented in FIG. 2. Typically, an MMU will have a combination of circuitry and programming forming an address translator 18. The translator 18 has the capacity of translating all virtual addresses into corresponding physical addresses by a common formula or mapping function. The translation is usually performed upon predetermined most significant bits (MSB's) of the virtual address to produce corresponding MSB's of the physical address. This process is illustrated in FIG. 2 where a virtual address 20 having least significant bits (LSB's) 0-8 and MSB's MSB-9 is presented to the MMU 14. Address translation is performed by the translator 18 operating on the virtual address MSB's to produce the MSB's of the physical address 22. As is typical, the LSB's of the virtual address will be carried over without translation to form the LSB's of the physical address.
Translation of the virtual address is accompanied by provision of overhead bits (shown in FIG. 2 as being obtained from the address translator 18) which are used by the MMU to manage the cache. One bit is called the "in cache" bit; other bits, called "status bits", are used to implement to cache management policy of the MMU.
The overhead bits are stored in the cache table together with the physical address so that, when the physical address is retrieved from the table, it is accompanied by the overhead bits stored with it.
The operation of the cache memory address apparatus of the present invention which can assist the process of address translation by functioning as a novel cache memory table is illustrated in FIG. 3. In FIG. 3, a cache address memory storage device 23 includes a pair of conventional RAM's 24 and 26. Each of the RAM's 24 and 26 contains 1024 (1K) addressable storage locations, each location having the capacity of storing 8 bits of information; thus the designation 1K×8 for each RAM. In the preferred embodiment, only six of the eight available bit positions in each storage location of the RAM's 24 and 26 are used, with one bit from each RAM being provided to the input of a NAND gate 28 and the other five combining to form a 10-bit address which is fed to the address (A) port of a 1K×20 RAM 30. The RAM 30 is enabled to output data stored at a location indicated by the address input at the A port when an ENABLE signal from the NAND gate 28 is fed to the chip select (CS) port of the RAM 30.
In operation, the upper ten MSB's of a virtual address 32 are fed to the A port of the RAM 24 and the lower ten MSB's of the virtual address 32 are fed to the address A port of the RAM 26. If the virtual address 32 is one that has recently been provided by the CPU 10, a 10-bit cache address 34 will have been stored in the RAM's 24 and 26, with the MSB's, bits 5-9, of the cache address stored at the location in the RAM 24 addressed by the upper MSB's of the virtual address 32 and the cache address LSB's, bits 0-4, in the location in RAM 26 addressed by lower MSB's of the virtual address 32. In practice, the cache address can be provided by a cache address translation, not shown, that can be implemented using well-known methods in an MMU such as the MMU 14.
In addition, when bits 5-9 of the cache address 34 are stored at the RAM storage location addressed by MSB's 19-28 of the virtual address 32, one of the remaining three bits is set. This function can also be conventionally implemented in an MMU such as MMU 14. Likewise, when the LSB's of the cache address 34 are stored in the RAM storage location addressed by the upper MSB's of the virtual address 32, one of the three remaining bits is set. It is the two set bits which are provided to the NAND gate 28 that cause its output to go low and to produce the ENABLE signal for the RAM 30. When the output of the NAND gate 28 goes low, data residing at the storage location in the RAM 30 addressed by the cache address 34 is output from the data output (D o ) port of the RAM 30. If the "in cache" bit output by the RAM 30 is set, the 20 address bits stored at the addressed location will provide the 20 MSB's (bits 28-9) of the physical address 36, with the LSB's of the physical address being taken from the corresponding LSB's of the virtual address 32 as described above.
In FIG. 4A, the data format 40 represents each of the addressable storage spaces in the RAM 24 when the FIG. 3 cache memory address apparatus is set to an initial state, as when the processing system it forms a part of is initially turned on or reset. Similarly, the data format 42 represents the initial setting of each of the addressable storage locations in the RAM 26. At the start of operation, the bit in bit position 7 of each of the data formats 40 and 42 is set to zero. Both of these bit positions are the data outputs which are sampled by the NAND gate 28 each time the RAM's 24 and 26 are addressed. Thus, whenever the RAM location addressed by one of the two MSB portions of a virtual address has had no data written to it, the gate 28 will provide a 1, indicating that the current virtual address has had no cache address assigned to it. The 1 output by the gate 28 in these circumstances can also form a conventional MISS signal that will cause the MMU 14 to undertake appropriate operations, described below, necessary to make a cache entry for the current virtual address.
As illustrated in FIG. 4B, when a virtual address is assigned a cache address, the cache address, comprising ten bits, will be split as described above between the RAM 24 and RAM 26, with the five bits in the RAM 24 designated the cache address MSB's (CAM) and the lower five bits the cache address LSB's (CAL). When the MSB's and LSB's of a cache address are entered into the respective RAM's, each will be entered into bits 0-4 of the 8-bit space addressable by the corresponding MSB's of the virtual address to which the cache address is assigned. At the same time that the CAM's and CAL's are entered, bit 7 in each of their respective storage locations is set. Then, when the same virtual address occurs after the entry of the cache address portions into the RAM's, the set seventh bits will cause the output of the gate 28 to go low, enabling the RAM 30 to output the data stored at its storage location addressed by the cache address comprising the upper and lower cache address portions currently output. If the physical address translated from the current virtual address has been stored at the location accessed by the cache address, the physical address MSB's will be output by the RAM 30 together with the "in cache" and status bits stored with it.
A typical example of how the cache memory address apparatus of FIG. 3 is to be used in a system embracing the elements of FIG. 1 will now be described. When the system is initially turned on, or after it is reset, the following data pattern will be written into all locations of the RAM's 24 and 26 to indicate that the cache is empty: 0xxx xxxx, where 0 indicates a bit is reset, and x indicates a "don't care" state.
When the CPU 12 provides a virtual memory address, the upper and lower MSB groups described above are provided to the RAM's 24 and 26, respectively. Assume, for example, that the first virtual address provided is:
(0000 0000 00) UM (00 0000 0000) LM (x--x)LSB's
where UM indicates (upper) MSB's 28-19 and LM, (lower) MSB's 18-9. The output of both of the RAM's 24 and 26 is 0xxx xxxx, since the system was just initialized. Therefore the output of the gate 28 will be high, indicating that the virtual address sector represented by its 20 most significant bits has no corresponding entries in the cache. At this time, an MMU such as MMU 14 will select a cache address of 10 bits to correspond to the virtual address, for example, 0000 0000 00, and will write 1xx0 0000 into the RAM 24 at address 0000 0000 00 (corresponding to MSB's 28-19 of the first virtual address). Likewise, 1xx0 0000 will be entered into the RAM 26 at address 0000 0000 00 (corresponding to MSB's 18-9 of the first virtual address).
Now, the cache address 0 0000 0 0000 goes to the RAM 30, the RAM is enabled in a typical fashion to have data written to it, and the physical address translated from the first virtual address is entered, together with the "in cache" and status bits, at the location accessed by the cache address 0 0000 0 0000 output by the RAM's 24 and 26. As is known, the capacity of the RAM 30 can be expanded to store at each addressable location status bits corresponding to information such as "location has been accessed", "location has been written to", "process number", "write protect", "read protect", and so on according to the needs of the preferred memory management policy.
Assume now that on the next process cycle the same memory location is accessed and the first virtual memory address is again provided to the MMU 14. Now, when the upper MSB's 0000 0000 00 are provided to the RAM 24, and the lower MSB's 0000 0000 00 to the RAM 26, the output of gate 28 will be low, corresponding to the ENABLE signal, and cache address 0 0000 0 0000 will be provided to the RAM 30 where the physical address (PA) MSB's and status bits will be provided as an output.
Assume now that on the third memory access, a different memory location is indicated. For example, the following virtual address might be provided:
(0000 1000 00) UM (0000 0010)LM (x--x)LSB's
When the virtual address MSB groups are presented to their respective RAM's, bit 7 of the accessed location in each RAM will contain a 0, causing the gate 28 to provide the MISS signal, indicating that the virtual address has no corresponding entry in the cache. Then the MMU will assign, for example, the cache address 0 0001 00001 to the current virtual address and enter 1xx0 0001 into the RAM 24 at address location 0000 1000 00 and into the RAM 26 at 0000 0000 0010. Now, the cache address 0 0001 00001 is provided to the RAM 30 where the translated physical address of the current virtual address is written together with the appropriate overhead bits.
This process can proceed until the RAM 30 is full. At this time a replacement algorithm will have to be employed to replace one of the physical addresses stored in the RAM 30. Many algorithms are available to accomplish this, the "least recently used" (LRU) replacement algorithm being one example. When one of the physical addresses is to be replaced in the RAM 30, its corresponding virtual address is provided to the RAM's 24 and 26 where 0xxx xxxx is written to the address locations in those RAM's. Then, the current virtual address is provided to the RAM's 24 and 26 and the cache address of the removed physical address is assigned to the current virtual address and entered as described above into the locations and RAM's 24 and 26 accessed by the current virtual memory. At the same time that the cache address is reassigned to the current virtual address, bit number 7 in the addressed locations in the RAM's 24 and 26 is set. Then, the physical address translated from the current virtual address is entered with the required overhead bits into the location in the RAM 30 accessed by the reassigned cache address.
It should be evident that a virtual address whose translated physical address has not yet been entered into the RAM 30 can nevertheless stimulate the production of an ENABLE signal from the gate 28. This can occur when, for example, the upper MSB's of the current virtual address have occurred in one recent preceding virtual address, while the lower MSB's are the same as the lower MSB's in a different recently preceding virtual address. When this occurs, both of the MSB sectors will access a pair of filled cache memory address storage locations, each of which has a 1 in bit position 7 resulting from the two preceding virtual addresses. Then, the RAM 30 will be enabled and may provide data that is not equivalent to the physical address translated from the current virtual address. In this case the "in cache" bit indicates whether the correct physical address is or is not in cache. In the preferred embodiment, the "in cache" bit being set indicates the physical address is in cache. Thus, if the bit is true, the MMU will treat the data at the addressed location as the MSB's of the correct physical address; if false, the entry of the physical address MSB's will be made and the bit set.
In keeping with conventional memory management nomenclature, a high output from the gate 28 can be used as a typical MISS signal, indicating that a physical address is not in cache. Similarly, the "in cache" bit, if set, can be used as a HIT signal, to show the presence of a physical address in cache.
The HIT and MISS signals are used by the MMU 14 to take the appropriate steps to enter the currently-translated physical address into the RAM 30 when appropriate. The HIT/MISS signal can also be used to forward the physical address signal stored in the RAM 30 to other circuitry, not shown, for memory access or exchange procedures.
The MMU 14 can be conventionally configured by means of a programmable controller, to control the cache memory address apparatus of the invention by means of a procedure illustrated in FIG. 5. Thus, when the MMU 14 and cache memory address apparatus are first turned on or reset, the RAM's 24, 26 and 30 are initialized and the first virtual address is sent to the MMU 14. When the first virtual address is received, the MMU 14 translates the physical address and obtains a cache address, for example, from a cache address table. Next, the cache address MSB and LSB portions, CAM and CAL, are entered into the RAM's 24 and 26 at the memory address locations determined by the upper and lower MSB's of the virtual address as described above. Then, with CAM and CAL entered, and bit 7 of both locations set, the gate 28 selects the RAM 30 and the MMU 14 can enter the physical address through a conventional write cycle at the address location in the RAM 30 determined by the cache memory address resulting from a combination of the MSB and LSB cache address portions available from the RAM's 24 and 26.
During the first tour through the FIG. 5 procedure, the MMU 14 can check the overhead bits stored with the physical address entered into the RAM 30. Initially a check of the status bits would be a validity check since no history of prior activity will have affected them.
After the initial virtual address has set up the apparatus of the invention, the next virtual address is translated by the MMU 14 and the virtual address MSB's are sent to the RAM's 24 and 26. Now, the MMU 14 will monitor the output from the gate 28 to determine whether a cache address has been assigned to the current virtual address. It should be evident that if the output of the gate 28 is high, then, as explained above, a cache memory portion has not been stored at either or both of the locations addressed by the virtual address MSB's. In this event, a MISS will be interpreted, the MMU 14 will undertake a procedure for assigning a cache address and storing a physical address in the RAM 30, if need be, by a least recently used (LRU) algorithm to replace a previously-stored physical address.
In the event that the gate 28 enables the RAM 30, the MMU 14 will inspect the "in cache" bit at the addressed location of the RAM to determine whether the current virtual address has its translated physical address stored in the RAM 30. In the event that the "in cache" bit is set, indicating that the addressed physical address in the RAM 30 is equivalent to the translated physical address, the MMU 14 will update the status bits of the stored with the physical address, without changing the address MSB's, and then wait for the next virtual address.
In the event that the "in cache" bit is reset, the MMU 14 again undertakes to store the currently-translated physical address at an appropriate location in the RAM 30. Under these circumstances, if all of the storage locations in the RAM 30 are filled, the LRU process will be employed to select the least recently used physical address, appropriating the cache memory address where the least recently used physical address is stored as the cache memory address to be associated with the current virtual address. The current virtual address will then be assigned the appropriated cache memory address by means of the storage procedure for the RAM's 24 and 26 described above. In addition, the currently-translated physical address will be stored, together with its overhead bits, in the RAM 30 at the location addressed by the appropriated cache memory address.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described. | In a processor system with a virtual memory organization and a cache memory table storing the physical addresses corresponding to the most-recenty used virtual addresses, access to the cache table is enhanced by associating upper and lower MSB portions of a virtual address with corresponding upper and lower portions of an associated cache address. The separate cache address portions are placed in separate cache address storage devices. Each cache address storage device is addressed by respective virtual address MSB portions. A physical address storage device stores physical addresses translated from virtual addresses in storage locations addressed by cache addresses associated with the respective virtual addresses from which the physical addresses were translated. | 6 |
BACKGROUND OF THE INVENTION
1) Field of the Invention
This invention relates to apparatus for measuring volumes of material for filling cans or other containers. Most specifically, this invention relates to measuring apparatus for measuring volumes of two materials, such as semi-solid and liquid materials, for mixing together to fill containers.
2) Prior Art
The canning of semi-liquid, pasty or heterogeneous products such as jam containing lumps of fruit, animal foods with large lumps of meat, or foods for human consumption with lumps of meat or vegetables raises problems as to the control of quantity. Some of the machines known in the prior art utilize a plurality of measuring chambers mounted on a rotary support, each of said chambers including a cylinder housing a piston to receive and then discharge product. The chambers are generally arranged vertically around a circumference of the rotary support. In this configuration, an upward stroke of the piston sucks product from a tank through a supply conduit into the cylinder, with the tank generally being located in a central area of the rotary support. A downward stroke of the piston delivers the product from the cylinder into a delivery nozzle which includes a second piston to force the product therefrom into a can. A valve, located in the chamber, selectively controls the opening or closing of passages between the chamber and the tank and delivery nozzle. See, for example, U.S. Pat. No. 4,466,557.
Accurate measurement of the quantity of product delivered by the apparatus is dependent upon a great number of factors. In the past, canning of a product which comprises a liquid and a solid phase has been accomplished generally in one of two ways. A first way has been to use two separate pieces of equipment for filling a can with product. In particular, a first piece of equipment is used to fill the can partially with the more solid, viscous product, and then a second machine adds the liquid product thereto before the can is sealed. This method of canning has proved to be less than satisfactory in that two pieces of equipment or machines are required to complete a single dose for each can.
A second prior art approach involves mixing the solid viscous product with the liquid product in the tank of a single apparatus and then discharging the mixture into cans. This method has also proven to be less than satisfactory in that the more solid parts of the product tend to settle to the bottom of the tank so that the first cans filled tend to have more solid product packed therein, while the cans filled later in the process tend to contain more liquid.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the present invention to provide a system for overcoming the aforesaid disadvantages by utilizing a single apparatus capable of a two-stage measurement of solid and liquid portions of a product to be canned.
It is further an object of the present invention to provide a two-stage apparatus for canning a two-constituent product which allows for adjustment of the relative proportion of the two constituents making up the final product.
It is further an object of the present invention to provide a two-stage filling apparatus which will significantly mix liquid and solid portions of a product just prior to the measured dose of product being placed in the can.
These and other objects of the present invention are realized in an improvement in apparatus for controlling the quantity and relative proportions of constituents of a product for canning. The apparatus includes a quantity measuring chamber which is substantially vertical and mounted on a support. The chamber itself comprises a tubular enclosure having its lower part connected, by a pair of supply conduits, to a pair of tanks containing a first constituent (such as a liquid product), and a second constituent (such as a solid product), respectively. The lower part of the tubular enclosure is also connected by a delivery conduit to a vertical cylindrical filling nozzle. A first piston is slidably disposed in the tubular enclosure and a second piston is slidably disposed in the vertical cylindrical filling nozzle. The delivery conduit opens into the vertical cylindrical filling nozzle through a lateral opening. A control valve is located in the chamber to open and close the supply conduits and delivery conduit in predetermined succession for allowing filling of the chamber with the first and second constituents and delivery of the combination of the constituents into the filling nozzle.
In accordance with one aspect of the invention, the support is formed in a circular configuration, as is the control valve in the chamber. The control valve is caused to rotate by a cam and follower system, with the cam being located on the circular support, and the follower being formed as part of the control valve. The cam can be adjusted as to its location on the circular support to thereby control the movement of the control valve from a first stage, in which the first constituent is drawn into the chamber, to a second stage, in which the second constituent is drawn into the chamber. Such adjustment directly controls the relative proportion of constituents of a product which comprises a complete dose to be delivered to the filling nozzle.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more readily understood on reading the following description with reference to the accompanying drawings, like numerals in each drawing being used to represent like elements, in which:
FIG. 1 is a partial, top cross-sectional view of measuring apparatus embodying the principles of the present invention;
FIG. 2 is a cross-sectional view of part of the apparatus of FIG. 1 taken along lines II--II;
FIG. 3 is a partial side view showing the control of the pistons of the apparatus according to the principles of the present invention;
FIG. 4 is a top plan view of a portion of the circular support which includes camming structure by which a cam follower of a control valve cams through various stages of operation of the apparatus;
FIG. 5 is an enlarged, fragmented view of an adjustable position camming structure by which the cam follower of the control valve is cammed from the first stage to the second stage of a product measurement operation; and
FIG. 6 is a cross-sectional view of the structure of FIG. 5 taken along lines VI--VI of FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIGS. 1 and 2, canning apparatus 10 of the present invention includes a circular support 13 disposed to rotate (under power of an electrical, hydraulic or like motor, not shown) about a vertical axis 11, a plurality of quantity measuring chamber defining structures 12 which are oriented generally vertically and are integrally attached to the circular support, and a viscous or solid material supply tank 14. The quantity measuring chambers 12 are generally vertically mounted on the periphery of the circular support 13 such that the central axis 11 thereof is generally parallel to the axes of the chambers 12.
Each chamber 12 is formed essentially into a tubular enclosure which contains a piston 15 (FIG. 2) which is operably mounted to slide longitudinally in the enclosure when actuated by a control mechanism in a manner to be described hereinafter. Each chamber 12 (FIG. 2) includes a control valve 16 which is of generally hollow cylindrical shape and which extends from an upper portion 17 of the measuring chamber 12 to form a continuous elongated chamber opening of uniform diameter. The control valve 16 includes a bottom section 16a which effectively closes off the end of the elongated tubular interior of the chamber 12. The control valve 16 communicates with a viscous or solid material supply conduit 18 through a valve opening 19, and alternatively with delivery conduit 20. Also, control valve 16 can communicate with liquid material supply conduit 21 through valve opening 22. The openings 19 and 22 in the control valve 16 allow supplying and delivering viscous and liquid materials into and out of the measuring chamber 12. The viscous material supply conduit 18 allows for material flow from the viscous material supply tank 14 to the measuring chamber 12. Likewise, the liquid material supply conduit 21 is in fluid flow connection with a liquid material supply tank 23 (shown in FIG. 3) via a supply line 23a, and with the measuring chamber 12.
Delivery conduit 20 allows measured product to pass from measuring chamber 12 therethrough into a vertical, cylindrical filling nozzle 24 and out through a filling nozzle opening 25. Under the lower end of the filling nozzle 24, a can (not shown) would be placed for filling. A secondary piston 26 is mounted for sliding in the filling nozzle 24 between two positions, a lower position (shown in FIG. 2), and an upper position in which the lower end of the piston face 26a is just level with the upper edge of the filling nozzle opening 25.
Valve opening 19 of control valve 16 is aligned with either the viscous material supply conduit 18 or the delivery conduit 20. The valve opening 22 is either aligned with liquid material conduit 21 or is sealed off from fluid flow therethrough by a chamber skirt 27. Since the chamber skirt 27 does not rotate relative to the chamber 12, openings 28, 29 and 30 in the chamber skirt remain constantly aligned with conduits 20, 18 and 21 respectively.
The control valve 16 is rotated to its proper orientation in the filling and delivery stages of the apparatus 10 during operation by a lever 31 (FIG. 2) which is provided with a cam follower 32 operable to cooperate with fixed and adjustable camming units (identified at 33, 34 and 35 in FIG. 4) in a manner to be described hereafter.
FIG. 3 diagrammatically illustrates the control mechanism for the chamber piston 15 and nozzle piston 26. A nozzle piston rod 26b and a chamber piston rod 15b are slidably mounted in a support bracket 36 which is integrally mounted with the viscous material supply tank 14 and rotates therewith. The rods 15b and 26b are provided with laterally mounted rollers 37 and 38 respectively, which rotate about axes 37a and 38a respectively. The rollers 37 and 38 are operable to roll along pathways formed by runners 39a and 39b, and 40a and 40b respectively. The runners 39a and 39b, and 40a and 40b are secured to a supporting structure forming a part of a fixed frame (not shown) of apparatus 10. The running paths 39 and 40 constitute guides for rollers 37 and 38 and control the upward and downward strokes of piston 15 and 26 through suitable slopes imparted to them during movement of the pistons 15 and 26 about axis 11 of the apparatus 10. As is readily evident, runners 39a and 40a control the downward movement of the pistons, while rollers 39b and 40b control their upward movement.
The runners 39a and 39b, and 40a and 40b need only be given slopes, i.e. profiles, which are adapted to the particular stroke (and speed of the stroke) desired for each piston as the piston moves about axis 11 at a constant speed. The runners can in fact be made in several sections to allow the adaptation of one or more parts of each roller to the kinematics required for the particular pistons and likewise to allow modifications thereof if desired.
FIG. 4 diagrammatically illustrates the camming units 33, 34 and 35 which control the rotational orientation of the control valve 16 by moving the cam follower 32 (FIG. 2) to predetermined circumferential orientations relative to measuring chamber 12 as chamber 12 rotates (moves) about axis 11 of the apparatus 10. Each of the camming units 33, 34 and 35 functions to reorient cam follower 32 (which in turn reorients control valve 16 and the openings 19 and 22 therein) from one phase of operation to the next phase thereof as the particular measuring chamber 12 passes through each camming unit during a complete cycle of rotation about axis 11 of the apparatus 10.
Cam follower 32 is rigidly attached by means of lever 31 to the bottom 16a of the control valve 16. Therefore the follower 32 is allowed to move only in a circumferential direction around the longitudinal axis of the measuring chamber 12. Each camming unit causes the follower 32 to be oriented at a predetermined circumferential position corresponding to a particular alignment of valve openings 19 and 22 with conduits 18, 20 or 21 and thus a particular phase of the measuring and delivering process.
Camming units 33 and 34 are fixedly attached to a nonrotating portion of the apparatus 10 such as support arc 41. Camming unit 35, which is adjustable, is also attached to a nonrotating portion of apparatus 10 such as the support arc 41. However, it is attached, for example by a clamp 35a which can be tightened and untightened, so as to be slidably positionable at any point between fixed camming units 33 and 34 while remaining at a constant radial distance from axis 11.
Fixed camming units 33 and 34 function in the manner well known in conventional prior art canning apparatus of the present type. Fixed camming unit 33 includes a cam plate 42 in which a cam channel 43 is formed. The cam plate 42 is located such that it lies directly beneath the path of movement of the measuring chamber 12, such that cam channel 43 can accept follower 32 therein.
The cam channel 43 is enlarged, or widened, at its entrance opening 44 so that follower 32, regardless of its orientation beneath measuring chamber 12, will be picked up by the camming channel entrance when the particular measuring chamber 12 passes thereover. As the measuring chamber 12 continues to pass over cam plate 42, the follower 32 is forced into a position relative to the measuring chamber 12 which corresponds to the first phase of the process cycle. An exit opening 45 of cam channel 43 is narrowed to a width approximately equal to the diameter of follower 32 so that as follower 32 leaves cam plate 42, it is precisely located in its proper orientation corresponding to the first phase of the process cycle. This first phase of the process cycle is also the first stage of filling of the measuring chamber 12. As seen in FIG. 1, referring specifically to the topmost measuring chamber 12 in the drawing, the control valve 16 is caused to be rotated such that valve opening 19 aligns with the viscous material conduit 18.
Referring again to FIG. 4, adjustable camming unit 35 includes a cam plate 46 into which a cam channel 47 has been formed. Cam channel 47 includes an entrance 48 which is of sufficient width to entrap follower 32 regardless of its relative orientation with respect to measuring chamber 12, and an exit opening 49 which is of a width substantially equal to the diameter of the follower 32. As can be seen, the cam channel 47 causes the follower 32 to be adjusted to a new circumferential position relative to measuring chamber 12 as it passes over the camming unit 35. The position of follower 32 as it passes from the exit opening 49 corresponds to the second phase of the processing cycle which is also the second filling stage. As best seen in FIG. 1, measuring chamber 12' shows the control valve 16' in its orientation corresponding to the position of follower 32 after passing through cam channel 47. As can be seen, in this position valve opening 22' is aligned with the liquid material conduit 21'.
Referring again to FIG. 4, the fixed camming unit 34 includes a camming plate 50 which has a cam channel 51 formed therein. Channel 51 has an entrance opening 52 formed therein which is of a sufficient width to trap the follower 32 therein regardless of the relative circumferential orientation of follower 32 with respect to the measuring chamber 12 as it passes thereover. Further, channel 51 includes an exit opening 53 which is of a width approximately equal to the diameter of follower 32.
When the measuring chamber 12 passes over cam plate 50, follower 32 is moved into cam channel 51 and reoriented in its circumferential position relative to measuring chamber 12. When follower 32 passes from exit opening 53, it is oriented in a position corresponding to the third phase of the process cycle which corresponds to the delivery stage. As shown in FIG. 1, measuring chamber 12" shows the control valve 16" in its orientation corresponding to the orientation of follower 32 as it leaves exit opening 53 of cam plate 50. In this orientation, the valve opening 19" is aligned with delivery conduit 20".
Again referring to FIG. 4, there is shown a secondary cam channel 54 which is formed in cam plate 46 of the adjustable camming unit 35, and also a secondary cam channel 55 located in cam plate 50 of the fixed camming unit 34. Cam channels 54 and 55 include exit opening 56 and 57 respectively. Adjustable camming unit 35 includes a mobile cam element 58 which locks closed an entrance opening 59 of the secondary channel 54 during normal operating conditions of the apparatus 10. However, should the apparatus 10 fail to be provided with cans to be filled thereby (or more specifically should the apparatus 10 sense that there is no can properly positioned below delivery nozzle 24) the mobile can element 58, moves to unlock the entrance opening 59 of channel 54. Due to the shape of the entrance opening 48, the follower 32, when passing therein, will automatically be directed into channel 54 unless mobile cam element 58 is in position to block the entrance 59 thereof.
If follower 32 has passed through the adjustable camming unit 35 by exiting through exit opening 56 (instead of exiting through exit opening 49), its subsequent orientation as it passes into entrance opening 52 of the fixed camming unit 34 causes it to pass into cam channel 55 and out of exit opening 57 thereof. It should be noted that the radial distance from the axis 11 to the exit opening 57 is equal to the radial distance from the axis 11 to the exit opening 45 of fixed camming unit 33, and equal to the radial distance from axis 11 to the exit opening 56 of adjustable camming unit 35. Further, cam channel 55, cam channel 43, and cam channel 54 are all arcuate in shape with each arc thereof lying on the circumference of an imaginary circle having its center at axis 11. It is evident therefore that follower 32, once orientated in its position dictated by its passage through cam channel 43 and exit opening 45 thereof, will not be reoriented by adjustable camming unit 35 or fixed camming unit 34 if the apparatus 10 senses that no can is present at the delivery nozzle and therefore causes mobile cam element 58 to move out of its locking position of opening 59. Thus, due to the apparatus 10 sensing that no cans are present to receive delivery from delivery nozzle 24, control valve 16 remains stationary throughout the entire process cycle (in fact the control valve 16 remains stationary through any number of process cycles it is caused to execute) due to the fact that mobile cam element 58 no longer blocks entrance opening 59.
It is to be understood that the means in which apparatus 10 senses that a can is not present under the delivery nozzle 24 is the same type of sensing means used in the well known prior art apparatus of this type.
As shown in FIGS. 5 and FIG. 6, a driving cylinder 60 (FIG. 6) is shown for driving the mobile camming element 58; this cylinder may be of the hydraulic or pneumatic type. The cylinder 60 is attached to a lever arm 61 which is attached to the mobile cam element 58. Lever arm 61 is fixed for rotational movement about pin 62.
In operation, mobile cam element 58 is located in its "up" position as is shown in FIG. 6 during normal operation of the apparatus 10. However, should the apparatus 10 sense that no cans are located therein, it signals the driving cylinder 60 which causes lever arm 61 to rotate about pin 62 resulting in mobile cam element 58 lowering into a recess 63 until it no longer blocks opening 59 of channel 54.
Mobile camming element 58 includes a smoothly curving, generally arcuately shaped surface 64 which corresponds to the shape of channel 47 (FIG. 5), and an extension 65 which is intended to match with abutment 66 of the cam plate 46 when the mobile cam element 58 is in its "up" position.
The operation of apparatus 10 of the drawings will now be further described.
The operator first adjusts the location of adjustable camming unit 35 along the support arc 41 (see FIG. 4) to a position which corresponds to the proper ratio of viscous and fluid materials which are to be drawn into the measuring chamber 12. It should be noted that movement of adjustable camming unit 35 toward the fixed camming unit 33 causes phase one of the cycling process (which corresponds to the first filling stage thereof) to be completed within a smaller portion of the entire cycle so that less viscous material is supplied to the measuring chamber 12. Alternatively, movement of adjustable camming unit 35 toward the fixed camming unit 34 causes the second phase of the process cycle to be shortened so that less liquid material is supplied to the measuring chamber.
At the end of a process cycle, the chamber piston 15, nozzle piston 26, and control valve 16 are all positioned as shown in FIG. 2. The first phase of the processing cycle begins as measuring chamber 12 passes over fixed camming unit 33. Follower 32, and thus control valve 16, are reoriented by the fixed camming unit 33 to a position corresponding to the measuring chamber 12 as shown in FIG. 1 (topmost chamber in drawing). As the chamber 12 continues to rotate about axis 11, the chamber piston 15 is forced upward by the action of roller 37 (FIG. 3) and the upward slope of runner 39b. This piston motion causes viscous or dry material located in viscous material product supply tank 14 to pass through conduit 18, through valve opening 19 into measuring chamber 12 (FIG. 1).
Depending on the positioning of the adjustable camming unit 35, chamber piston 15 has traveled upwardly a predetermined amount of its total upward movement to thus fill chamber 12 a certain amount with the viscous material prior to chamber 12 passing over the adjustable camming unit 35. If the apparatus 10 senses that cans are properly positioned therein, the mobile cam element 58 remains in its "up" position and the follower 32 enters entrance 48 and is forced by arcuate surface 64 of the mobile cam element 58 into the cam channel 47 (FIG. 5). The movement of follower 32 causes the rotation of the control valve 16 to the orientation shown by measuring chamber 12' of FIG. 1. In this position, valve opening 22' is aligned with conduit 21' thus allowing liquid material to pass from the liquid material supply tank 23 (as shown in FIG. 3) into the measuring chamber 12'. As is also evident, valve opening 19' is now partially aligned with delivery conduit 20'. However, due to the previous process cycle, delivery conduit 20 is generally filled with product remaining undelivered from the previous cycle and therefore has no effect of the measuring on the present cycle.
Chamber piston 15 continues its upward motion to draw liquid into measuring chamber 12 until the chamber 12 passes over the fixed camming unit 34. At this point, follower 32 passes through entrance 52 and is routed into cam channel 51 (FIG. 4) which causes it to again be reoriented relative to the measuring chamber 12. The reorientation of the follower 32 causes the reorientation of control valve 16" to the position shown in measuring chamber 12" of FIG. 1. Also, when the chamber 12" passes over the fixed camming unit 34, the chamber piston 15 has arrived at its highest position and is now forced downward by the contact of roller 37 (FIG. 3) with the runner 39a. Further, at this point, the nozzle piston 26 has been lifted by the contact of roller 38 with runner 40b to its highest position in preparation for the third phase of the process cycle which is also the delivery stage thereof. As the chamber 12" continues its rotation about axis 11 through the process cycle, the chamber piston 15 is forced downwardly by runner 39a contacting roller 37 and causes the product located in the chamber 12" to pass through valve opening 19" into delivery conduit 20" and from there into delivery nozzle 24. The chamber piston 15 proceeds to the bottom of measuring chamber 12" and subsequently the nozzle piston 26 is forced downwardly by the contact of roller 38 with runner 40a to push the product out of the nozzle opening 24a (FIG. 2) into the can positioned immediately therebelow. The orientation of the pistons 15 and 26 and the control valve 16 are once again arranged in their end of cycle position as shown in FIG. 2.
As can be seen, a volume of product is again trapped in delivery conduit 20, this amount of product being equal to the amount of product which was trapped in the previous cycle therefore negating its effect on measurement versus delivery of product.
In the instance where apparatus 10 senses that no cans are properly positioned under delivery nozzle 24, the control valve 16 remains with its valve opening 19 aligned with product delivery conduit 18 (as shown in FIG. 1 with reference to measuring chamber 12). The effect is that chamber piston 15 draws viscous material into the measuring chamber 12 at the beginning of the cycle (during the normal phases one and two thereof), but then immediately returns the product directly back into conduit 18 during the end of the cycle (during phase three). Therefore, although the chamber piston 15 (and also the nozzle piston 26) functions in an identical manner whether or not a can is sensed, the failure of control valve 16 to rotate effectively prevents delivery of any product through the opening 24a of the delivery nozzle 24.
It is to be understood that the above described embodiment of the present invention is only illustrative of the application of the principles thereof. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the present invention and the appended claims are intended to cover such modifications and arrangements. For example, the locations of chamber skirt 27 openings 28, 29 and 30 could be rearranged such as by positioning opening 30 between openings 28 and 29. With this configuration, a single valve opening, such as opening 19, would be sufficient to receive product into the chamber 12 and discharge it therefrom. | A two-stage apparatus for measuring quantities of constituents of a product for canning includes a quantity measuring chamber which is substantially vertical and mounted on a support which rotates about an axis. The chamber comprises a tubular enclosure inside which slides a first piston. A lower part of the chamber is connected by supply conduits to a respective one of a pair of tanks, each of which is for holding a different one of the constituent products. The chamber is also connected by a delivery conduit to a filling nozzle, in which slides a secondary piston. A control valve selectively opens and closes the passages through the supply conduits to the measuring chamber in a predetermined order, and for a predetermined period of time to thereby control the relative quantities of the constituents supplied to the chamber. The control valve is adjustable to vary the ratios of constituents introduced into the chamber. The valve also selectively opens the passage through the delivery conduit to allow the first piston to push the product from the chamber into the filling nozzle. The secondary piston may then push the product out of the filling nozzle into a can. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is continuation-in-part of U.S. patent application Ser. No. 14/177,097, filed on Feb. 10, 2014 which is a divisional application of U.S. patent application Ser. No. 13/686,756, filed on Nov. 27, 2012, now U.S. Pat. No. 8,657,525, which is a divisional application of U.S. patent application Ser. No. 12/347,467, filed on Dec. 31, 2008, now U.S. Pat. No. 8,322,945. The present application claims the benefits of U.S. Provisional Application Ser. No. 61/061,567, filed Jun. 13, 2008, entitled “MOBILE BARRIER”, and 61/091,246, filed Aug. 22, 2008, entitled “MOBILE BARRIER”, and 61/122,941, filed Dec. 16, 2008, entitled “MOBILE BARRIER” each of which is incorporated herein by this reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of trailers and other types of barriers used to shield road construction workers from traffic. More specifically, the present invention discloses a safety and construction trailer having a fixed safety wall and semi tractor hookups at both ends.
BACKGROUND
[0003] Various types of barriers have long been used to protect road construction workers from passing vehicles. For example, cones, barrels and flashing lights have been widely used to warn drivers of construction zones, but provide only limited protection to road construction workers in the event a driver fails to take heed. Some construction projects routinely park a truck or other heavy construction equipment in the lane between the construction zone and on-coming traffic. This reduces the risk of worker injury from traffic in that lane, but does little with regard to errant traffic drifting laterally across lanes into the construction zone. In addition, conventional barriers require significant time and effort to transport to the work site, and expose workers to significant risk of accident while deploying the barrier at the work site. Therefore, a need exists for a safety harrier that can be readily transported to, and deployed at the work site. In addition, the safety barrier should protect against lateral incursions by traffic from adjacent lanes, as well as traffic in the same lane.
SUMMARY
[0004] These and other needs are addressed by the various embodiments and configurations of the present invention. In contrast to the prior art in the field, the present invention can provide a safety trailer with a fixed safety wall and semi tractor hookups at one or both ends.
[0005] In a first embodiment, a safety trailer includes:
[0006] (a) first and second removably interconnected platforms, at least one of the first and second platforms being engaged with an axle and wheels, the first and second platforms defining a trailer; and
[0007] (b) a plurality of wall sections supported by the trailer, the wall sections, when deployed to form a barrier wall, are positioned between the first and second interconnected platforms
[0008] (c) wherein at least one of the following is true: [0009] (c1) the trailer supports a ballast member, the ballast member being positioned near a first side of the trailer and the ballast member near a second, opposing side of the trailer, the ballast member offsetting, at least partially, a weight of the plurality of wall sections, and [0010] (c2) the axle of the trailer is engaged with a vertical adjustment member, the vertical adjustment member selectively adjusting a vertical position of a surface of the trailer.
[0009] In a second embodiment, a safety trailer includes:
[0010] (a) first and second platforms;
[0011] (b) a plurality of interconnected wall sections positioned between and connected to the first and second platforms, the plurality of wall sections defining a protected work area on a side of the trailer;
[0012] (c) wherein each wall section has at least one of the following features: [0015] (c1) a plurality of interconnected levels, each level comprising first and second longitudinal members, a plurality of truss members interconnecting the first and second longitudinal members, and being connected to an end member; [0016] (c2) a longitudinal member extending a length of the wall section, the longitudinal member being positioned at the approximate position of a bumper of a vehicle colliding with the wall section; [0017] (c3) a plurality of full height and partial height wall members, the full height wall members extending substantially the height and width of the wall section and the partial height wall members extending substantially the width but less than the height of the wall section, the full height and partial height members alternating along a length of the wall section; and [0018] (c4) first and second end members, each of the first and second end members comprising an outwardly projecting alignment member and an alignment-receiving member, the first and second end members having the alignment and alignment-receiving members positioned in opposing configurations.
[0013] In a third embodiment, a trailer includes:
[0014] (a) a trailer body;
[0015] (b) a removable caboose engageable with the trailer body, the caboose having a nose portion and at least one axle and wheels; and
[0016] (c) a caboose receiving member, the caboose receiving member comprising an alignment device, wherein, in a first mode when the caboose is moved into engagement with the trailer body, the alignment device orients the caboose with a king pin mounted on the trailer body and, in a second mode when the caboose is engaged with the trailer body, the alignment device maintains a desired orientation of the caboose with the trailer.
[0017] In a fourth embodiment, a safety system includes:
[0018] (a) a vehicle;
[0019] (b) first and second platforms;
[0020] (c) a barrier engaged with the first and second platforms, the barrier and first and second platforms forming a protected work space; and
[0021] (d) a caboose, wherein the vehicle and caboose are engaged with the first and second platforms, respectively, wherein the vehicle has a movable king pin plate engaged with a first king pin on the first platform, and wherein the caboose has a fixed king pin plate engaged with a second king pin on the second platform.
[0022] In a fifth embodiment, a safety system includes:
[0023] (a) a vehicle;
[0024] (b) first and second platforms;
[0025] (c) a barrier engaged with the first and second platforms, the barrier and first and second platforms forming a protected work space; and
[0026] (d) a caboose, wherein the vehicle and caboose are engaged with the first and second platforms, respectively, wherein the vehicle and caboose have braking systems that operate independently.
[0027] In a sixth embodiment, a trailer includes:
[0028] (a) first and second platforms;
[0029] (b) a barrier engaged with the first and second platforms, the barrier and first and second platforms forming a protected work space, wherein the barrier is formed by a plurality of interconnected wall sections and wherein the interconnected wall sections slidably engage one another.
[0030] In a seventh embodiment, a trailer includes:
[0031] (a) first and second platforms;
[0032] (b) a barrier engaged with the first and second platforms, the barrier and first and second platforms forming a protected work space, wherein the barrier is formed by a plurality of interconnected wall sections and wherein the interconnected wall sections telescopically engage one another.
[0033] In an eighth embodiment, a trailer includes:
[0034] (a) first and second platforms;
[0035] (b) a barrier engaged with the first and second platforms, the barrier and first and second platforms forming a protected area, wherein the barrier is formed by a plurality of interconnected wall sections, and wherein at least one of the following is true: [0042] (b1) a bottom of the barrier is positioned at a distance above a surface upon which the trailer is parked and wherein the distance ranges from about 10 to about 14 inches; [0043] (b2) a height of the barrier above the surface is at least about 3.5 feet; and [0044] (b3) a height of the barrier from a bottom of the barrier to the top of the barrier is at least about 2.5 feet.
[0036] The present invention can provide a number of advantages depending on the particular configuration.
[0037] In one aspect, the barrier (and thus the entire trailer) is of any selected length or extendable, but the wall is “fixed” to the platforms on one side of the trailer. That side, however, can be changed to the right or left side of the road, depending on the end to which the semi tractor attaches. This dual-ended, fixed-wall design thus can eliminate the need for complex shifting or rotating designs, which are inherently weaker and more expensive, and which cannot support the visual harriers, lighting, ventilation and other amenities necessary for providing a comprehensive safety solution. The directional lighting and impact-absorbing features incorporated at each end of the trailer and in the caboose can combine with the fixed wall and improved lighting to provide increased protection for both work crews and the public, especially with ever-increasing amounts of night-time construction. End platforms integral to the trailer's design can minimize the need for workers to leave the protected zone and eliminate the need for separate maintenance vehicles by providing onboard hydraulics, compressors, generators and related power, fuel, water, storage and portable restroom facilities. Optional overhead protection can be extended out over the work area for even greater environmental relief (rain or shine). The fixed wall itself can be made of any rigid material, such as steel. Lighter weight materials having high strength are typically disfavored as their reduced weight is less able to withstand, without significant displacement, the force of a vehicular collision. The trailer can carry independent directional and safety lighting at both ends and will work with any standard semi tractor. Optionally, an impact-absorbing caboose can be attached at the end of the trailer opposite the tractor to provide additional safety lighting and impact protection.
[0038] In one aspect, the trailer is designed to provide road maintenance personnel with improved protection from ongoing, oncoming and passing traffic, to reduce the ability of passing traffic to see inside the work area (to mitigate rubber-necking and secondary incidents), and to provide a fully-contained, mobile, enhanced environment within which the work crews can function day or night, complete with optional power, lighting, ventilation, heating, cooling, and overhead protection including extendable mesh shading for sun protection, or tarp covering for protection from rain, snow or other inclement weather.
[0039] Platforms can be provided at both ends of the trailer for hydraulics, compressors, generators and other equipment and supplies, including portable restroom facilities. The trailer can be fully rigged with direction and safety lighting, as well as lighting for the work area and platforms. Power outlets can be provided in the interior of the work area for use with construction tools and equipment, with minimal need for separate power trailers or extended cords. Both the caboose and the center underside of both end platforms can provide areas for fuel, water and storage. Additional fuel, water and miscellaneous storage space can be provided in an optional extended caboose of like but lengthened design.
[0040] In one aspect, the trailer is designed to eliminate the need for separate lighting trucks or trailers, to reduce glare to traffic, to eliminate the need for separate vehicles pulling portable restroom facilities, to provide better a brighter, more controlled work environment and enhanced safety, and to, among other things, better facilitate 24-hour construction along our nation's roadways. Other applications include but are not limited to public safety, portable shielding and shelter, communications and public works. Two or more trailers can be used together to provide a fully enclosed inner area, such as may be necessary in multi-lane freeway environments.
[0041] With significant shifts to night construction and maintenance, the trailer, in one aspect, can provide a well-lit, self-contained, and mobile safety enclosure. Historical cones can still be used to block lanes, and detection systems or personnel can be used to provide notice of an errant driver, but neither offers physical protection or more than split second warning for drivers who may be under the influence, of alcohol or intoxicants, or who, for whatever reason, become fixated on the construction/maintenance equipment or lights and veer into or careen along the same,
[0042] The trailer can provide an increased level of physical protection both day and night and workers with a self-contained and enhanced work environment that provides them with basic amenities such as restrooms, water, power, lighting, ventilation and even some possible heating/cooling and shelter. The trailer can also be designed to keep passing motorists from seeing what is going on within the work area and hopefully facilitate better attention to what is going on in front of them. Hopefully, this will reduce both direct and secondary incidents along such construction and maintenance sites.
[0043] Embodiments of this invention can provide a safety trailer with semi-tractor hookups at both ends and a safety wall that is fixed to one side of the trailer. That side, however, can be changed to the right or left side of the road, depending on the end to which the semi-tractor attaches. A caboose can be attached at the end of the trailer opposite the tractor to provide additional lighting and impact protection. Optionally, the trailer can be equipped with overhead protection, lighting, ventilation, onboard hydraulics, compressors, generators and other equipment, as well as related fuel, water, storage and restroom facilities and other amenities.
[0044] These and other advantages will be apparent from the disclosure of the invention(s) contained herein.
[0045] As used herein, “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
[0046] It is to be noted that the term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), one or more and at least one can be used interchangeably herein. It is also to be noted that the terms “comprising” “including”, and “having” can be used interchangeably.
[0047] The preceding is a simplified summary of the invention to provide an understanding of some aspects of the invention. This summary is neither an extensive nor exhaustive overview of the invention and its various embodiments. It is intended neither to identify key or critical elements of the invention nor to delineate the scope of the invention but to present selected concepts of the invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] FIGS. 1A-1E show a loaded trailer, in accordance with embodiments of the present invention;
[0049] FIGS. 2A-2C show a deployed protective wall, in accordance with embodiments of the present invention;
[0050] FIGS. 3A-3C show a wall section in accordance with embodiments of the present invention;
[0051] FIGS. 4A-4H show a platform and its components in accordance with embodiments of the present invention;
[0052] FIGS. 5A-5B show a caboose, in accordance with embodiments of the present invention;
[0053] FIGS. 6A-6G show a truck mounted attenuator attached to the caboose shown in FIGS. 5A-5B ;
[0054] FIG. 7 shows an interconnection member between a platform and a truck mounted attenuator;
[0055] FIG. 8 shows a forced air system, in accordance with embodiments of the present invention;
[0056] FIG. 9 shows the loaded trailer, including a storage compartment;
[0057] FIG. 10 is a flow chart illustrating a method of deploying a protective barrier;
[0058] FIG. 11 is a flow chart illustrating a method of balancing the weight of a protective barrier;
[0059] FIG. 12 is a flow chart illustrating a method of changing the orientation of a protective barrier/trailer;
[0060] FIG. 13 is a flow chart illustrating a method of disassembling a protective barrier and loading the component parts for transport;
[0061] FIGS. 14A-C are illustrations of a fixed wall protective barrier in accordance with alternative embodiments of the present invention;
[0062] FIG. 15A-C are illustrations of a fixed wall protective barrier in accordance with another alternative embodiment of the present invention;
[0063] FIG. 16 shows a configuration of the caboose according to an embodiment;
[0064] FIG. 17 shows a configuration of the caboose according to an embodiment; and
[0065] FIG. 18 shows a configuration of the caboose according to an embodiment.
[0066] FIG. 19 shows an alternate embodiment of a deployed mobile barrier
DETAILED DESCRIPTION
[0067] Embodiments of the present invention are directed to a mobile traffic barrier. In one embodiment, the mobile traffic barrier includes a number of inter-connectable wall sections that can be loaded onto a truck bed. The truck bed itself includes two (first and second) platforms. Each platform includes a king pin (not shown); the king pin providing a connection between the selected platform and either a caboose or a tractor. By enabling the tractor to hook at either end, the trailer can incorporate a rigid fixed wall that is open to the right or left side of the road, depending on the end to which the tractor is connected. The side wall and the ends of the trailer define a protected work area for road maintenance and other operations. The tractor and caboose may exchange trailer ends to change the side to which the wall faces. The dual-hookup, fixed-wall design can enable and incorporate compartments (in the platforms) for equipment and storage, onboard power for lighting, ventilation, and heating and/or cooling devices and power tools, and on-board hydraulics for hydraulic tools. The design can also provide for relatively high shielding from driver views, and in general, a larger and better work environment, day or night.
[0068] Referring initially to FIG. 1A , a trailer in accordance with an embodiment is generally identified with reference numeral 100 . The trailer 100 includes two (first and second) platforms 104 a,b and a number of wall sections 108 a - c . As described in greater detail below, the wall sections 108 a - c are adapted to interconnect to each other and to the platforms 104 a,b to form a protective wall. In FIG. 1A , the wall sections 108 a,b are disconnected from each other and secured in a stored position on top of the interconnected platforms 104 a,b . In this position, the trailer 100 is configured so that it may be transported to a work site. In the transport configuration illustrated in FIG. 1A , the platforms 104 are bolted to each other to form a truck bed that operable to carry the wall sections 108 and other components.
[0069] In addition to the wall sections 108 a - c , the platforms 104 a,b carry two rectangular shaped ballast members 112 a,b , which are shown as boxes of sand. As will be appreciated, the ballast members can be any other heavy material. The weights of ballast boxes 112 a,b counter balance the weights of the wall sections 108 a - c , when the wall sections 108 a - c are deployed to form a protective barrier and when being transported atop the platforms. The ballast boxes 112 a,b hold between about 5,000 and 8,000 lbs. of weight, particularly sand. At 8,000 lbs., the ballast boxes 112 a,b counter balance three wall sections 108 a - c , when the wall sections are deployed or being transported. In one configuration, the wall sections 108 a - c weigh approximately 5,000 lbs. each.
[0070] The truck bed formed by the interconnected platforms 108 a,b is connected at one end to a standard semi-tractor 116 and at the other end to an impact-absorbing caboose 120 . Both of the platforms 108 a,b include a standard king pin connection to the tractor 116 or caboose 120 , as the case may be. The caboose 120 may include an impact absorbing Track Mounted Attenuator (“TMA”) 136 , such as the SCORPION™ manufactured by TrafFix Devices, Inc. In accordance with alternative embodiments, the caboose 120 and/or tractor 116 may include a rigid connection to the rear platform 104 .
[0071] FIG. 1B shows a reverse side of the trailer 100 shown in FIG. 1A . Each platform 104 a,b includes at least one storage compartment 124 . The doors 128 to the storage compartment 124 are shown in FIG. 1A . The reverse perspective of FIG. 1B shows a rigid wall 132 forming the rear of the storage compartment 124 .
[0072] FIG. 1C shows a rear view of the trailer 100 . In FIG. 1C , the TMA 136 is shown in its retracted position. FIG. 1D shows a rear view of the trailer 100 with the TMA 136 in a deployed position.
[0073] FIG. 1E shows a top plan view of the trailer 100 . As can also be seen in FIGS. 1D and 1E , the trailer 100 includes three wall sections 108 stored on top of the platforms 104 a,b . Two of the wall sections 108 a,b nearest the right side of the trailer are positioned end-to-end, with one being positioned on top of each platform. The third wall section 108 c is positioned between the wall sections 108 a,b and the ballast boxes 112 and is approximately bisected by the longitudinal axis A of the trailer (or the first and second platforms). Effectively, by substantially co-locating the longitudinal axis of the third wall section 108 c with the longitudinal axis A of the trailer, the weight of the third wall section 108 c is effectively counter-balanced. The weight of ballast box 112 a therefore counterbalances effectively the first wall section 104 a and ballast box 112 b counterbalances effectively the second wall section 104 b . The platforms 104 a,b are asymmetrical with respect to the longitudinal axis A. Accordingly, the weights of the ballast boxes can be greater than the weights of the wall sections to counter balanced the asymmetrical portion of the platforms. The loading of the trailer shown in FIG. 1E thus serves to balance the weight of the various trailer components with respect to the longitudinal axis A,
[0074] Referring now to FIG. 2A , the trailer 100 is shown in its unloaded or deployed configuration. As can be seen in FIG. 2A , the wall sections 108 a - c have been removed from theft loaded positions on top of the platforms 104 a,b and connected between the platforms 104 a,b to form a protective barrier 200 . This is accomplished by removing the wall sections 108 a - c , such as for example through the use of cranes or a forklift, and then disconnecting the two platforms 104 a,b from each other. After the platforms 104 a,b have been disconnected, the platforms 104 a,b are spatially separated and the wall sections 108 a - c are then inserted there-between. As can be seen in FIG. 2A , the two ballast boxes 112 a,b remain in place on top of the platforms 104 a,b . The ballast boxes provide a counter-balance to the weight of the wall sections 108 a - c , which are disposed on the opposite side of the platforms 104 a,b.
[0075] FIG. 2A shows a view of the protective barrier 200 from the perspective of the protected work zone area. From the protected work zone, the storage compartment doors 128 and other equipment are accessible. The protected work zone area 204 can seen in FIG. 2B , which shows a top plan view of the protective barrier 200 shown in FIG. 2A . As can be seen, the protective barrier creates a protected work area 204 , which includes a space adjacent to the wall sections 108 a - c and between the platforms 104 a,b . The road or other work surface is exposed within the work zone area 204 . The work zone area 204 is sufficiently large for heavy equipment to access the work surface.
[0076] FIG. 2C shows the traffic-facing side of the protective barrier 200 . As can be seen in FIG. 2C , the protective barrier 200 presents a protective wall 208 proximate to the traffic zone. The protective wall 208 includes the rigid wall 132 and number of wall sections 108 a - c , which are interconnected to the two platforms 104 a,b . The bottoms of the wall sections 108 a - c are elevated a distance 280 above the roadway 284 . FIGS. 5A-B additionally show a portion of the caboose 120 , which interconnects to and is disposed underneath a selected one of the platforms 104 a,b . The wheels of the caboose 120 , in the deployed position of the trailer 100 shown in FIG. 2C , are covered with a piece of sheet metal 212 .
[0077] During transport, this piece of sheet metal 212 can be disconnected from the platform 104 and positioned in a stowed manner on top of one of the platforms 104 .
[0078] Although stands 290 are shown in place at either end of the protective barrier 200 and may be used to support individual wall sections 108 of the barrier 200 , it is to be understood that no stands are required to support the barrier 200 . The barrier 200 has sufficient structural rigidity to act as a self-supporting elongated beam when supported on either end by the tractor 116 and caboose 120 . This ability permits the barrier 200 to be located simply by locking the tractor and caboose brakes and relocated simply by unlocking the brakes, moving the barrier 200 to the desired location, and relocking the brakes of the tractor and caboose. Requiring additional supports or stands to be lowered as part of barrier 200 deployment can not only immobilize the barrier 200 but also increase barrier rigidity to the point where it may cause excess damage and deflection to a colliding vehicle and excess ride down and lateral G forces to the occupant of the vehicle.
[0079] The wall section height is preferably sufficient to prevent a vehicle colliding with the barrier 200 from flipping over the wall section into the work area and/or the barrier 200 from cutting into the colliding vehicle, thereby increasing vehicle damage and lateral and ride-down G forces to vehicular occupants. Preferably, the height of each of the wall sections is at least about 2.5 feet, more preferably at least about 3.0 feet, even more preferably at least about 3.5 feet, and even more preferably at least about 4.0 feet. Preferably, the height of the top of each wall section above the surface of the ground or pavement 284 is at least about 3.5 feet, more preferably at least about 4 feet, even more preferably at least about 4.5 feet, and even more preferably at least about 5 feet.
[0080] The protective wall or barrier 200 may additionally include attachment members 216 operable to interconnect a visual barrier 220 to the protective wall 200 . A visual barrier 220 in accordance with embodiments is mounted to the protective wall 200 and extends from the top of the protective wall 200 to approximately four feet above the wall 200 . The visual barrier 220 is interconnected to attachment members 216 , such as poles, which are interconnected to the wall 200 . In accordance with an embodiment, the attachment members 216 comprise poles which extend 10 feet upwardly from the wall section 200 . Each pole may support a 6 lb. light head at the top which generates over 3,000 alums of light. The poles may additionally provide an attachment means for the visual barrier 220 . While attached to the poles, the visual barrier 220 extends approximately 4 feet upwardly from the protective wall 200 .
[0081] The visual barrier 220 provides an additional safety factor for the work zone 204 . Studies have shown that a major cause of highway traffic accidents in and around work zone areas is the tendency for drivers to “rubber-neck” or look into the work zone from a moving vehicle. In this regard, it is found that such behavior can lead to traffic accidents. In particular, the “rubber-necking” driver may veer out of his or her traffic lane and into the work zone, resulting in a work zone incursion. The present invention can provide a structurally rigid wall 200 that prevents incursion into the work zone 204 , as well as a visual barrier. 220 which discourages this, so called, “rubber necking” behavior.
[0082] Studies have indicated that people are drawn to lights and distractions, and that they tend to steer and drive into what they are looking at. This is particularly hazardous for construction workers, especially where cones and other temporary barriers are being deployed on maintenance projects. Studies also indicate that lighting and equipment movement within a work zone are important factors in work site safety. Significant numbers of people are injured not only from errant vehicles entering the work zone, but also simply by movement of equipment within the work area. The trailer can be designed not only to keep passing traffic out of the work area, but also to reduce the amount of vehicles and equipment otherwise moving around within the work area.
[0083] In terms of lighting, research indicates more is better. Current lighting is often somewhat removed from the location where the work is actually taking place. Often, the lighting banks are on separate carts which themselves contribute to equipment traffic, congestion and accidents within the job site.
[0084] These competing considerations of motorists, at night, steering towards lights and roadside workmen being safer at night with more lighting can be satisfied by the trailer. The trailer can use the light heads 270 to provide substantial lighting where it is needed. If the work moves, the lighting moves with the work area, rather than the work area moving away from the lighting. Most importantly, the safety barrier—front, back and side—can move along too, providing simple but effective physical and visual barriers to passing traffic. Referring to FIGS. 2B and 2C , the light heads 270 positioned along the barrier 200 have a direction of illumination that is approximately perpendicular or normal to the direction of oncoming traffic. This configuration provides not only less glare to oncoming motorists but also less temptation for motorists to steer towards and into the barrier 200 .
[0085] FIGS. 2A-2C show the protective barrier 200 deployed for use in connection with a work-zone area. The design of the support members and the traffic facing portion of the protective barrier 200 , serve to provide a safe means for mitigating the effects of such a collision. In particular, the barrier 200 can re-direct the impacted moving car down the length of the protective wall 208 . Here, the moving car is not reflected back into traffic. Further incidents are prevented by not reflecting the moving car back from the mobile barrier into other cars, thereby enhancing safety not only of the driver of the vehicle colliding with the barrier but also of other drivers in the vicinity of the incident. The inherent rock/roll movement in the tractor 116 and trailer (caboose) springs and shocks assist dissipation of shock from vehicular impact. In addition, by deflecting the moving vehicle down the length of the protective wall 208 , the work zone 200 is prevented from sustaining an incursion by the moving vehicle, thereby enhancing safety of workers.
[0086] A number of factors are potentially important in maintaining this desirable effect. Firstly, the protective barrier 204 is maintained in a substantially vertical position. This is accomplished through a ballasting system and method in accordance with an embodiment. In particular, the wall sections 108 are balanced in a first step with the ballast boxes 112 . In a following step, a more precise balancing of the protective barrier 200 position is achieved through a system of movable pistons associated with the caboose 120 . This aspect of the invention is described in greater detail below. Second, the structural design of the wall sections 108 serve to provide optimal deflection of an incoming car. Finally as shown in FIG. 2B , the protective wall or barrier 200 is substantially planar and smooth (and substantially free of projections) along its length to provide a relatively low coefficient of friction to an oncoming vehicle. As will be appreciated, projections can redirect the vehicle into the wall and interfere with the wall's ability to direct the vehicle in a direction substantially parallel to the wall.
[0087] Turning now to FIG. 3A , an individual wall section 108 is shown in perspective view from the traffic side of the wall section 108 . As can be seen in 3 A, the wall section 108 includes a wall skin portion 300 , which faces the traffic side of the protective barrier 200 and is smooth to provide a relatively low coefficient of friction to a colliding vehicle. The wall skin 300 is adapted to distribute the force of the impact along a broad surface, thereby absorbing substantially the impact. As additionally can be seen in FIG. 3A , the wall section 108 includes a first end portion or wall end member 304 a . The first end portion 304 a includes a conduit box 308 , a number of bolt holes 312 , a protruding alignment member, which is shown as a large dowel 316 a , and an alignment receiving member, which is shown as a small dowel receiver hole 320 a . As will be appreciated, the alignment member can have any shape or length, depending on the application. The first end portion 304 a of the wall section 108 is adapted to be interconnected to a second end portion 304 b of an adjacent wall section 108 or platform 104 . A second end portion 304 b can be seen in FIG. 38 , which shows the opposite end 304 b of the wall section 108 shown in FIG. 3A , including a protruding small dowel 316 b and a large dowel receiver hole 320 b . For each wall section 108 , the large dowel 316 a disposed on the top of the first end portion 304 a is operatively associated with a large dowel receiver hole 320 b in the second end portion 304 b of an adjacent wall section 108 or platform 104 . Similarly, the small dowel 316 b on the second end portion 304 b is operatively associated with the small dowel receiver hole 320 a in the first end portion 304 a of an adjacent wall section 108 or platform 104 . Additionally, the wall sections 108 are interconnected through a screw-and-bolt connection using the bolt holes 312 associated with the wall ends 304 . The conduit box 308 is additionally aligned with an adjacent conduit box 308 , providing a means for allowing entry and pass-through of such components as electrical lines, air hoses, hydraulic lines, and the like.
[0088] In FIG. 38 , a portion of the wall skin 300 is not shown in order to reveal the interior of the wall section 108 . As can be appreciated, such a partial wall skin 300 is shown here for illustrative purposes. As can be seen in FIGS. 3B and 3C , the wall section 108 includes three bracing sections 324 a - c vertically spaced equidistant from one another. Each of the bracing sections 324 includes two opposing horizontal beams 328 a - b , with the free ends being connected to the adjacent wall end member 304 a,b . The two horizontal beams 328 a - b are interconnected with angled steel members 332 to form a truss-like structure. The wall section 108 includes three bracing sections: the first bracing section 324 a being at the top, the second bracing section 324 b being at the middle and the third bracing section 324 c being at the bottom. Additionally, the wall section 108 includes a number of full-height vertical wall sections 336 a,b , the wall end members 304 a,b , and a number of partial-height vertical wall sections 340 a - c . As shown in FIG. 3A , the full-height wall sections 336 a,b and partial-height wall sections 340 a - c alternate. Additionally, it can be seen that the angled steel members 332 intersect at points where the partial-height wall 340 or full height wall 336 section, as the case may be, meets the horizontal beam 328 a,b , which, on one side, faces the traffic side of the wall section 108 . Additionally, the wall section includes a fourth horizontal member 344 . Unlike the structural members 328 and 336 which are preferably configured as rectangular steel beams, this fourth horizontal member 344 is configured as a steel C-channel beam. The C-channel is preferably positioned substantially at the height of a car or SUV bumper. In use, the bottom of the wall section 108 sits approximately eleven inches off of the ground, and the fourth horizontal member 344 sits approximately twenty inches off of the ground.
[0089] The wall sections 108 constructed as described and shown herein are specifically adapted to prevent gouging of the wall as a result of an impact from a moving car. In particular, gouging as used herein refers to piercing or tearing or otherwise drastic deformation of the wall section, which results in transfer of energy from a moving car into the mobile barrier 200 . As described herein, by deflecting the car down the length of the protective wall 200 , a desirable amount of energy is absorbed by the wall and therefore not transferred to other portions of the protective wall 200 . It is additionally noted that the floating king pin plate of the standard trailer 116 provides a shock absorbing effect for impacts which are received by the protective wall 200 . The shock absorbing effect of the trailer's 116 floating king pin plate 500 is complemented by fixed king pin plate associated with the caboose 120 (which is discussed below).
[0090] In accordance with an embodiment, the dimensions of the various trailer and wall components vary. By way of example, the length of each wall section 108 preferably ranges from about to 30 feet in length, more preferably from about 15 to 25 feet in length, and more preferably from about 18 to 22 feet in length. The width of each of the wall sections preferably ranges from about 18 to 30 inches, more preferably from about 22 to 28 inches, and more preferably from about 23 to 25 inches. The height of each of the wall sections 108 preferably ranges from about 3 to 4.5 feet, more preferably from about 3.75 to 4.25 feet, and more preferably from about 3.9 to 4.1 feet. It should be noted that these height ranges and distances measure from the base of a wall section 108 to the top of the wall section 108 and do not include the wall section's height when it is displaced with respect to the ground. In use, the wall section 108 typically is disposed at a predetermined distance from the ground. In particular, this distance preferably ranges from about 10 to 14 inches, more preferably from about 11 to 13 inches, and more preferably from about 11.5 to 12.5 inches. In accordance with an embodiment, a wall section is approximately 20 feet long, 24 inches wide, 4 feet high as measured from the base of the wall section to the top of the wall section and, when deployed, disposed at a distance of 12 inches from the ground.
[0091] The beams 328 a and 328 b span the length of the entire wall section. In accordance with an embodiment, the horizontal beams 328 a and 328 b measure from about 3-5 inches by about 5-7 inches, more preferably from about 3.5 inches to 4.5 inches by 5.5 inches to 6.5 inches, and even more preferably are about 4 inches by 6 inches. In accordance with an embodiment, the longer dimension of the beam is disposed in the horizontal direction. For example, with 4.times.6 beams, the 4-inch dimension is disposed in the vertical direction and the 6-inch dimension in the horizontal direction. In this embodiment with three sets of horizontal beams, the bottom and middle beams are separated by about 18 inches and the middle and the top beams also by about 18 inches. In this configuration, the total height of the wall section is 4 feet. In other portions of the mobile barrier 200 , the orientations of the horizontal beams may differ. In particular, the longer 6 inch dimension may be in the vertical direction, and the shorter 4 inch dimension may be in the horizon a direction. In accordance with an embodiment, this orientation for the horizontal beams is implemented in connection with the platforms 104 .
[0092] The wall skin 300 may be comprised of a single homogeneous piece of steel that is welded to the wall section 108 . The wall skin 300 is preferably between about 0.1 and 0.5 inch thick, more preferably between about 0.2 and 0.4 inch, and even more preferably approximately 0.25 inches thick. These dimensions are also applicable to the partial-height and full height wall members 340 , 336 . The wall end portions or plates 304 b and 304 a are preferably between about 0.25 and 1.25 inch thick, more preferably between about 0.5 and 1 inch thick, and even more preferably are about 0.75 inch thick.
[0093] In accordance with a preferred embodiment where the wall sections 108 are approximately 20 feet in length, a work space area 204 is defined when these wall sections are deployed that measures approximately 80 feet in length. In particular, the three wall sections total 60 feet in addition to 10 feet on each side of additional space provided by the interior portions of the platforms 104 .
[0094] Referring again to FIG. 3C , a wall section 108 may include a number of attaching devices, which provide a means for interconnecting various auxiliary components to the wall section 108 . In particular, a wall section 108 may include an attachment member mounting 348 , operable to mount an attachment member 216 , such as a pole. The attachment member mounting shown in FIG. 3C includes a lever which, through a quarter turn, is operable to lock the light pole in place. A pole may be used to mount a light in connection with using the wall barrier during night-time hours. As can be appreciated in such conditions, the work area will be required to be illuminated. Such illumination can be accomplished by light poles and corresponding lights which are mounted to the wall section. The light poles, lights and other auxiliary components may be stored in the storage compartments 124 .
[0095] The wall section 108 additionally may include attachments for jack stands 352 . The jack stands 352 provide a means for supporting the wall section 108 at the above-mentioned height of approximately eleven inches from the ground.
[0096] The wall section 108 may additionally include, so called, “glad hand boxes” (not shown), which provide means for accessing 12, 110, 120, 220, and/or 240 volt electricity. In accordance with the embodiments, the protective barrier 200 includes an electric generator and/or one or more batteries (which may be recharged by on-board solar panels) providing electricity which is accessible through the glad hand box and is additionally used in connection with other components of the protective barrier 200 described herein. The generator and/or the batteries may additionally be stored the storage compartments 124 , and the batteries used to start the generator and support electronics when the generator is turned off or is not operational.
[0097] The wall section 108 may be comprised of, or formed from, any suitable material which provides strength and rigidity to the wall section 108 . In accordance with embodiments, the beams of the wall section are made of steel and the outer skin of the wall section is made from sheets of steel. In accordance with alternative embodiments, the wall section 108 is made from carbon fiber composite material.
[0098] Referring now to FIG. 4A , a side perspective view of a platform 104 is shown. In FIG. 4A the platform is resting on a jack stand 352 . Additionally, the outline of the caboose 120 is shown in FIG. 4A . With the caboose 120 attached, the platform 104 shown in FIG. 4A would correspond to the rear of the protective barrier 200 and/or the rear of the loaded trailer 100 . As can be seen in FIG. 4A , the platform includes a king pin 400 . The king pin 400 provides an interconnection between the platform 104 and the caboose 120 . The king pin 400 is disposed on the underside of the platform 104 in a position that allows the king pin 400 to connect with a standard floating king pin plate associated with a semi-tractor 116 or a fixed king pin plate associated with the caboose 120 . In this way, either the caboose 120 or the semi-tractor 116 may be connected to the platform 104 using the king pin 400 . A nose receiver 404 portion of the platform 104 provides a means for receiving the end, or nose portion of the caboose 120 . This aspect of the invention is described in greater detail below.
[0099] In FIG. 4B and FIG. 4C , two opposed platforms 104 are shown with a central external cover plate of the central portions of the platforms being removed to show the structural members while the ballast box external support plates are in position, in FIG. 4D , a platform is shown with all exterior cover plates removed, and in FIG. 4G a platform is shown with all external cover plates in position. As can be seen, the first end 408 of the platform 104 is wider than the second end 412 of the platform 104 . Here, the platform 104 includes support members 421 for supporting the king pin (not shown), a sloping plate 428 for receiving the nose portion of the caboose, a flat plate assembly 422 positioned above and supporting the jack stands 423 , and a sloped or narrowing section 416 , which slopes from the larger, first-end 408 width, to the smaller, second-end 412 width. This sloped portion 416 of the platforms 104 includes the storage compartment 124 . The two second-ends 412 of the platform 104 are adapted to be interconnected to each other. The two first-ends 408 of the platform 104 are adapted to interconnect to either the tractor 116 or the caboose 120 , as described above. As can be seen in FIG. 4D , the platform 104 includes two side channels 420 a - b . Typically, the channel 420 a proximate to the work zone is adapted to receive a ballast box 112 , both in the mobile and the deployed positions.
[0100] FIGS. 4D , 4 E, and 4 F further show the structural members of each of the platforms. The platforms are identically constructed but are mirror images of one another. The traffic-facing, or elongated, side 460 of the platform 104 includes upper, middle, and lower horizontal structural members 464 , 468 , and 472 . The upper, middle, and lower horizontal structural members are at the same heights as and similar dimensions to the upper, middle, and lower horizontal beams 328 , respectively. The members 464 , 468 , and 472 , unlike the beams 328 , are oriented with the long dimension vertical and the shorter dimension horizontal. By orienting the members differently from the beams, the need for a member similar to the fourth horizontal member 344 is obviated. The upper structural member 464 is part of an interconnected framework of interconnected members 476 , 480 , 484 , 488 , 490 , and 492 defining the upper level of the platform. Lateral structural members 494 provide structural support for the ballast boxes, depending on where they are positioned, and lateral members 496 provide further structural support for the upper level and for the king pin and other caboose interconnecting features discussed below. The first end of the lower structural member attaches to a corner member 497 and second ends of the upper and lower structural members to the second end member 498 . At the level of the lower structural member 472 , lower structural members 473 , 474 , 475 , and 477 define the lower level of the platform. Additional vertical and corner members 478 , 479 , and 481 attach the lower and upper levels of the platform and horizontal support member 483 interconnects corner members 497 and 481 and vertical members 478 and 479 . The lower level further includes lateral members 475 and elongated member 477 to provide further structural support for the lower level and provide support for the bottom of the storage compartment.
[0101] In FIGS. 4G and 4H , portions of the platform 104 are shown, which include the underside of platform 104 . As can be seen in FIG. 4E , the platform 104 includes a king pin 400 disposed substantially in alignment with a longitudinal axis 405 bisecting a space 407 defined by the nose receiver portion 404 . The nose receiver portion 404 includes two angled components 424 a,b as well as a downwardly facing deflection plate 428 . FIG. 4H shows, in plan view, the components 424 a,b , each of which includes a straight portion 409 a,b and angled portion 411 a,b . The space 407 between the angled portions is in substantial alignment with the king pin 400 .
[0102] As the caboose 120 is backed into the space underneath the platform 104 , the king pin 400 is received in a king pin receiver channel 524 ( FIG. 5 ) in a fixed king pin plate on the caboose 120 , and the nose of the caboose is received in the nose receiver 404 portion of the platform 104 . The nose receiver portion 404 , namely the angled portions of the components 424 a,b and sloped deflection plate 428 , guide the an angled front-nose portion 520 ( FIG. 5 ) of the caboose as the caboose is brought into position underneath the platform 104 to align the king pin with the king pin receiver channel 524 ( FIG. 5 ). In particular, the two angled components 424 operate to provide lateral guidance for the position of the caboose 120 . Here, the two angled components 424 ensure that the king pin 400 is received in the king pin receiver channel 524 associated with the caboose 120 . The downwardly facing deflection plate 428 exerts a downward force on the nose 520 of the caboose that results in the rear of the caboose 120 raising up to engage the rear of the platform 104 . The interconnection between the caboose 120 and the rear of the platform 104 is described in greater detail below.
[0103] In FIG. 5A , a side perspective view of the caboose 120 is shown. As shown in FIG. 5A , the caboose 120 includes the fixed king pin plate 500 . The king pin plate 500 includes a king pin receiver channel 524 provided at the end of the plate 500 . This pin receiver channel 524 is adapted to receive the king pin 400 and provides a locking mechanism for locking the caboose 120 to the end of the platform 104 . In addition, the caboose 104 includes a vertical adjustment member, which is shown as movable pneumatically or hydraulically actuated piston 508 (as can be seen in FIG. 4A ), disposed on each side between the two wheels of the caboose 120 . Although a piston is shown, it is to be understood that any suitable adjustment member may be used, such as a mechanical lifting device (e.g., a jack or crank). The movable piston 508 is associated with a piston cylinder and is interconnected to a top 512 portion and a bottom portion 516 of the caboose 120 . The bottom portion 516 provides a mounting for the wheel axles as well as the wheel suspension. The movable piston 508 , as described in greater detail below, is operable to be inflated, thereby adjusting the height of the selected, adjacent side of mobile barrier 200 . More specifically, the movable piston 508 moves the caboose 120 off of its suspension or leaf springs.
[0104] In FIG. 5A , a side perspective view of the caboose 120 is shown. As can be seen in FIG. 5B , the fixed king pin plate 500 includes the king pin receiver channel 524 . The king pin receiver channel 524 includes a front, wide portion 528 , which leads into a rear, narrow portion 532 , as this king pin receiver channel 524 allows the caboose 120 to be positioned properly while the caboose is being backed into and underneath the platform 104 . In this regard, the nose 520 of the caboose 120 is additionally received in the nose receiver portion 404 , disposed on the underside of the platform 104 . This aspect of the present invention is described in greater detail below
[0105] Referring now to FIG. 5B , an additional side perspective view of the caboose 120 is shown. In FIG. 5B , the king pin plate 500 is shown removed from the caboose 120 . As can be seen in FIG. 5B , underneath the king pin plate 500 , the caboose 120 includes a number of air cylinders 536 . These air cylinders 536 are associated with a standard ABS braking system and operate independently of the braking system of the tractor 116 . As described in greater detail below, the air cylinders 536 can be locked by an auxiliary mechanism associated with the caboose 120 to hold the caboose 120 in place. The auxiliary mechanism may be adjusted to allow the brakes to be engaged and the caboose 120 held in place even if the caboose 120 is disconnected from the platform 104 . This mechanism additionally provides a means for inflating and deflating the movable piston 508 disposed on either side of the caboose 120 .
[0106] FIGS. 5A , 58 , and 8 depict the removable attachment mechanism between the caboose and the platform. The caboose includes permanently attached first and second pairs 580 a,b of opposing attachment members 584 a,b . Each attachment member 584 a,b in the pair 580 a,b has matching and aligned holes extending through each attachment member. In FIG. 8 , first and second pairs 804 a,b of attachment members 808 a,b are permanently attached to the platform. Each attachment member 808 a,b in the pair includes matching and aligned holes extending through the attachment member 808 . When the caboose is in proper position relative to the platform, the holes in the attachment members 584 a,b and 808 a,b are aligned and removably receive a pin 802 having a cotter pin or key 810 to lock the dowell 802 in position in the aligned holes of each set of engaged pairs of attachment members 580 and 804 .
[0107] An embodiment includes a truck mounted crash attenuator, or equivalently, a Truck Mounted Attenuator (TMA). Referring again to FIG. 1A , a truck mounted attenuator 136 is shown interconnected to the trailer 100 at the caboose 120 . In FIG. 1A , the truck mounted attenuator 136 is shown in a retracted position. The truck mounted attenuator 136 includes a first portion 140 and a second portion 144 . In the retracted position, the first portion 140 is positioned substantially vertically and supports the weight of the second portion 144 , which is held in a substantially horizontal position over the caboose 120 . A movable electronic billboard 148 and light bar 150 (which can provide a selected message to oncoming traffic) is located underneath the second portion 144 of the truck mounted attenuator 136 .
[0108] The deployment of the truck mounted attenuator 136 and the electronic billboard and light bar 148 is illustrated in FIGS. 6A-6G . As shown in FIG. 6A through FIG. 6F , the truck mounted attenuator 136 is extended and lowered into a position wherein both the first portion 140 and the second portion 144 are substantially horizontal and proximate to the ground. As shown in FIG. 6G , the electronic billboard 148 and light bar 150 are then raised. Referring to FIG. 7 , the TMA 136 is typically bolted by a bracket 700 to the caboose 120 . The TMA is thus readily removable simply by unbolting the TMA from the vertical plate of the bracket 700 . Additionally, the bracket 700 and associated components provide a means for attaching the electronic billboard 148 and light bar 150 to the caboose 120 . The bracket 700 is mounted to provide a desirable height for the truck mounted attenuator in its deployed position, more specifically, approximately ten to eleven inches off of the ground. The bracket 700 is additionally mounted to provide visibility of the caboose brake lights and other warning lights associated with the trailer 100 . In FIG. 1C , a rear view of the loaded trailer 100 is illustrated. As shown herein, the truck mounted attenuator 136 is raised into its tracked position. As can be seen, the brake lights 152 of the caboose 120 are visible underneath the truck mounted attenuator 136 . A beacon 156 is also visible, despite the presence of the truck mounted attenuator 136 . The beacon 156 provides a visual indication of an end portion of the trailer 100 . As with the caboose 120 , the truck mounted attenuator 136 may be associated with either of the two platforms 104 and thereafter either end of the trailer.
[0109] Turning now to FIG. 8 , a forced air system 800 in accordance with an embodiment is shown. The forced air system 800 includes two lever attenuators 804 operable to lock the brakes of the caboose 120 independently of the brakes of the tractor 116 . As used herein, locking the brakes includes disconnecting or disabling the automatic brake system, typically associated with the caboose 120 . Here, the brakes are forced into a locked position, thereby locking or preventing movement of the caboose 120 . Also shown in FIG. 8 is a knob 808 operable to control the inflation and/or deflation of the moveable pistons 508 . As described above, the pistons 508 are used to provide a finer grade vertical adjustment of the balancing of the protective harrier 200 by vertically lifting or lowering a selected side of the caboose and interconnected platform. In other words, inflating the piston on a first side of the caboose lifts the first side of the platform relative to the second side of the platform and vice versa. In accordance with embodiments, the air provided to the pistons 508 is delivered from an air supply associated with the trailer 116 and not from an air compressor.
[0110] The interconnection between the platform 104 and the king pin plate 500 is illustrated in FIG. 8 . A removable pin interconnects the platform to the caboose. The pin is removable, and may be locked in place with attachment member 802 .
[0111] Turning now to FIG. 9 , a loaded trailer 100 is shown from the work area-side of the trailer 100 . As shown herein, the wall sections 108 are loaded on top of the platforms 104 and the platforms 104 are interconnected. As described above, this loaded position corresponds to an arrangement of the various components, which can be used to transport the entire system. As shown in FIG. 9 , the platform includes a storage compartment. Various auxiliary components described herein are stored in this storage compartment 124 . As can be seen in FIG. 9 , such components, as the light poles 900 , the corresponding lights themselves 904 , the visual barrier 220 , as well as various electrical components, are shown inside of the compartment. For example, FIG. 9 includes an onboard computer 908 and a generator 912 . In this configuration or in the deployed configuration, various lines 916 , such as electrical lines or air lines, may run along the length of a wall section 108 through the various adjacent conduit boxes 308 .
[0112] Referring now to FIG. 10 , a flow chart is shown which illustrates the steps in a method of deploying a mobile barrier in accordance with an embodiment. Initially at step 1004 , the trailer arrives at a worksite. At step 1008 , the wall sections 108 are unloaded from the trailer bed. This may be done with the use of cranes, a fork lift, and/or other heavy equipment operable to remove and manipulate the weight associated with the wall sections 108 . At step 1012 , the platforms 104 are disconnected from each other. More particularly, the bolt connections that interconnect the platforms 104 are removed. At step 1016 , the platforms 104 are separated. Here, the brakes of the caboose 120 may be locked and the disconnected platform portion of the trailer 116 attached to the tractor 116 may be driven away from the location of the caboose 120 and its attached platform. A dolly or castor wheel may be connected to the end of the platform 104 to provide mobility for the portion of the platform 104 attached to the tractor 116 , thereby allowing the platform to move into position to be engaged with the end wall section. Alternatively, a first platform connected to the tractor 116 is positioned at the desired location before disconnection of the platforms. Jacks attached to the first platform are lowered into position with the roadway. The platforms are then disconnected, with the second platform being supported by the caboose. A forklift or other vehicle is used to move the second platform into position for connection with the wall sections. In any event at step 1020 , the platforms 104 and wall sections 108 are interconnected to form a protective barrier 200 . At this point a continuous protective barrier 200 is formed from the various components of the trailer. Next, a number of steps or operations may be employed. At step 1024 , it may be determined that the protective barrier 200 must be balanced. More particularly, the weight of the protective barrier 200 must be adjusted such that the protective barrier 200 wall comes into a substantially vertical alignment. If no balancing of the protective barrier 200 is needed, work may be commenced within the protected area 204 of the protective wall 200 . At step 1028 , it may be determined that the direction or orientation of the protective barrier 200 may need to be changed. This may be done by jacking the second platform, disconnecting the caboose, and reversing the positions of the tractor 116 and caboose 120 . Alternatively, the jack stands may be retracted and the truck, while the wall sections are deployed, driven, while attached to the barrier, to a new location. At step 1032 , work may be completed and the protective barrier 200 may then be disassembled for transport.
[0113] Turning now to FIG. 11 , a method of balancing a protective barrier 200 (step 1024 ) is illustrated. This method assumes that the ballast boxes are not adequate to counter-balance completely the deployed barrier. At step 1104 , the protective barrier 200 or wall is inspected to determine whether or not the wall is disposed at a substantially vertical orientation. This can be done using a manual or automatic level detection device. If at decision 1108 the wall is substantially vertical, step 1112 follows. At step 1112 the process may end. If at decision 1108 , it is determined that the wall is not substantially vertical, step 1116 follows. At step 1116 , one or more of the piston cylinders 508 are inflated or deflated to provide a counter balance to the weight of the protective barrier 200 and desired barrier 200 orientation.
[0114] FIG. 12 illustrates a method of changing directions for the protective barrier 200 . Initially, at step 1204 , the caboose-engaging platform is placed on jack stands and thereafter the caboose is disconnected from the platform to which it is attached. At step 1208 , the caboose is towed out from underneath the platform 104 . Here, the caboose 120 may be connected to or otherwise attached to a tractor, forklift, or pickup truck, which is operable to tow the caboose 120 . At step 1220 , the tractor-engaging platform is placed on jack stands and the tractor 116 is disconnected from the platform 104 to which it is attached. At step 1216 , the tractor 116 is driven out from underneath the platform 104 . At step 1220 , the positions of the caboose 120 and tractor 116 are interchanged. At 1224 , the caboose 120 is positioned underneath and connected to the platform 104 to which the tractor 104 was formally attached. As described above, this includes a nose receiver portion 404 , providing guidance to the caboose 120 in order to guide the king pin 400 into the king pin receiver channel 532 associated with the king pin plate. At step 1228 , the tractor 116 is positioned with respect to and connected to the platform 104 to which the caboose 120 was formally attached.
[0115] Referring now to FIG. 13 , a method of loading a trailer in accordance with embodiments is illustrated. Initially at step 1304 , the platforms 104 and wall sections 108 are placed on jack stands and disconnected from one another. This includes removing the bolt connections which interconnect the opposing faces of the platforms 104 and/or wall sections 108 . At step 1308 , the platforms 104 are brought together. As described above, this includes interconnecting a castor or dolly wheel to at least one platform end and driving the platform 104 in the direction of the opposing platform. Alternatively, the platform engaging the caboose is taken off of its jack stands and maneuvered by a vehicle to mate with the other, stationary platform. At step 1312 , the platforms 104 are interconnected by such means as bolting the platforms together. At step 1316 , the wall sections 108 are loaded onto the truck bed. Because the ballast boxes typically do not counter-balance precisely the loaded wall sections and vice versa, the piston cylinders 508 are inflated or deflated, as desired, to provide a level ride of the trailer. Finally, at step 1320 , the trailer 100 departs from the worksite. In one configuration, castor or dolly wheels may be put on each of the two platforms so that, when they are disconnected from end wall sections of the barrier, the first and second platforms may be moved into engagement with and connected to one another. The wall sections may then be disconnected from one another and loaded onto the connected platforms.
[0116] The above discussion relates to a mobile barrier in accordance with an embodiment that includes a number of interconnectable wall sections, which are, in one configuration placed on the surface of a truck bed. In a second configuration, these wall sections are removed from the truck bed and interconnected with portions of the trailer to form a protective barrier. In this way, a fixed wall is formed that provides protection for a work area. The present invention can provide a non-rotating wall that is deployed to form the protective barrier. Alternative embodiments of a fixed wall mobile barrier are illustrated in FIGS. 14A-C and FIGS. 15A-C .
[0117] FIGS. 14A-C illustrate a “sandwich” type extendable protective wall. As shown in HG. HA, the mobile barrier 1400 includes two platforms 104 and three interconnected wall sections 1404 a , 1404 b and 1404 c . FIG. 14A illustrates a contracted or retracted position wherein the wall sections 1404 a -care disposed adjacent to one another in a “sandwich position”. FIG. 14B illustrates an intermediate step in the deployment of the mobile barrier 1400 . Here, the platforms 104 are moved away from each other and the sandwiched wall sections extended. From this intermediate position, the sections 1404 a and 1404 c move forward to a position adjacent to the forward position of the wall section 1404 a . In accordance with embodiments, the wall sections 1404 a - c are disposed on sliding rails which allow the displacement shown in FIG. 14B-C . Additionally between wall sections 1404 a and 1404 a (similarly 1404 b and 1404 c ) an articulating mechanism is provided, which allows motion between the adjacent wall sections. FIG. 14C shows the final position of the mobile barrier 1400 . Here, the various wall sections 1404 a - c and the platforms 104 provide a continuous mobile barrier included a protected work space.
[0118] FIGS. 15A-15C illustrate a telescoping type protective wall system 1500 . FIG. 15A shows a retracted, or dosed, position of the protective barrier 1500 . The protective barrier includes opposing platforms 104 . The protective barrier in this embodiment includes two wall sections, the first wall section 1504 encloses the second wall section 1508 in the contracted position shown in FIG. 15A . In the intermediate position shown in FIG. 15B , the second wall section 1508 is extended outward from the first wall section 1504 in a telescopic manner. In the final position shown in FIG. 15C , the second wall section 1508 moves forward to a position adjacent to the first wall section 1504 . In the final position shown in FIG. 15C , the first wall section 1504 , second wall section 1508 and portions of the two platforms 104 form a continuous protective harrier including protective interior space.
[0119] A number of alternative caboose embodiments will now be discussed.
[0120] Referring to FIG. 16 , the caboose 1600 has one or more steerable or articulating axles 1604 a,b or wheels 1608 a - d to avoid a selected area 1612 , such as a work area containing wet concrete. The wheels 1608 a - d are turned to a desired orientation, which is out of alignment with the tractor 116 tires, so that, when the trailer is pulled forward by the tractor 116 , the trailer moves both forward and laterally out of alignment with the path of movement of the tractor 116 . This may be effected in many ways. In one configuration, steering arms (not shown) are attached to the axles 1604 , and the arms are controlled by electrically operated hydraulic cylinders incorporated into the caboose frame assembly. The caboose axles are turned out when pulling ahead to more quickly move the rear of the trailer out and away from the area 1612 . Once the tractor and trailer are out of alignment with the area 1612 , the axles are returned, such as by the hydraulics, to their original positions in alignment with the tractor wheels. The electronics controlling the hydraulics are controlled from the tractor cab or a special switch assembly located in the caboose or on the trailer near the caboose. Alternatively, the axles or wheels may be steered manually, such as by a steering wheel mounted on the platform or caboose. The nose portion of the caboose remains stationary in the members 404 a,b , or the caboose does not rotate about the kingpin but remains aligned with the longitudinal axis of the trailer throughout the above sequence.
[0121] Referring to FIG. 17 , the caboose 1700 articulates or rotates about the king pin 400 . One or more electrically driven hydraulic cylinders at the front of the caboose laterally displaces the nose 1704 in a desired orientation relative to the longitudinal axis of the trailer. When the caboose is rotated to place the wheels 1708 a - d in a desired orientation, which is out of alignment with the tractor 116 tires, the tractor pulls the trailer forward. The trailer moves both forward and laterally out of alignment with the path of movement of the tractor 116 . The hydraulics then push the nose of the caboose to the aligned, or normal, orientation in which the wheels of the caboose are in alignment with the wheels of the tractor. The hydraulic cylinder(s) can be connected directly to a front pivot (not shown) or incorporated into the nose portion or the current “V” wedge assembly, which includes the members 404 a,b . In the latter design, the members 404 a,b are mounted on a movable plate, and the hydraulic cylinder(s) move the plate to a desired position while the nose portion 1704 is engaged by, or sandwiched between, the members 404 a,b . Unlike the prior caboose embodiment, the caboose rotates about the kingpin and does not remain aligned with the longitudinal axis of the trailer throughout the above sequence.
[0122] Referring to FIG. 18 , the caboose 1800 has an elongated frame with articulated steering on one or more axles 1804 a - c , with the rear axle 1804 a being preferred. When only the rear axle is steerable, the axle 1804 a is steered, as noted above, to place the wheels 1808 a,b in the desired orientation. After the caboose is rotated to place the wheels 1808 a,b in a desired orientation, which is out of alignment with the tractor 116 tires, the tractor pulls the trailer forward. The trailer rotates about the king pin 400 and moves both forward and laterally out of alignment with the path of movement of the tractor 116 . The wheels 1808 are then moved back into alignment with the wheels of the tractor. Like the prior embodiment, the caboose rotates about the kingpin and does not remain aligned with the longitudinal axis of the trailer throughout the above sequence. To make this possible, the nose portion of the caboose may need to be removed from engagement with the members 404 a,b , such as by moving a movable plate, to which the members are attached, away from the nose portion.
[0123] In another embodiment, the caboose is motorized independently of the tractor. An engine is incorporated directly into the caboose to provide self-movement and power. In one configuration made possible by this embodiment, the platforms could engage simultaneously two cabooses with a TMA positioned on each caboose to provide crash attenuation at both ends of the trailer. One or both of the cabooses is motorized. This is particularly useful where the trailer may be on site for longer periods and needs only nominal movement from time-to-time, such as at gates, for spot inspection stations, or for security and/or military applications where unmanned and/or more protected movement is desired.
[0124] In other embodiments, the caboose is attached permanently to the platform. In this embodiment, different tractor/trailers, that are mirror images of one another, are used to handle roadside work areas at either side of a roadway.
[0125] FIG. 19 shows an alternate embodiment for the mobile barrier. FIG. 19 is a view similar to FIG. 2A and like reference numerals will be used to denote structure already described. As in FIG. 2A , the trailer 100 is shown in its unloaded or deployed configuration. The wall section 108 has been removed from the loaded positions on top of the platforms 104 a,b and connected between the platforms 104 a,b to form a protective barrier 200 . As can be seen in FIG. 19 , the two ballast boxes 112 a,b remain in place on top of the platforms 104 a,b . The ballast boxes provide a counter-balance to the weight of the wall section 108 , which are disposed on the opposite side of the platforms 104 a,b.
[0126] FIG. 19 shows a view of the protective barrier 200 from the perspective of the protected work zone area. From the protected work zone, the storage compartment doors 128 and other equipment are accessible. As can be seen, the protective barrier creates a protected work area 204 , which includes a space adjacent to the wall section 108 and between the platforms 104 a,b . The road or other work surface is exposed within the work zone area 204 .
[0127] In the embodiment shown in FIG. 19 , the wall section has been modified to include a base bracket 1900 that can accommodate the attachment of accessories to the mobile barrier. One of ordinary skill in the art will readily appreciate that the inclusion of this base bracket is optional for the performance of the mobile barrier as a crash barrier; but it allows the barrier to also function as specialized equipment at a fraction of the cost thereof.
[0128] In the embodiment shown in FIG. 19 , a crane with a hook 1901 is shown mounted on the base bracket 1900 . It should be appreciated, however, that a crane with a hook is not the only accessory that can be attached to the base bracket. Other possible accessories include a crane with a bucket to remove debris; or a crane with a bucket for workers to do overhead work (e.g. utility or telecommunications work). Another possible accessory is an attachment for pulling or setting posts for guardrails and the like. Still other accessories include a paint sprayer for painting bridges or tunnels and a power washer to clean and wash bridges and tunnels. The accessory may also be a guide or a roller for pulling cable along roads. The accessory may also consist of a device for breaking and removing pavement, such as a jackhammer, a concrete cutter or a trencher. The accessory may also consist of a box frame that can be lowered into trenches and moved along to protect from wall collapse, or a slide for pouring concrete, or a leveler/compacter for concrete, asphalt or dirt and the like. The crane 1901 may be controlled by a wireless remote control, or it may be controlled by manual controls adjacent to the base bracket 1900 . An outrigger 1902 is also provided in the assembly of base bracket 1900 . Outrigger 1902 act as a balance to keep the assembly from leaning too much. The outrigger 1902 swings and locks against the wall 108 when not in use.
[0129] The present invention, in various embodiments, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various embodiments, sub combinations, and subsets thereof. Those of skill in the art will understand how to make and use the present invention after understanding the present disclosure. The present invention, in various embodiments, includes providing devices and processes in the absence of items not depicted and/or described herein or in various embodiments hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and/or reducing cost of implementation.
[0130] The foregoing discussion of the invention has been presented for purposes of illustration and description. The foregoing is not intended to limit the invention to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the invention are grouped together in one or more embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the invention.
[0131] Moreover, though the description of the invention has included description of one or more embodiments and certain variations and modifications, other variations and modifications are within the scope of the invention, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative embodiments to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter. | In one embodiment, a safety trailer has semi-tractor hitches at both ends and a safety wall that is fixed to one side of the trailer. That side, however, can be changed to the right or left side of the road, depending on the end to which the truck attaches. A caboose can be attached at the end of the trailer opposite the tractor to provide additional lighting and impact protection. Optionally, the trailer can be equipped with overhead protection, lighting, ventilation, onboard hydraulics, compressors, generators and other equipment, as well as related fuel, water, storage and restroom facilities and other amenities. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a fluorescent x-ray analyzer and, more particularly, to an improved fluorescent x-ray analyzer that can monitor the status of the x-ray tube and thereby increase the effective life of the instrument, while ensuring accurate readings.
2. Description of Related Art
Fluorescent x-ray instruments have been utilized as analytical instruments. Reference can be made to FIG. 4 to disclose a schematic construction of one form of a fluorescent x-ray analyzer. In this regard, a sample can be held on a sample monitoring stage (not shown) and subjected to irradiation from primary x-rays 3 from an x-ray tube 2. As a result, fluorescent x-rays and scattered x-rays 6 are generated at the sample, and a filter 4 is placed before an x-ray detector 5. An output signal from the x-ray detector is processed in a pulse height analyzer (not shown) after suitable amplification to conduct a predetermined analysis.
FIG. 5 discloses one form of construction for controlling the output of the x-ray tube 2. The x-ray tube 7 supports a vacuum and contains a thermal cathode 10 that includes a filament 8 and a cathode 9 that is connected to an appropriate power source so as to generate thermal electrons 11. The cathode 9 is connected through a buffer amplifier 12 to the input terminal 13a of a comparator 13. An x-ray tube electric current I x may flow through a detecting resistance 14 provided on the input side of the buffer amplifier 12, to thereby generate a voltage V x obtained by converting the x-ray tube electric current I x into a voltage value. This voltage V x is input as one signal to the comparator 13.
A target 16 is mounted at the other end of the tube member 7 as an anode, and it is connected with a high-voltage power source 15. An x-ray transmissive window 17 made, for example, of beryllium is formed and provides an output from the tube 7 of the primary x-ray 3. A first grid member 18 is capable of regulating the quantity of thermal electrons 11 that are permitted to collide with the target 16. The quantity of thermal electrons 11 is a function of the x-ray tube electric current I x , and the grid 18 can provide a constant value of control thermal electrons 11. A second grid member 19 is used for contracting thermal electrons before they collide with the target 16 so that the stream of electrons is not excessively expanded and are controlled to be arranged between the thermal cathode 10 and the target 16.
A controlled set value for regulating the x-ray tube electric current I x can be input by the operator into the other input terminal 13b of the comparator 13 as the voltage signal V R . This voltage signal V R is compared with the voltage signal V x in the comparator 13 to provide a feedback loop to apply a voltage to the first grid 18 through a level converter circuit 20. As a result, a controlled grid voltage of the first grid 18 can be desirably controlled so as to provide a predetermined x-ray tube electric current I x .
A problem that can impact on the use of fluorescent x-ray instruments has been the stability and life of the x-ray tube 2. The inside of the tube member 7 can deteriorate in degree of vacuum where the thermal cathode 10 can deteriorate to produce an emitting factor of the thermal electrons 11. As a result, the ability to provide constant current control deteriorates, and eventually can become impossible. In the conventional fluorescent x-ray analyzer, it becomes difficult to determine the specific time period in which an x-ray tube becomes inaccurate or its control current starts to deteriorate. As a result, erroneous readings can occur as the quantity of x-rays emitted by the x-ray tube 2 is reduced. As can be appreciated, when the x-ray tube 2 loses its ability to be controlled by the operator, it is necessary to exchange the x-ray tube 2. The life of the x-ray tube 2, however, cannot be readily determined. The prior art has frequently resorted to periodic changes of the x-ray tube 2 to guard against analytical errors. As can be appreciated, however, the life of an x-ray tube 2 could be extended beyond the periodic changing, since the maintenance schedule usually requires a safety factor to avoid erroneous readings. Thus, the cost of x-ray tubes 2 must be increased to cover the wasteful utilization of them in an analytical instrument.
The prior art is still seeking an improved fluorescent x-ray instrument for analytical use.
SUMMARY OF THE INVENTION
An improved fluorescent x-ray instrument utilizes an x-ray tube capable of generating primary x-rays with a control grid that can be regulated by the operator to control the production of the primary x-rays. Voltage is applied to the control grid, and this voltage can be monitored by providing an output signal representative of the monitor control grid voltage to the operator, to thereby enable the operator to determine the operative status of the x-ray tube.
In one embodiment of the invention, an output signal representative of the monitor control grid voltage can be compared with a predetermined reference voltage to determine the operative life of the x-ray tube by providing an indication of such a comparison directly to an operator, for example, through an appropriate warning control light or an alarm.
The present invention therefore provides a fluorescent x-ray tube analyzer that is capable of determining the degree of deterioration and defining a specific exchange time or maintenance cycle of an x-ray tube without affecting the readings of the analytical instrument. By monitoring the control grid voltage, both the degree of deterioration and the exchange time period of the x-ray tube can be easily managed by the operator to increase the effective life of the x-ray tube and lower the operating cost of the instrument. It is possible to provide an appropriate monitoring signal to define a first warning period wherein the x-ray tube should be replaced but is still operative, and a second warning period in which the life cycle of the x-ray tube has deteriorated to a point where it can no longer be reliably utilized in an analytical measurement.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and 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, may best be understood by reference to the following description, taken in connection with the accompanying drawings.
FIG. 1 is a schematic drawing disclosing one construction of the principal components of a fluorescent x-ray analyzer according to one embodiment of the present invention;
FIG. 2 is a schematic drawing disclosing another example of a construction of an x-ray tube for the present invention;
FIG. 3 is an electric circuit disclosing an example of providing an output alarm to an operator;
FIG. 4 is a schematic drawing disclosing a prior art fluorescent x-ray analyzer;
FIG. 5 is a schematic drawing disclosing a circuit for driving a conventional fluorescent x-ray analyzer; and
FIG. 6 is an illustrative chart showing a relationship between a grid control voltage G 1 and an x-ray tube electric current I x .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventors of carrying out their invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the generic principles of the present invention have been defined herein specifically to provide an improved fluorescent x-ray analyzer and monitoring system.
To appreciate an application of the features of the present invention, reference is made to FIG. 6, which discloses mutual conversion characteristics (hereinafter referred to as G 1 -I x characteristics) between a grid control voltage G 1 of a first grid member 18 and an x-ray tube electric current I x . Referring to FIG. 6, an axis of abscissa designates the voltage G 1 of the first grid 18, while an axis of ordinate designates the x-ray tube electric current I x . As can be appreciated, the common elements of the x-ray tube are identified with the same reference numbers as shown, for example, in FIGS. 1 and 5. The G 1 -I x characteristic curve is expressed by a curve shown by the full line in FIG. 6 during the time period when an x-ray tube 2 is new and fresh and is operated as per its original specifications.
After a substantial period of use, the x-ray tube 2 can deteriorate in degree of vacuum, or the thermal cathode 10 can deteriorate to reduce the emitting factor of the thermal electrons 11. These factors, alone or in combination, can deteriorate the output of the x-ray tube 2, and will result in shifting the curve A shown in FIG. 6 in the direction shown by the arrow D in FIG. 6. As a result, a constant current control can be conducted so that the x-ray tube electric current I x may be equal to the setting electric current I 1 , so that the grid control voltage G 1 is changed to -V 1 , -V 1 ', and -V 1 ", to thereby gradually approach a zero voltage. As can be appreciated, the constant current control will become impossible over this progressive deterioration.
Referring to FIG. 1, a schematic drawing of a construction of the present invention for a fluorescent x-ray tube analyzer is disclosed. In this regard, the fluorescent x-ray analyzer is specifically designed to continually monitor the control grid voltage of the grid 18. This can be accomplished in a number of different methods. For example, as shown in FIG. 1, the control grid voltage G 1 of the first grid 18 can, through an appropriate I/O circuit (not shown) be converted from an analog to a digital value by an A/D converter 21. The output signal can then be monitored by a CPU or microprocessor-based system 22. In a fluorescent x-ray analyzer having such a construction, the x-ray tube electric current I x that flows through a detecting resistance 14 from the cathode 9 will generate a detecting voltage V x across the resistance 14. This voltage signal V x can be compared with the setting voltage V R in the comparator 13. The obtained result is fed back to the first grid 18 through a level converter circuit 20.
For example, the level converter circuit 20 can regulate the control grid voltage G 1 to the--side when V x >V R , and to the + side when V x <V R . The thermal electrons 11 will come into collision with the target 16 as a result of regulating a control grid voltage G 1 in the above-described manner to generate the primary x-rays 3, when can then be applied to a sample 1 to conduct the desired analysis.
In operation, the control grid voltage G 1 of the first grid 18 is constantly monitored, and a value representative of that voltage is input into the CPU 22 through the A/D converter 21. This value of the control grid voltage G 1 can be displayed to an operator in charge of the analysis. Alternatively, if it arrives at a predetermined value such as -V 1 ' in FIG. 6, an x-ray tube exchange alarm or monitoring warning alarm can be output directly to the operator. If the control grid voltage G 1 arrives at a value -V 1 " as shown in FIG. 6, a life-ending alarm can be output and the system can be rendered inoperative to avoid any false readings.
Although the x-ray tube 2 disclosed is a tetrode transmission type in the above-described preferred embodiment of FIG. 1, it may also be a triode transmission-type tube without a second grid 19, or a reflection-type tube as shown in FIG. 2. Referring to FIG. 2, an alternative embodiment of the present invention can be utilized wherein a filament 23 serves as the thermal cathode and a Wenert's electrode serves as the grid 24. In FIG. 2, the target 25 is positioned adjacent an x-ray transmissive window 26, and a high-voltage power source 27 is applied to the target.
Referring to FIG. 3, an alternative embodiment of the present invention can be utilized wherein the control grid voltage G 1 is monitored by an analog circuit having two separate comparator circuits 28 and 29, to each output a separate alarm. In FIG. 3, reference numbers 30 and 31 are directed to a standard voltage source, while reference numbers 32 and 33 refer to an LED monitoring light. Reference numbers 32 and 33 refer to resistance values. In this embodiment, if the control grid voltage G 1 becomes less than a value determined by the standard voltage source 30, an "x-ray tube exchange alarm" indicator is provided by the LED 32. Further, if the control grid voltage G 1 becomes less than a value determined by the standard voltage source 31, a life termination signal for the x-ray tube can be output.
As can be readily appreciated, a number of alarms can be optionally selected to accommodate variations in the above-described embodiments. In addition, in the preferred embodiment shown in FIG. 3, the passive LED alarms 32 and 33 can instead be input to a CPU to provide an on/off signal for the driving of a display device such as a CRT or a liquid crystal display.
Thus, according to the present invention, the degree of deterioration in an accurate exchange maintenance time period for the x-ray tube can be achieved, since the life cycle of the x-ray tube can be readily monitored. Additionally, the x-ray tube can be fully utilized throughout its useful life. Therefore, the costly periodic change to avoid even the possibility of erroneous readings in the analytical measurements can be eliminated. Thus, the quantity of x-rays that are utilized in an analytical measurement can be guaranteed by the utilization of the present invention.
In operation, an improved fluorescent x-ray instrument can monitor the control grid voltage to a specific x-ray tube. The specific type of x-ray tube will have a predetermined grid control voltage and x-ray tube electric current relationship that can be empirically established for a type of x-ray tube. As shown in FIG. 3, a corresponding voltage value can be set as a reference. When the grid voltage reaches that value, an appropriate alarm or warning can be issued to the operator. Thus, an initial alarm can indicate that an x-ray tube is approaching the end of its life, and a subsequent alarm can indicate that the grid voltage has reached a value wherein the quantity of x-rays being produced by the x-ray tube cannot be dependably controlled to meet the needs of the analyzer instrument.
Those skilled in the art will appreciate that various adaptations and modifications of the just-described preferred embodiment can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein. | An improved fluorescent x-ray instrument includes an x-ray tube for generating x-rays, with a control grid regulating the production of x-rays. An operator can set the voltage to be applied to the control grid, and a feedback system will set a desired voltage to the control grid. An operator will be provided an output signal representative of the monitor control grid voltage to enable the operator to determine the operative status of the x-ray tube. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a three-dimensional electroformed shell for a mold and a process for manufacturing the same. The shell can be used for a variety of kinds of molds including a mold for making paper from pulp fiber, a mold for blowing a fibrous or granular material, a mold for foaming beads of polystyrene, polypropylene, or modified polyphenylene ether, a screen mold for preforming glass fiber, and a mold for making a molded resin product by vacuum, blow, stamping, injection, RIM urethane, or compression molding.
2. Description of Related Art
A three-dimensional electroformed shell having a multiplicity of apertures is used for a mold for making paper from pulp fiber. The apertures usually occupy about 1 to 50% by area of the surface of the shell. A number of methods have hitherto been employed for manufacturing such a shell, as summarized below.
(1) A punched metal plate having a multiplicity of apertures is pressed into a three-dimensional shape. It has, however, been impossible to form a punched metal plate into a complicated three-dimensional shape because of its poor press formability. Moreover, the use of an expensive press tool has resulted in an expensive product.
(2) A punched metal plate is bent, cut and welded into a three-dimensional shape. This method has, however, been able to make only a product of low dimensional accuracy. Moreover, the necessity of a great deal of time and labor has resulted in an expensive product.
(3) A three-dimensional shell having a small wall thickness is cast from e.g. an aluminum alloy, and apertures are drilled in the shell. The shell has however, been low in dimensional accuracy because of e.g. the warpage of its wall having a small thickness. Moreover, the necessity of a great deal of time and labor for drilling a multiplicity of apertures has resulted in an expensive product. It has even been difficult to drill the apertures in some portion or portions of the shell if it has a complicated shape.
SUMMARY OF THE INVENTION
Under these circumstances, it is an object of this invention to provide a novel three-dimensional electroformed shell for a mold which is easy to manufacture at a low cost and has a high dimensional accuracy, even if it may have a complicated shape.
This object is attained by a shell which comprises a three-dimensional thin-walled body having a multiplicity of base holes, and an electroformed coating deposited on the body. The shell is so simple in construction that its manufacture calls for only a small amount of time and labor. The electroformed coating may be so formed as to diminish the base holes of the thin-walled body in size to form a multiplicity of apertures in the shell. In this case, the shell can be used for the molds from which air, gas or water must be removed through the apertures, such as a mold for making paper, a blowing mold, a mold for foaming beads, a screen mold, a mold for vacuum molding, and a mold for RIM urethane molding. The shell can be also used for such a mold as to make a product by blow, stamping, injection, or compression molding, so that the apertures provide vent holes for removing gas from the mold. The coating may alternatively be so formed as to close the base holes of the thin-walled body completely. In this case, the shell can be used for such a mold to make a product by blow, stamping, injection, or compression molding.
It is another object of this invention to provide a process which can manufacture a three-dimensional electroformed shell for a mold easily at a low cost and with a high dimensional accuracy.
This object is attained by a process which comprises the steps of deforming a thin-walled body having a multiplicity of base holes into a three-dimensional shape on and along the surface of a three-dimensional model, and forming an electroformed coating on the deformed thin-walled body. This process facilitates the manufacture of a three-dimensional shell having a high dimensional accuracy, while enabling a reduction in time and labor, even if it may have a complicated shape. The electroforming conditions are appropriately selected to form apertures in the shell, or not to form any aperture, or to vary the percentage by area which the apertures may occupy in the surface of the shell.
The step of deforming a thin-walled body may be carried out while bonding it to the surface of the model. This is the easiest way to carry out the step.
The step of forming an electroformed coating may include forming a preliminary thin electroformed coating on the deformed thin-walled body to prepare an intermediate shell product, removing at least the major part of the model from the intermediate product, and forming a final electroformed coating on the intermediate product. In this case, the preliminary electroformed coating fixes the thin-walled body, so that the removal of at least the major part of the model from the intermediate product does not bring about any deformation of the latter. The final electroformed coating can be formed uniformly on both sides of the intermediate product from which at least the major part of the model has been removed, and hold it against warpage.
The step of deforming a thin-walled body may include fixing the deformed thin-walled body with a resin, removing at least the major part of the model from the thin-walled body, and imparting electric conductivity to the surface of the thin-walled body. In this case, the resin fixes the thin-walled body, so that the removal of at least the major part of the model from the thin-walled body does not bring about any deformation of the latter. An electroformed coating can be formed uniformly on both sides of the thin-walled body from which at least the major part of the model has been removed, and hold it against warpage.
The step of deforming a thin-walled body may alternatively include placing a layer of granular material in the base holes of the deformed thin-walled body, fixing the thin-walled body and the granular material with a resin, removing at least the major part of the model from the thin-walled body, and imparting electric conductivity to the surfaces of the thin-walled body and the granular material. In this case, as the base holes of the thin-walled body are closed by the granular material, no prolonged electroforming operation is required for making a shell having no aperture.
The step of forming an electroformed coating may include forming a preliminary thin electroformed coating on the deformed thin-walled body to prepare an intermediate shell product, removing the thin-walled body from the intermediate product, and forming a final electroformed coating on the intermediate product.
The thin-walled body may be a network body, and the base holes may be the openings of the network body. The network body may be of an electrically conductive or non-conductive material, of which examples are shown below. If it is of a non-conductive material, electric conductivity is imparted to its surface prior to electroforming.
(a) Conductive material:
(1) Stainless steel, galvanized iron, brass, copper, aluminum, or other metal (or alloy) wire;
(2) Yarn formed by holding carbon fibers together;
(3) Yarn formed by holding together monofilaments of an electrically conductive resin, or electrically conductive fibers;
(b) Non-conductive material:
(1) Yarn formed by holding together inorganic fibers, such as glass, ceramic, or quartz fibers;
(2) Yarn formed by holding together chemical fibers, such as nylon, polyester, or polypropylene fibers, or monofilaments of a resin;
(3) Yarn formed by holding together natural fibers, such as hemp or cotton fibers.
Although it is usual to prepare the network body by knitting wires, yarns or monofilaments together as the intersecting elements, it is also possible to prepare it by welding the intersecting elements together, or sticking them together with an adhesive.
If the network body is of a non-conductive material, electric conductivity is imparted to its surface by e.g. applying a conductive paint (a paste of a conductive powder, such as a silver, copper or aluminum powder), a silver mirror reaction, electroless plating, vacuum evaporation, or sputtering.
The thin-walled body may alternatively be of metallic foil, and the base holes may be formed in the metallic foil. The metallic foil may be of e.g. aluminum, copper or stainless steel.
A conductive network body can be bonded to the surface of a three-dimensional model by, for example, employing a double-sided pressure-sensitive adhesive tape, a pressure-sensitive adhesive, or another type of adhesive therebetween.
The model may be of a material such as a resin, solid wax, plaster, wood, ceramics, metal, or carbon, and may be prepared by a method which depends on the material selected. The electroformed coating can be formed from e.g. nickel, a nickel-cobalt alloy, copper, or a copper-cobalt alloy.
Other and further objects of this invention will become obvious upon an understanding of the illustrative embodiments about to be described or will be indicated in the appended claims, and various advantages not referred to herein will occur to one skilled in the art upon employment of the invention in practice.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a model and an inverted model as prepared in accordance with a first embodiment of this invention;
FIG. 2 is a sectional view of the inverted model shown in FIG. 1 and a double-sided pressure-sensitive adhesive tape applied to it;
FIG. 3 is a sectional view further including a network body stuck to the adhesive tape;
FIG. 4(a) is an enlarged top plan view of the network body shown in FIG. 3, and FIG. 4(b) is an enlarged sectional view thereof;
FIG. 5 is a diagram illustrating an electroforming operation for the network body;
FIG. 6 is a sectional view of an intermediate shell product as prepared by the electroforming operation and the inverted model having its major part removed from the intermediate product;
FIG. 7(a) is an enlarged top plan view of the intermediate product shown in FIG. 6, and FIG. 7(b) is an enlarged sectional view thereof;
FIG. 8 is a sectional view of an electroformed shell as manufactured by another electroforming operation for the intermediate product;
FIG. 9(a) is an enlarged top plan view of the shell shown in FIG. 8, and FIG. 9(b) is an enlarged sectional view thereof;
FIG. 10 is a sectional view of an inverted model and a network body as deformed thereon and fixed with a resin in accordance with a third embodiment of this invention;
FIG. 11(a) is an enlarged top plan view of the network body shown in FIG. 10, and FIG. 11(b) is an enlarged sectional view thereof;
FIG. 12 is a sectional view of the network body shown in FIG. 10 and the inverted model having its major part removed from the network body;
FIG. 13(a) is an enlarged top plan view of a network body and a granular material placed on it in accordance with a fourth embodiment of this invention, and FIG. 13(b) is an enlarged sectional view thereof;
FIG. 14(a) is an enlarged top plan view of metallic foil employed in a fifth embodiment of this invention, and FIG. 14(b) is an enlarged sectional view thereof;
FIG. 15 is an enlarged sectional view of an intermediate shell product as prepared by an electroforming operation for the metallic foil;
FIG. 16 is an enlarged sectional view of the intermediate shell product as removed from the metallic foil; and
FIG. 17(a) is an enlarged top plan view of an electroformed shell as manufactured by another electroforming operation for the intermediate product shown in FIG. 16, and FIG. 17(b) is an enlarged sectional view thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference is first made to FIGS. 1 to 9 for the description of the first embodiment of this invention directed to an electroformed shell having a complicated three-dimensional shape and adapted for use with a mold for blowing a fibrous or granular material, and a process for manufacturing the same.
A model 1 having a complicated three-dimensional shape was formed from an epoxy resin, and secured on a table 2, as shown in FIG. 1. The model 1 was surrounded by a frame 3, and a molten epoxy resin was poured onto the surface of the model 1 to form an inverted model 4 shaped like a shell.
Then, the frame 3 and the inverted model 4 were turned upside down, and a double-sided pressure-sensitive adhesive tape 5 was applied to the upper surface of the inverted model 4 (its surface which was complementary to the surface of the model 1), as shown in FIG. 2.
Then, a network body 6 was placed on the adhesive tape 5, and deformed into a three-dimensional shape so as to adapt itself to the three-dimensional upper surface of the inverted model 4, while it was bonded to the inverted model 4 by the adhesive tape 5, as shown in FIG. 3. Although the whole network body 6 could easily be deformed along the inverted model 4, it is sometimes possible that the three-dimensional surface may have so complicated a shape that a network body has a portion or portions failing to be properly deformed. In such a case, it is effective to, for example, cut any such portion and weld it by using a small spot welding machine. This method hardly brings about any reduction in dimensional accuracy. The network body 6 was of the construction as shown in FIGS. 4(a) and 4(b), and was a grid formed by knitting stainless steel wires having a diameter of 0.4 mm, and had an opening size of 10 mesh.
The network body 6 bonded to the inverted model 4 was immersed as a cathode in an electroforming solution 8 held in a vessel 7, in which a nickel electrode 9 employed as a source of supply of the metal to be deposited was also immersed as an anode, as shown in FIG. 5. A DC voltage was applied between the two electrodes from a DC power source 10 to carry out an electroforming operation. The electroforming solution 8 contained 300 to 450 g of nickel sulfamate, 0 to 10 g of nickel chloride and 30 to 45 g of boric acid, per liter. The solution 8 had a pH of 2.5 to 4.2, and a temperature of 30° to 50° C.
The electroforming operation was continued for two days at a cathode current density of 1 to 3 A/dm 2 , whereby the network body 6 was covered with a thin electroformed coating 11 to yield an intermediate shell product 12, as shown in FIGS. 6, 7(a) and 7(b). The electroformed coating 11 surrounding the intersecting elements of the network body 6 had a thickness of 0.05 to 0.2 mm, and the intersecting elements of the intermediate product 12 had an outside diameter of 0.4 to 0.8 mm. The electroformed coating 11 fixed the intersecting elements of the network body 6 and their intersections, and thereby made the intermediate product 12 strong enough to resist deformation without the aid of the inverted model 4.
The electroforming operation was interrupted, and the frame 3, the inverted model 4 and the intermediate product 12 were removed from the electroforming solution 8. They were heated, whereby the adhesive tape 5 was softened, and the intermediate product 12 was separated from the inverted model 4 and the adhesive tape 5. The major parts of the inverted model 4 and the adhesive tape 5 were cut off their edge portions, and the intermediate product 12 was attached again to their edge portions, as shown in FIG. 6.
The frame 3, the edge portion of the inverted model 4 and the intermediate product 12 were immersed again in the electroforming solution 8, and the electroforming operation was resumed on both sides of the intermediate product 12. The operation was continued for four days at a cathode current density of 1 to 3 A/dm 2 , whereby the network body 6 was covered with a thicker electroformed coating 11 to yield an electroformed shell 13, as shown in FIGS. 8, 9(a) and 9(b). The electroformed coating 11 surrounding the intersecting elements of the network body 6 had a total thickness of 0.35 to 0.5 mm, and the intersecting elements of the electroformed shell 13 had an outside diameter of 1.1 to 1.4 mm. The openings of the network body 6 were diminished in size by the electroformed coating 11 to form a multiplicity of apertures 14 in the shell 13. The apertures 14 occupied about 25% by area of the shell 13.
The shell 13 was separated from the remaining edge portion of the inverted model 4. There was no warpage of the shell 13. This was apparently due to the absence of any internal stress as a result of uniform electroforming on both sides of the intermediate product 12.
Description will now be made of the second embodiment of this invention. After the process as hereinabove described with reference to FIGS. 1 to 4 had been repeated, an electroforming operation was continued for 10 days at a cathode current density of 1 to 3 A/dm 2 on a network body 6 bonded to an inverted model 4 as shown in FIG. 5 to make an electroformed shell 13 as shown in FIGS. 8 and 9. The apertures 14 occupied about 20% by area of the shell 13.
The shell 13 was substantially comparable to the product according to the first embodiment. The second embodiment, however, called for a longer electroforming time than the first embodiment, since the coating was formed mainly on one side of the network body 6 bonded to the inverted model 4.
Reference is now made to FIGS. 10 to 12, as well as the figures which have already been referred to, for the description of the third embodiment of this invention. After the step as described with reference to FIG. 1 had been repeated, a network body 6 was applied directly without the aid of any adhesive tape onto the upper surface of an inverted model 4 turned upside down, and was fixed with an epoxy resin 15, as shown in FIGS. 10, 11(a), and 11(b). The network body 6 was a grid formed by knitting together yarns of glass fibers having a cross-sectional size of 1×1.2 mm, and had an opening size of 8 mesh. The hardening of the epoxy resin 15 adhering to the yarns and their intersections, and penetrating the glass fibers made the network body 6 strong enough to resist deformation without the aid of the inverted model 4.
The network body 6 was separated from the inverted model 4, and after the major part of the inverted model 4 had been cut off its edge portion, the network body 6 was attached again to the remaining edge portion of the inverted model 4, as shown in FIG. 12. Electric conductivity was imparted to the surface of the network body 6 by a silver mirror reaction (not shown). An electroforming operation was continued for eight days at a cathode current density of 1 to 3 A/dm 2 on both sides of the network body 6 to yield an electroformed shell 13 which was similar to that shown in FIGS. 8 and 9. The apertures 14 occupied about 30% by area of the shell 13.
Attention is now directed to FIGS. 13(a) and 13(b) showing the fourth embodiment of this invention. This embodiment is characterized by placing a layer of granular material 16 in the openings of a network body 6 deformed on an inverted model 4, and fixing the network body 6 and the granular material 16 with an epoxy resin 15. It is otherwise equal to the third embodiment. An electroforming operation was continued for five days at a cathode current density of 1 to 3 A/dm 2 on both sides of the network body 6 and the granular material 16 to which electric conductivity had been imparted, whereby an electroformed shell having no aperture was obtained.
Reference is now made to FIGS. 14(a) to 17(a) for the description of the fifth embodiment of this invention. In this embodiment, aluminum foil 18 in which a multiplicity of base holes 17 were punched (as shown in FIG. 14(a)) was used in place of the network body. The aluminum foil 18 had a thickness of 50 μm, and each of the base holes 17, which were formed so as to have a distance of 5 mm between the centers of the adjacent holes 17, had a diameter of 3 mm.
The aluminum foil 18 was bonded to an inverted model 4 by a double-sided pressure-sensitive adhesive tape 5, as shown in FIG. 14(b). An electroforming operation was carried out for the aluminum foil 18 bonded to the inverted model 4 to yield an intermediate shell product 12, as shown in FIG. 15. An electroformed coating 11 formed on one side (where the inverted model 4 was not bonded) of the aluminum foil 18 had a thickness of about 0.05 mm, and thereby made the intermediate product 12 strong enough to resist deformation without the aid of the inverted model 4. The other side of the aluminum foil 18 had no electroformed coating.
The electroforming operation was interrupted, and the intermediate product 12 was separated from the inverted model 4, the adhesive tape 5 and the aluminum foil 18, as shown in FIG. 16. The electroforming operation was resumed on both sides of the intermediate product 12, whereby an electroformed coating 11 with another thickness of about 0.5 mm was formed on each side of the intermediate product 12. This resulted in yielding an electroformed shell 13 having a thickness of about 1.5 mm, as shown in FIG. 17. The base holes 17 were diminished in size by the electroformed coating 11 to form a multiplicity of apertures 14 in the shell 13. Each of the apertures 14 had a diameter of about 1.5 mm.
As many apparently widely different embodiments of this invention may be made without departing from the spirit and scope thereof, it is to be understood that the invention is not limited to the specific embodiments thereof except as defined in the appended claims. | A three-dimensional electroformed shell for a mold consists of a three-dimensional thin-walled body, and an electroformed coating deposited on it. The coating may, or may not close the base holes of the thin-walled body completely. If it does not close the base holes completely, the shell has a multiplicity of apertures. A process for manufacturing the shell is also disclosed. | 2 |
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/110,263, filed Oct. 31, 2008, the contents of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] 1. Background of the Invention
[0003] The present invention relates to a process for synthesizing higher diamondoids. More specifically, the process involves augmenting diamondoid molecules through the bonding of carbon atoms to smaller diamondoid species with intramolecular cross-linking to form larger diamondoids containing face-fused diamond-crystal (adamantane) cages with carbon frameworks superimposable on the cubic-diamond crystal lattice.
[0004] 2. Description of Related Art
[0005] Although the structure of a molecule containing a cubic diamond crystal cage was first proposed by Decker in 1924, its synthesis proved extraordinarily difficult. The first successful synthesis of “adamantane” (the smallest diamondoid, containing only a single diamond crystal cage) was not achieved until 1941, and then with a yield of only 0.16%. In 1957, Schleyer discovered that adamantane can be formed in high yields from C 10 tricyclic intermediates by carbocation-mediated thermodynamically-controlled equilibration reactions. He used this method to also synthesize diamantane (a diamondoid containing two diamond crystal cages). An alternative name for diamantane is “congressane” because its synthesis had been posed as an exceedingly difficult challenge to chemists at the Nineteenth Congress of the International Union of Pure and Applied Chemistry.
[0006] The overall reaction of a strained C 14 H 20 polycyclic isomer, e.g., tetrahydrobisnor-S, to yield diamantane by the carbocation-mediated equilibration is in fact a staggeringly complex network of thousands of reaction pathways. Graphical analysis of the mechanisms for adamantane formation from endo-tetrahydrodicyclopentadiene shows an amazing 2897 different pathways (Whitlock, et al., 1968), many of the details of which have now been verified. Graphical analyses have also been performed for carbocation equilibration reactions leading to the diamondoids methyladamantane and diamantane. Limited analysis of the heptacyclooctadecane (triamantane) system suggests the existence of at least 300,000 intermediates.
[0007] The synthesis of triamantane by carbocation-mediated thermodynamically-controlled equilibration reactions was achieved in 1966. Since then, exhaustive research has established that higher diamondoids (diamondoids containing more than three face-fused diamond crystal cages) cannot be synthesized by the superacid-carbocation equilibration methods. Accordingly, a characteristic that distinguishes the lower diamondoids from the higher ones is that lower diamondoids can be synthesized by carbocation equilibration reactions while higher diamondoids can not. In fact only one of the higher diamondoids, [121]tetramantane, has ever been synthesized, and this by a complex, low-yielding, gas-phase double homologation of diamantane (Burns et al., J. Chem. Soc., Chem. Commun., 1976, pp. 893).
[0008] In 1980, the likelihood of the development of successful higher diamondoid syntheses was assessed and it was concluded that prospects were extremely unlikely because of a lack of large polycyclic precursors, increasing problems with rearranging intermediates becoming trapped in local energy minima, rising potential for disproportionation reactions leading to unwanted side products, and rapidly expanding numbers of isomers as carbon numbers of target higher diamondoid products increase (Osawa et al., 1980). With the failure to implement carbocation-mediated syntheses of higher diamondoids, attempts to synthesize higher diamondoids were largely abandoned in the 1980's.
[0009] Although attempts to synthesize higher diamondoids have up to now been unsuccessful, the thermodynamic stabilities of higher diamondoids are high relative to other hydrogenated carbon materials of comparable nanometer size.
[0010] Attempts to identify the presence of higher diamondoids in diamond products formed by a CO 2 -laser-induced gas-phase synthetic methods and diamond materials produced by commercial chemical vapor disposition (CVD) using methane as the carbon source have been unsuccessful. Unlike the synthetic chemical approaches discussed above which employ carbocation reaction mechanisms, these gas-phase diamond-forming processes involve free-radical reaction mechanisms (Butler et al., Thin Film Diamondoid Growth Mechanisms in Their Film Diamondoid , Lettington and Steeds Eds., London, Chapman & Hall, pp. 15-30, 1994). Thus, it previously appeared that no method for synthesizing higher diamondoids would be found.
[0011] Although they have never been synthesized, the existence of higher diamondoids in petroleum and their isolation for commercial applications has now been successful. However, a process for successfully synthesizing higher diamondoids would be of great value to the industry.
SUMMARY OF THE INVENTION
[0012] In some embodiments of the present invention, there is provided a method (or methods) for synthesizing higher diamondoid molecules. The method comprises sufficiently heating (or otherwise activating) diamondoid molecules having at least three cages so as to break carbon-carbon bonds to form small reactive carbon species, and then allowing a reaction to occur between these reactive species and diamondoid molecules having at least three cages to thereby add sufficient carbon atoms (that cross-link with dehydrogenation) to add at least one diamond crystal (adamantane) cage to such diamondoid molecules. The synthesized higher diamondoid molecules are then recovered. The heating can take place in a closed reactor, generally under an inert atmosphere, or the heating can take place in a chemical vapor deposition (CVD)-type chamber using a filament (or other excitation source) to create a concentration of reactive carbon species. Certain nondiamondoid carbon species, for example norbornane, isobutene, isobutane, can be added to the reaction mixture to promote the reaction, generating larger yields of higher diamondoids. Synthesized higher diamondoid molecules made via methods of the present invention are herein often referred to as “augmented higher diamondoids” or “synthetic higher diamondoids” (the terms are synonymous) to distinguish them from naturally-occurring higher diamondoids.
[0013] Among other factors and mechanisms, the present invention has discovered that higher diamondoids can be synthesized by employing free-radical reaction pathways. The reaction generally involves the addition of four carbons to a diamond face, controlled by steric effects such as those involving 1-3 diaxial interactions, thereby resulting in the formation of a new diamond crystal cage and the next larger diamondoid in the series (of progressively larger diamondoids). Particularly effective is the use of a gas phase reaction using the kinds of free radical reactions responsible for the growth of CVD-diamond. Smaller diamondoids act as seeds from which the next larger diamondoids are grown. Surface hydrogen atoms are removed and replaced by carbon-containing radicals generated from diamondoid starting material or certain added reactants, such as norborane. The process provides a method by which an effective synthesis of valuable nanomaterials (e.g., the higher diamondoids) can be achieved.
BRIEF DESCRIPTION OF FIGURES
[0014] FIG. 1 illustrates changing yields of tetramantane higher diamondoids from triamantane with changing reaction temperatures.
[0015] FIG. 2 illustrates the carbon framework structures of the four possible tetramantane higher diamondoids and where each is grown from specific faces of the triamantane starting molecules.
[0016] FIG. 3 illustrates the carbon framework structures of pentamantane higher diamondoids and which can be grown from [1(2)3]tetramantane.
[0017] FIG. 4 illustrates the carbon framework structures of pentamantane higher diamondoids and which can be grown from [121]tetramantane.
[0018] FIG. 5 illustrates the carbon framework structures of pentamantane higher diamondoids and which can be grown from [123]tetramantane.
[0019] FIG. 6 is a scanning electron micrograph (SEM) of diamond produced by chemical vapor deposition (CVD) nucleated by higher diamondoids.
[0020] FIG. 7 illustrates a side-view of a diamond growth reactor for producing higher diamondoids by a CVD process.
[0021] FIG. 8 illustrates a plan-view of a diamond growth reactor for producing higher diamondoids by a CVD process.
[0022] FIG. 9 represents a CVD free-radical reaction sequence in which higher diamondoids are formed from lower ones in addition to intermediate methylated precursors.
[0023] FIG. 10 illustrates CVD reaction steps in which sequential diamondoid radical formation/radical quenching with CVD-generated methyl radicals leads to formation of the next higher diamondoid species.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Higher diamondoids are nanometer-sized diamond molecules (containing 4 or more face-fused diamond crystal cages) having properties, such as negative-electron-affinity, that are valuable for commercial application in the microelectronics and other industries. Unlike the lower diamondoids (i.e., adamantane, diamantane and triamantane), higher diamondoids e.g., as discussed in U.S. Pat. No. 6,815,569; U.S. Pat. No. 6,843,851; U.S. Pat. No. 7,094,937; U.S. Pat. No. 6,812,370; U.S. Pat. No. 6,828,469; U.S. Pat. No. 6,831,202; U.S. Pat. No. 6,812,371; U.S. Pat. No. 7,034,194; U.S. Pat. No. 6,743,290, which are hereby incorporated by reference in their entirety, with the exception of one of the tetramantanes, have never been synthesized, despite intensive efforts to do so.
[0025] The present invention provides an effective and efficient method for synthesizing higher diamondoids. More specifically, it has been discovered that tetramantanes can be made from triamantane, that pentamantanes can be made from tetramantanes, and so on. In accordance with some embodiments of the present invention, the method involves the heating of diamondoid species (material) having at least three cages in a reactor. The reaction temperature is typically in the range of from 200-600° C. The reaction can be done with or without a catalyst, and is typically carried out under an inert atmosphere (at least initially). With a catalyst, reaction temperatures can be lower, e.g., preferably 275-475° C., more preferably 300-400° C., and most preferably 325-375° C. Without a catalyst, a higher temperature is employed, preferably in the range of 400-600° C., and more preferably in the range of 450-550° C.
[0026] Higher diamondoids can also be formed via gas-phase reactions employing the kinds of free-radical reactions responsible for the growth of CVD-diamond. In such processes, smaller diamondoids act as seeds from which the next larger diamondoids are grown. In such processes, surface hydrogen atoms are removed and replaced by carbon-containing radicals generated from diamondoid starting material and/or certain added reactants, such as isobutane. Four-carbon additions to a diamond face, at 1-3 diaxial sites formed via hydrogen abstractions, result in the formation of a new diamond crystal cage and the next larger diamondoid in the series.
[0027] Those of skill in the art will recognize that numerous variations exist on the above-described methods of the present invention, and that these variations are seen to fall within the scope of the instant invention, especially wherein they provide for augmented or synthetically-derived higher diamondoid species. Examples of such variations include, but are not limited to, reactant precursor composition and activation means (e.g., thermal, photolytic, and/or chemical) for providing reactant species.
[0028] In the examples below, diamondoid material is heated in a sealed, evacuated 316 stainless steel reaction vessel, and the presence and absence of a clay mineral (montmorillonite), with and without additional hydrocarbon reactants. A variety of reaction times and temperatures were employed and studied. After a given reaction was complete, the products were extracted and analyzed. Reaction products include alkylated forms of the starting diamondoid, smaller diamondoids, and valuable larger diamondoids. These examples are provided to demonstrate particular embodiments of the present invention. It should be appreciated by those of skill in the art that the methods disclosed in the examples which follow merely represent exemplary embodiments of the present invention. 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 described and still obtain a like or similar result without departing from the spirit and scope of the present invention.
Example 1
[0029] The first reactant was the lower diamondoid triamantane (C 18 H 24 ), isolated from petroleum and recrystallized 8-times to remove higher diamondoids. See, e.g., U.S. Pat. No. 7,173,160 for isolation of diamondoids from petroleum. Diamondoid impurities remaining in the starting materials after recrystallization were determined quantitatively by gas chromatography-mass spectrometry (GCMS) and referenced to the starting weight of triamantane reactant. [121]tetramantane, at a concentration of 10.5 ppm, was the only higher diamondoid detected in the recrystallized triamantane. The triamantane was loaded into the 316 stainless steel reaction vessel and montmorrilonite clay was added. The results of one series of reactions are shown in Table 1. This reaction series used identical conditions, except that a different hydrocarbon reactant was added to each reaction mixture. However, one experiment used triamantane without added hydrocarbons, i.e., neat. The objective was to study the possible reaction of triamantane with other compounds and with itself
[0000]
TABLE 1
Yields of Individual Tetramantane Products from Triamantane Alone and
with Various Added Reactants in the Presence of Montmorillonite Catalyst
for 96 at 280° C.
Reactants
Triamantane
Triamantane &
Triamantane &
Triamantane
Triamantane &
Products
neat
Adamantane
Diamantane
& Norbornane
Norbornane
[1(2)3]Tetramantane
2433
731
539
4365
4377
[121]Tetramantane
1176
407
318
1692
1333
[123]Tetramantane
880
32
30
201
123
(Yields are given as ppm of starting triamantane. 25 mg of triamantane and 25 mg of montmorillonite were used in each experiment).
[0030] Surprisingly, results listed in Table 1 show that most of the additional reactants inhibit rather than promote tetramantane formation. Triamantane alone generated tetramantane products, but yields dropped when adamantane or diamantane was added to the reaction mixture. Similar tetramantane product inhibition was found when hexane, 1,4-dimethylcyclohexane, bi-adamantane, bicylcoheptadiene, decaline or cubane was added. Only norborane improved yields of [1(2)3]tetramantane (by a factor of 1.8). However, yields of the other two tetramantanes fell relative to yields using only triamantane as the starting material.
[0000]
TABLE 2
Yields of Individual Tetramantane Products from Triamantane
and Norborane Reactants in the Presence of Montmorillonite
Catalyst for 96 Hours at Various Temperature
Product
280° C.
280° C.
300° C.
350° C.
400° C.
450° C.
[1(2)3]Tetramantane
4365
4377
4132
5403
4026
2993
[121]Tetramantane
1692
1333
1640
2111
1379
401
[123]Tetramantane
201
123
211
173
72
9
(Yields are given as ppm of starting triamantane. 25 mg of triamantane, montmorillonite, and norborane were used in each experiment).
[0031] Table 2 lists results for a series of experiments, each run for 96 hours but at varying temperatures, the temperatures ranging from 280° C. up to 450° C. FIG. 1 is a plot of the data from Table 1 showing the yields of the three tetramantanes as a function of reaction temperature. A reaction temperature of approximately 350° C. gave the highest yields of tetramantanes under these conditions. The main products of the reactions are alkylated triamantanes. While not intending to be bound by theory, it is presumed that some of the triamantane in the reaction mixture cracks, thereby forming hydrocarbon radicals that can abstract hydrogen from intact triamantanes, forming stable alkyltriamantanes products. In addition to alkylated triamantanes, all three of the tetramantane higher diamondoids are formed.
Example 2
[0032] In addition to triamantane, the three structural forms of tetramantane were also isolated and reactions were conducted with them to determine if any of the 6 stable, molecular weight (mw) 344, pentamantanes could be synthesized. Pentamantanes that are formed by the replacement of 3 tetramantane tri-axial hydrogens with a 4-carbon isobutane-shaped unit to form a new closed cage without breaking any of the original tetramantane carbon-carbon bonds—are highly favored. The most favored of these are those with the least steric hindrance associated with access to the tetramantane reactant face.
[0033] Table 3 presents results of experiments using [1(2)3]tetramantane as a starting material. The only possible pentamantanes that can be derived from the addition of 4 carbons to this tetramantane are [1(2,3)4]pentamantane, [12(1)3]pentamantane, and [12(3)4]pentamantane ( FIG. 3 ). In Table 3 it can be seen that two of these three pentamantanes were synthesized by the process. FIG. 3 illustrates the carbon frame-work structures of the six pentamantane higher diamondoids and indicates which can be grown from [1(2)3]tetramantane. Diamond crystal cages that can be added to [1(2)3]tetramantane are circled with dashed lines. Structures above the straight, horizontal dashed line in FIG. 3 are found in the reaction products, while structures below the line are not found, or found at trace levels. As measure of steric interference, Table 3 lists the number of 1,3-diaxial interactions associated with reactant faces from which specific pentamantanes could be formed by direct face-fusing of a diamond cage to [1(2)3]tetramantane. The data show that steric effects control which pentamantanes are formed from [1(2)3]tetramantane. Also shown in Table 3 are the number of ways in which a four carbon addition to a particular tetramantane will result in a particular pentamantane. This seems to be much less important than steric considerations.
[0000]
TABLE 3
Production of Pentamantane Products from [1(2)3]Tetramantane 280°
C., Montmorillonite Catalyst, Reaction time = 96 hours
Pentamantane Yields and Characteristics
Number of
Number of 1,3-
Tetramantane
Specific
Diaxial
Reactant Faces
Specific
Pentamantane
Interactions on
That Can Form
Pentamantane
Products
Tetramantane
Specific
Products
(ppm)
Reactant Face
Pentamantane
[1(2,3)4]Pentamantane
7030
3
1
[12(1)3]Pentamantane
1417
6
6
[1212]Pentamantane
[1213]Pentamantane
[12(3)4]Pentamantane
12
3
[1234]Pentamantane
(Yields are given as ppm of starting material, [1(2)3]tetramantane. 9.0 mg of [1(2)3]tetramantane was used as starting material)
[0034] Even in this un-optimized reaction, the yield of valuable pyramidal [1(2,3)4]pentamantane is approaching 1 weight percent.
[0035] Table 4 presents results of experiments using [121]tetramantane as a starting material. In Table 4 it is seen that three of the six mw 344 pentamantanes were synthesized by the process.
[0000]
TABLE 4
Production of Pentamantane Products from [121]Tetramantane 280°
C., Montmorillonite Catalyst, Reaction time = 96 hours
Pentamantane Yields and Characteristics
Number of
Number of 1,3-
Tetramantane
Specific
Diaxal
Reactant Faces
Specific
Pentamantane
Interactions on
That Can Form
Pentamantane
Products
Tetramantane
Specific
Products
(ppm)
Reactant Face
Pentamantane
[1(2,3)4]Pentamantane
[12(1)3]Pentamantane
655
6
4
[1212]Pentamantane
2965
3
2
[1213]Pentamantane
332
6
4
[12(3)4]Pentamantane
[1234]Pentamantane
(Yields are given as ppm of starting material, [121]tetramantane. 10.8 mg of [121]tetramantane was used as starting material)
[0036] As measure of steric interference, Table 4 lists the number of 1,3-diaxial interactions associated with reactant faces from which specific pentamantanes could be formed by direct face-fusing of a diamond cage to [121]tetramantane. FIG. 4 illustrates the carbon frame-work structures of the six pentamantane higher diamondoids and indicates which of these can be grown from [121]tetramantane. Diamond crystal cages that can be added to [121]tetramantane are circled with dashed lines. Structures above the straight, horizontal dashed line in FIG. 4 are found in the reaction products, while structures below the line are not found, or found at only trace levels. Again, the data show that steric effects control which pentamantanes are formed from [121]tetramantane, whereas the number of ways a specific pentamantane could be formed (Table 4) is not important. Even in this un-optimized reaction, the yield of valuable rod-shaped[1212]pentamantane is already ca. 0.3 weight percent.
[0000]
TABLE 5
Production of Pentamantane Products from [123]Tetramantane 280°
C., Montmorillonite Catalyst, Reaction time = 96 hours
Pentamantane Yields and Characteristics
Number of
Number of 1,3-
Tetramantane
Specific
Diaxial
Reactant Faces
Specific
Pentamantane
Interactions on
That Can Form
Pentamantane
Products
Tetramantane
Specific
Products
(ppm)
Reactant Face
Pentamantane
[1(2,3)4]Pentamantane
[12(1)3]Pentamantane
5971
3
2
[1212]Pentamantane
[1213]Pentamantane
1403
3
2
[12(3)4]Pentamantane
5
2
[1234]Pentamantane
5
2
(Yields are given as ppm of starting material, [123]Tetramantane. 13.1 mg of [123]tetramantane was used as starting material)
[0037] Table 5 presents results of experiments using [123]tetramantane as a starting material. In Table 5 it is seen that two of the mw 344 pentamantanes were synthesized by the process. As measure of steric interference, Table 5 lists the number of 1,3-diaxial interactions associated with reactant faces from which specific pentamantanes could be formed by direct face-fusing of a diamond cage to [123]tetramantane. FIG. 5 illustrates the carbon frame-work structures of the six pentamantane higher diamondoids and indicates which can be grown from [123]tetramantane. Diamond crystal cages that can be added to [123]tetramantane are circled with dashed lines. Structures above the straight, horizontal dashed line in FIG. 5 are found in the reaction products, while structures below the line are not found, or found at trace levels. Again, the data show that steric effects control which pentamantanes are formed from [123]tetramantane, whereas the number of ways a specific pentamantane could be formed (Table 5) is not important. Even in this un-optimized reaction, the yield of valuable [12(1)3]pentamantane is already ca. 0.6 weight percent.
[0038] As stated previously, the pentamantanes that form experimentally from a particular tetramantane are the pentamantanes that can be formed by the addition of 4 carbons. Where the breaking of a tetramantane cage is required to form a particular pentamantane, that pentamantane will either not be generated from that particular tetramantane or it will be in very small relative amounts. The 4 carbons that are added take the form of isobutane and replace 3 tri-axial hydrogens on the tetramantane surface.
[0039] Starting with the linear [121]tetramantane, one can create a cage at the end of the molecule, extending the linear arrangement, to give the [1212]pentamantane. Alternatively, one could create a cage on the side of [121]tetramantane, which would give either [12(1)3] or [1213]pentamantane. One could not, however, form either [1(2,3)4], [12(3)4], or [1234]pentamantane without breaking cages and reconstructing the molecule. Interestingly, it is clear from Table 4 that the main products of reacting [121]tetramantane are [1212], [12(1)3] and [1213]pentamantane. Addition of the extra cage at one of the ends would involve the least steric hindrance, and this addition at the ends seems to be born out experimentally by the favored formation of [1212]pentamantane.
[0040] For [1(2)3]tetramantane, it is possible to put the isobutyl group on the top to form the pyramidal [1(2,3)4]pentamantane. Additionally, by completing cages along the sides of this tetramantane one can make [12(1)3] or [12(3)4]pentamantane. Table 3 shows that the predominant pentamantanes made by experimental pyrolysis of [1(2)3]tetramantane are in fact [1(2,3)4] or [12(1)3]pentamantane. Addition of the new cage to form [1(2,3)4]pentamantane would have the least steric hindrance and indeed [1(2,3)4]pentamantane is the predominant product. No [12(3)4]pentamantane was detected from the experiment and there was a slight amount of [1212]pentamantane, the latter of which would have had to have been formed by another mechanism.
[0041] Lastly, by adding an isobutyl to [123]tetramantane, one could theoretically make [1234], [12(3)4], [1213] and [12(1)3]pentamantane. Steric considerations would favor the formation of [12(1)3]pentamantane. Experimental data in Table 5 show that all of these pentamantanes are in fact formed, with [12(1)3]pentamantane predominating. No detectable [1(2,3)4]pentamantane was formed, and only trace amounts of [1212]pentamantane were seen, presumably formed by a different mechanism.
Example 3
[0042] A series of experiments were performed to determine the importance of the montmorillonite clay in the synthesis of the higher diamondoids. Triamantane was sealed in an inert gold tube without montmorillonite catalyst and heated to 500° C. for 96 hours. Even without the montmorillonite the formation of higher diamondoids, both tetramantanes and pentamantanes was observed, as shown in Table 6. The reaction temperatures needed to be increased compared to the temperatures for reactions in the presence of montmorillonite, but yields were comparable. This result demonstrates that the montmorillonite is not essential for the higher diamondoid formation reaction.
[0000]
TABLE 6
Production of Tetramantane and Pentamantane
Products from Triamantane without Catalyst
at 500° C., and with Isobutane or Isobutene
(at 500° C. without Catalyst)
Triamantane,
Triamantane
Triamantane
neat
& Isobutane
& Isobutene
[1(2)3]Tetramantane
1567
11413
16274
[121]Tetramantane
718
7163
8576
[123]Tetramantane
183
1304
1782
[1(2,3)4]Pentamantane
2
183
141
[12(1)3]Pentamantane
13
299
229
[1212]Pentamantane
5
182
137
[1213]Pentamantane
6
125
92
[12(3)4]Pentamantane
0.9
8
9
[1234]Pentamantane
0.4
Reaction time = 96 hours. Yields are given as ppm of starting material, triamanatane. Reactants were sealed in evacuated gold tubes.
[0043] Because each diamondoid cage closure requires four carbons in an isobutyl configuration, isobutane and isobutene were added to the reaction as carbon sources for the additional higher diamondoid cages. Table 6 shows that yields of higher diamondoids can be greatly increased by the addition of either isobutene or isobutane to the reaction mixture.
[0000]
TABLE 7
Production of pentamantane products from [121]tetramantane
Reactants
[121]Tetramantane
[121]Tetramantane
[121]Tetramantane
& Isobutane
& Isobutene
Products
(ppm)
(ppm)
(ppm)
[1(2,3)4]Pentamantane
[12(1)3]Pentamantane
104
2922
1005
[1212]Pentamantane
114
7637
1970
[1213]Pentamantane
34
2634
617
[12(3)4]Pentamantane
[1234]Pentamantane
* Neat with isobutane or isobutene at 500° C. under argon in sealed gold tube
{circumflex over ( )} Neat at 500° C. under argon in sealed gold tube
[0000]
TABLE 8
Production of pentamantane products from [1(2)3]tetramantane
Reactants
[1(2)3]Tetramantane
[1(2)3]Tetramantane
[1(2)3]Tetramantane
& Isobutane
& Isobutene
Products
(ppm)
(ppm)
(ppm)
[1(2,3)4]Pentamantane
1723
2995
1341
[12(1)3]Pentamantane
332
2552
872
[1212]Pentamantane
62
21
[1213]Pentamantane
79
6
[12(3)4]Pentamantane
62
11
[1234]Pentamantane
* Neat with isobutane or isobutene at 500° C. under argon in sealed gold tube
{circumflex over ( )} Neat at 500° C. under argon in sealed gold tube
[0000] TABLE 9 Production of pentamantane products from [123]tetramantane Reactants [123]Tetramantane [123]Tetramantane [123]Tetramantane & Isobutane & Isobutene Products (ppm) (ppm) (ppm) [1(2,3)4]Pentamantane [12(1)3]Pentamantane 497 5886 1116 [1212]Pentamantane 214 231 37 [1213]Pentamantane 41 3318 613 [12(3)4]Pentamantane 39 462 60 [1234]Pentamantane 638 97 * Neat with isobutane or isobutene at 500° C. under argon in sealed gold tube {circumflex over ( )} Neat at 500° C. under argon in sealed gold tube
Similar runs, without any catalyst, where run to test conversion of individual tetramantane higher diamondoids into pentamantane higher diamondoids. Table 7 shows results using neat [121]tetramantane neat, with isobutene or isobutene, sealed in a gold tube under argon atmosphere and heated to 500° C. for 96 hours. Table 8 shows results using neat [1(2)3]tetramantane neat, with isobutene or isobutene, sealed in a gold tube under argon atmosphere and heated to 500° C. for 96 hours. Table 9 shows results using neat [123]tetramantane neat, with isobutene or isobutene, sealed in a gold tube under argon atmosphere and heated to 500° C. for 96 hours. These results further demonstrate that the montmorillonite is not essential for the higher diamondoid formation reaction and that yields of higher diamondoids can be greatly increased by the addition of either isobutene or isobutane to the reaction mixture.
[0044] It is clear from the experiments above (Examples 1-3) that diamondoids are being “built up” by the addition of carbons, some replacing hydrogens to complete a cage or cages and form larger diamondoids. This mechanism is analogous to the growth of chemical vapor deposition (CVD) diamond. CVD diamond is typically grown in a very reducing hydrogen atmosphere (typically over 90%), much of it in atomic form to keep carbon-carbon double bonds from forming. Diamond growth is derived from the addition of methyl and/or ethyl radicals replacing hydrogen on the surface of small diamond seeds which are necessary for initiation of the process. In this way, new cages are formed and the size of the diamond increased. This process takes place at fairly high temperatures, generally in excess of 450° C.; however, pressures are low, usually near atmospheric. Conditions are much less optimal for higher diamondoid growth in natural gas fields, but the time frames are considerable, with oil generation and oil cracking taking place on the order of millions of years or more. This leads to the conclusion that if conditions were optimal, i.e., conditions used to grow CVD diamond, that it would be possible to effectively synthesize higher diamondoids and larger nanodiamondoids of a particular size range using lower diamondoids as seeds.
[0045] FIG. 6 is a scanning electron micrograph (SEM) of diamond produced by chemical vapor deposition (CVD) nucleated using alkyltetramantane higher diamondoids. This shows that diamondoids like the tetramantanes can act as seeds from which larger diamond crystals can be grown. The key is to identify conditions that stop the growth of the crystals growing from the diamondoid seed while particle sizes are still in the 1 to 2 nanometer size range.
[0046] These experimental conditions are less than ideal for growing CVD diamond (they were designed to mimic petroleum formation and oil cracking), yet they generated higher diamondoids with a yield of about 1%. Based on these results, if conditions are optimized in the CVD chamber small diamondoids seeds will readily grow larger diamondoids in the vapor phase. One could start with adamantane, diamantane or triamantane, which are readily available either through synthesis or isolation from petroleum. Having a relatively high vapor pressure at CVD diamond growth temperatures, these could then be put into a CVD chamber in the vapor phase to act as nucleation sites for diamond growth. By adjusting the conditions appropriately (time, temperature, gas composition including hydrogen and carbon source) tetramantanes, pentamantanes, hexamantanes, etc. can be grown in the gas phase. As the diamondoids grow larger, they precipitate from the vapor as their vapor pressure decreased. A cooler, collector substrate collects these larger diamondoids. If still larger diamondoids are desired, heating or mechanical agitation of the collector substrate keeps the diamondoids in the growth environment as long as desired. By this means, larger diamondoids/diamonds, e.g. diamondoids with ca. 100 carbons which could be used for photonic crystals and for catalysts will form. Furthermore, by beginning with a derivitized diamondoid, e.g., derivitized with an amine or borane group, one can effectively dope the larger diamondoids being grown with nitrogen or boron. Alternatively, one can derivitize and/or dope the diamondoid with functional groups by addition of appropriate reactants in the CVD chamber.
[0047] CVD growth of diamonds is believed to occur on a heated substrate via hydrogen extraction and hydrogen and carbon containing radical attachment mechanisms. Diamondoids with a sufficient number of internal degrees of freedom should act in the same way as the small diamond seed crystals used to nucleate conventional CVD diamond growth. A detailed description of this process can be found in the book Physics and Applications of CVD Diamond , Satoshi Koizumi; Christoph Nebel, Milos Nesladek, John Wiley and Sons, 2008.
[0048] A modification of a traditional hot-filament reactor designed for growing higher diamondoids is shown in FIGS. 7 and 8 . A vacuum chamber maintained at a pressure of approximately 1 Torr is filled with hydrogen (ca. 99%) and a carbon containing gas (e.g., CH 4 ca. 1%). The filament is heated to approximately 2000K to dissociate the hydrogen, thereby providing a source of atomic hydrogen. The diamondoid gas is supplied by a tube through the radiation shields. The collector substrate is placed within the radiation shield, and maintained at a temperature too low to produce diamond growth reactions. The temperature gradient between the filament and the collector substrate provides a range of conditions suitable to cause growth on the diamondoid surfaces. Growth rate and efficiency can be optimized by changing geometry and gas composition in the reactor. Formation of diamondoids of increasing diamond crystal-cage count by this CVD system is illustrated in FIGS. 9 and 10 . Hydrogen radicals (atoms) generated from hydrogen gas in the CVD chamber strip hydrogen atoms from diamondoid seed molecules, generating diamondoid free radicals that add carbon atoms by quenching with methyl radicals formed from methane in the CVD plasma. Methylated diamondoids are major products leading to subsequent ring/cage closure and formation of the next higher diamondoid with a cage count of N+1, where N is the number of diamond crystal cages in the seed diamondoid. FIG. 10 shows an example reaction sequence in the formation of [1(2)3]tetramantane from triamantane in the CVD chamber. Hydrogen atoms are stripped from a seed diamondoid face giving rise to a radical that is quenched by a methyl radical producing a methylated intermediate. Sequential 1, 3, 6 addition of methyl radicals by this mechanism generates the corresponding trimethyltrimantane in which the [1(2)3]tetramantane is formed by carbon radical addition, hydrogen abstraction, and ring/cage closure. This sequence can also form pentamantanes from tetramantanes, hexamantanes from pentamantanes, heptamantanes from hexamantanes, and so on.
[0049] All patents and publications referenced herein are hereby incorporated by reference to an extent not inconsistent herewith. It will be understood that certain of the above-described structures, functions, and operations of the above-described embodiments are not necessary to practice the present invention and are included in the description simply for completeness of an exemplary embodiment or embodiments. In addition, it will be understood that specific structures, functions, and operations set forth in the above-described referenced patents and publications can be practiced in conjunction with the present invention, but they are not essential to its practice. It is therefore to be understood that the invention may be practiced otherwise than as specifically described without actually departing from the spirit and scope of the present invention as defined by the appended claims. | In some embodiments, the present invention is directed to methods for synthesizing higher diamondoids, wherein said methods involve augmenting existing diamondoid molecules through the bonding of carbon atoms to such existing diamondoid species with intramolecular cross-linking so as to form larger diamondoids containing face-fused diamond-crystal (adamantane) cages with carbon frameworks superimposable on the cubic-diamond crystal lattice. | 2 |
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